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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for preparing optically active (+)-primary amines (I) of the formula: ##STR3## wherein R 1 is lower alkyl, which are useful intermediates for the production of the optically active dopamine derivatives (I), e.g., dobutamine. It further relates to key intermediates for the amines and the process therefor.
2. Prior Art
Dobutamine has been developed by Eli Lilly and Company and denoted by the following formula: ##STR4##
This compound is very useful, because it can increase myocardial contractility without isolating norepinephrine. The recemate, the 1:1 mixture of d-isomer and 1-isomer is clinically applied to the patients for the treatment of suddenly depressed myocardial contractility and shock.
There are two kinds of optical isomers in dobutamine and the optically active dobutamine have been prepared via optical resolution of the intermediate as disclosed in U.S. Pat. No. 3,987,200.
SUMMARY OF THE INVENTION
This invention provides an optically active (+)-secondary amine of the formula: ##STR5## wherein R 1 is a lower alkyl, and to a process for preparing optically active (+)-primary amine (I) of the formula: ##STR6## wherein R 1 is a lower alkyl, characterized by the reduction of said optically active (+)-secondary amine. The optically active amine (I) is a useful intermediate for the production of optically active dopamine derivatives.
DETAILED DESCRIPTION OF THE INVENTION
It has been reported that the d-isomer (hereinafter described as d-dobutamine) has more potent activity as a cardiotropic than the 1-isomer (hereinafter described as 1-dobutamine) has. Therefore, it is desired to prepare only d-dobutamine.
However, the conventional method is not economical since the optical resolution has been applied to the final intermediate for dobutamine preparation, namely, trimethyl ether compound. It is needless to say that the economical preparation of the aimed optically active compound can be achieved by obtaining an optically active intermediate at an earlier stage in a series of the reactions and applying it to the subsequent reactions.
The present inventors studied hard to solve the above mentioned problem.
As a result, they found that the reaction of (+)-α-methyl-benzylamine with compound (II) of the formula: ##STR7## wherein R 1 is the same as defined above, and the subsequent reduction gives an optically active (+)-secondary amine (III) of the formula: ##STR8## wherein R 1 is the same as defined above, in high yield and the subsequent reduction of the resulting amine gives an useful intermediate of d-dobutamine, namely, optically active (+)-primary amine (I) of the formula: ##STR9## wherein R 1 is the same as defined above.
As described afterward, the compound (I) is a very important intermediate in preparation of d-dobutamine.
Moreover, the compound (III) is very important as a starting material for the production of compound (I).
In this specification, lower alkyl shown by R 1 includes C 1 -C 6 alkyl, e.g., methyl, ethyl, propyl, isopropyl, butyl, tert-butyl, pentyl, hexyl, or the like.
Preferable R 1 is methyl and ethyl.
This invention is explained below in more detail.
As an asymmetric synthesis to prepare an optically active secondary amine (III) by the reaction of (+)-α-methylbenzylamine with the compound (II), there are the following two methods: (A) in one batch system, the reduction of the resulting Schiff base with a reducing catalyst such as nickel catalysts (e.g., Raney nickel), platinium oxide, or palladium-carbon, or the like, preferably, with nickel catalyst under an atmosphere of hydrogen, preferably, with a positive pressure or (B) the reduction of the Schiff base prepared through a dehydration condensation with a reducing catalyst such as nickel catalysts (e.g., Raney nickel), platinium oxide, or palladium-carbon, or the like, preferably with nickel catalyst under an atmosphere of hydrogen, preferably with a positive pressure.
The aimed asymmetric synthesis can be also attained if metal hydride such as sodium borohydride is employed.
The reduction may be carried out in an alcohol, e.g., methanol, ethanol, or the like or an ester, e.g., ethyl acetate, or the like under a mild pressure such as about 1 to about 20 Kg/cm 2 , preferably, about 3 to about 10 Kg/cm 2 . If necessary, acetic acid may be added.
The reaction time varis with the reaction conditions employed but could be several hours to several days for method (A) and several ten hours for method (B). The reaction system is contaminated with a by-product i.e., small amount of diastereomer of the compound (III) in the reduction, but can readily give the aimed optically active secondary amine through fractional cystallization from acetone and methanol-ethyl acetate.
The product prepared by the reduction may be isolated, if necessary, after converting into its desirable acid addition salt by treating with a mineral acid, e.g., hydrochlroric acid, hydrobromic acid, phosphoric acid, sulfuric acid, or the like.
The condensation is preferably carried out by the refluxe with benzene or toluene with an equipment to entrap the resulting water.
An optically active amine (I) can be prepared by the reduction of the compound (III) under an atmosphere of hydrogen, preferably with a positive pressure.
The reaction is carried out by the reduction under about 2 to 20 Kg/cm 2 of hydrogen pressure for several tens hours using catalyst such as palladium-carbon, palladium hydroxide, platinum oxide, or the like in an alcohol such as methanol, ethanol, or the like.
Alternatively, the reaction may be carried out with heating for several hours in the presence of ethyl chlorocarbonate.
This invention is explained in more detail by showing examples, but it should be understood that these examples are given only for the illustrative purpose and do not limit the scope of the present invention thereto.
EXAMPLE 1A
Method (A)
Preparation of N-(R)-α-methylbenzyl-(1R)-1-methyl-3-(4-methoxyphenyl)-1-propylamine hydrochloride IIIa ##STR10##
A mixture of 13.6 g of 4-(4-methoxyphenyl)-2-butanone IIa, 11.5 g of d-(+)-α-methylbenzylamine, and 1 g of Raney-nickel (Kawaken Finechemical; NDHT-90) in 90 ml of 98% ethanol is shaken at 4.85 Kg/cm 2 primary pressure for 5 days. The catalyst is removed by filtration and the filtrate is concentrated under reduced pressure. The residue is partitioned between dichloromethane and 10% diluted hydrochloric acid. The dichloromethane layer is washed with water, dried over anhydrous sodium sulfate, and concentrated under reduced pressure to give 14.9 g of the mixture of diastereomers IIIa and IIIb in the ratio of 6.7:1 in yield 60.9%. 74% d.e.
EXAMPLE IB
Method (B)
A solution of 1.78 g of 4-(4-methoxyphenyl)-2-butanone and 1.21 g of d-(+)-α-methylbenzylamine in benzene is refluxed for 5 hours under heating with removing resulting water and then the solvent is evaporated under reduced pressure.
The mixture of the resulting residue and 0.3 g of Raney-Nickel in 10 ml of 98% ethanol is shaken at 4.5 kg/cm 2 primary pressure for 22 hours. The catalyst is removed by filtration and the filtrate is concentrated under reduced pressure. The residue is partitioned between dichloromethane and 10% hydrochloric acid. The dichloromethane layer is washed with water, dried over anhydrous sodium sulfate, and concentrated under reduced pressure to give 2.14 g of the mixture of diastereomers IIIa and IIIb in the ratio of 5.8:1 in yield 66.9%.
Isolation of the Diastereomers IIIa and IIIb
To 2.14 g of the mixture prepared in Example 1B is added 20 ml of acetone and the resulting mixture is heated and then allowed to stand at room temperature for 2 hours. The precipitates 1 (71 mg) are collected by filtration. The solvent of the filtrate is changed to methanol-ethyl acetate (1:4) and the solution is allowed to stand at room temperature overnight to give 2 1.321 g of the crystals. The resulting mother liquor was successively recrystallized from acetone and methanol-ethyl acetate (1:4) to give 3 63 mg and 4 256 mg of crystals, respectively. The crystals 1 and 3 are the compound IIIb and the crystals 2 and 4 are IIIa.
Compound IIIa
100% d.e.
mp. 157° to 158° C.
[α] D +69.6° (c 1.117, methanol)
IRνmax(nujol) 2930, 1253cm -1
NMR(CDCl 3 ) δ1.51(3H, d, J=7 Hz), 1.88(3H, d, J=7 Hz), 2.11(2H, m), 2.32(1H, m), 2.72(2H, m), 3.78(3H, s), 4.29(1H, m), 6.75(2H, d, J=9 Hz), 6.95(2H, d, J=9 Hz), 7.34(3H, m), 7.54(2H, m), 9.64(1H, m), 10.00(1H, m).
Anal. Calcd. (%) for C 19 H 26 ClNO: C, 71.34; H, 8.19; Cl, 11.08; N, 4.38; Found (%): C, 71.30; H, 8.16; Cl, 11.11; N, 4.47.
Compound IIIb
m.p. 257° to 258° C.
[α] D -3.4°, [α] 365 -18.1° (c 0.976, 24° C., methanol)
IRνmax(nujol): 2950, 2930, 1240cm -1
NMR(CDCl 3 ) δ: 1.35(3H, d, J=6 Hz), 1.82 (3H, d, J=7 Hz), 1.8˜2.1(1H, m), 2.3˜2.6(3H), 2.35(1H, m), 3.70(3H, s), 4.29(1H, m), 6.66(2H, d, J=7 Hz), 6.94(2H, d, J=9 Hz), 7.39(3H), 7.62(2H), 9.51(1H, m), 10.04(1H, m).
Anal. Calcd. (%) for C 19 H 26 ClNO: C, 71.34; H, 8.19; Cl, 11.08; N, 4.38; Found (%): C, 71.14; H, 8.15; Cl, 10.79; N, 4.40
EXAMPLE 2
(+)-(R)-1-Methyl-3-(4-methoxyphenyl)-1-propylamine Ia
A suspension of 3.20 g of hydrochloride IIIa in ethyl acetate is shaken with an aqueous solution of sodium hydrogencarbonate. The organic layer is separated and the aqueous layer is extracted with ethyl acetate. The combined organic layer is washed with water once, dried over anhydrous sodium sulfate, and concentrated under reduced pressure. The residue is dissolved in 40 ml of ethanol and 0.8 g of 20% palldium hydroxide-carbon (Pearlman Catalyst) is added thereto. The mixture is shaken at 4.15 Kg/cm 2 hydrogen pressure for 20 hours. The catalyst is removed by filtration and then the mother liquor is concentrated under reduced pressure to give 1.68 g of the titled compound.
NMR(CDCl 3 ) δ1.11(3H, d, J=6 Hz), 1.5˜1.7(4H, m), 2.62(2H, m), 2.91(1H, m), 3.78(3H, s), 6.82(2H, d, J=7 Hz), 7.11(2H, d, J=8 Hz).
Hydrochloride of Ia: mp. 124°-125° C.
[α] D +7.0°, [α] 365 +23.6° (c 1.029, 24° C., methanol)
IRνmax(nujol): 3500, 3350, 1513, 1244cm -1 .
NMR(CD 3 OD) δ: 1.33(3H, d, J=7 Hz), 1.87 (2H, m), 2.65(2H, m), 3.25(1H, m), 3.76(3H, s), 6.85(2H, d, J=9 Hz), 7.14(2H, d, J=8 Hz).
Anal. Calcd. (%) for C 11 H 18 ClNO.0.2H 2 O: C, 60.24; H, 8.46; Cl, 16.16; N, 6.39; Found (%): C, 60.40; H, 8.49; Cl, 16.38; N, 6.66.
Anti-IIIb (1.11 g), namely, the enantiomer of IIIb prepared by reacting l-α-methylbenzylamine in the same manner as in Example 1A is allowed to react in the same manner as in Example 2 to give 0.53 g of hydrochloride Ia in 85.2% yield.
EXAMPLE 3
d-(+)-α-Methylbenzylamine and the compound IIa is allowed to react by the method in Example 1A under the conditions shown in Table 1 to give the compound IIIa. The results is also shown in Table 1.
TABLE 1__________________________________________________________________________ Hydrogen Reac- Reac- Produced Pressure tion tion Yd. RatioNo. Catalyst [kg/cm.sup.2 ] Time Tempt. Solvent (%) IIIa:IIIb__________________________________________________________________________1 Raney-Nickel 4.5 2.5 day rt. Ethanol 42.2 6.1:12 " 1 15 hrs rt. " 35.0 6.6:13 Platinum 1 4 hrs rt. Methanol- 79.7 2.8:1 Oxide Acetic Acid__________________________________________________________________________
EXAMPLE 4
d-(+)-α-Methylbenzylamine and the compound IIa is allowed to react by the method in Example 1B under the conditions shown in Table 2 to give the compound IIIa. The results is also shown in Table 2.
TABLE 2__________________________________________________________________________ Catalyst or Hydrogen Reac- Reac- Produced Reducing Pressure tion tion Yd. RatioNo. Agent [kg/cm.sup.2 ] Time Tempt. Solvent (%) IIIa:IIIb__________________________________________________________________________1 10% Pd-C 4.85 16 hrs rt. Ethyl 56.0 2.0:1 Acetate2 Sodium Boro- -- 2 hrs 0° C. Methanol 78.2 1.8:1 Hydride__________________________________________________________________________ rt. Room Temperature
In the following referencial example, the preparation of d-dobutamine from the optically active primary amine Ia is shown.
Referencial Example 1
(1) Preparation of (-)-(R)-2-(3,4-dimethoxyphenyl)-N-(4-methoxyphenyl-1-methyl-n-propyl)acetamide 4
To a solution of 2.08 g of 3,4-dimethoxyphenylacetic acid in 22 ml of dichloromethane is added 0.86 ml of thionyl chloride. After the mixture is refluxed for 1 hour under heating, the reaction mixture is concentrated to be half volumn under reduced pressure.
To 20 ml of suspension of 1.90 g of hydrochloride Ia in dichloromethane is added 5 ml of triethylamine with ice-cooling. The mixture is stirred at room temperature till the solide becomes disappear. To the resulting solution is dropwise added the solution of the acid chloride prepared above with ice-cooling. The mixture is allowed to stand at room temperature overnight, then washed with water, and dried over anhydrous sodium sulfate and the solvent is evaporated under reduced pressure. The residue is recrystallized from ethyl acetate: ether to give 2.48 g of the titled compound in 78.8% yield.
mp. 116°-117° C.
[α] D -31.2° (c 1.057, 24° C., CHCl 3 )
IRνmax(nujol): 3290, 1638, 1514, 1230 cm -1 .
NMR (CDCl 3 ) δ: 1.09(3H, d, J=7 Hz), 1.63 (2H, m), 2.49(2H, t, J=8 Hz), 3.49(2H, s), 3.78(3H, s), 3.87(3H, s), 3.89(3H, s), 4.01(1H, m), 5.19(1H, d, J=8 Hz), 6.73˜6.9(5H), 7.02(2H, d, J=9 Hz).
Anal. Calcd. (%) for C 21 H 27 NO 4 : C, 70.56; H, 7.61; N, 3.92; Found(%): C, 70.59; H, 7.66; N, 3.99.
(2) Preparation of (+)-(R)-3,4-dimethoxy-N-[3-(4-methoxyphenyl)-1-methyl-n-propyl]-2-phenylethylamine hydrochloride 5
To a solution of 1.92 g of amide 4 and 1.01 g of sodium borohydride in 22 ml of dioxane is dropwise added a solution of 1.61 g of glacial acetic acid in 5 ml of dioxane and the mixture is refluxed for 18 hours under heating. The ice-water is added to the reaction mixture which is then extracted with chloroform. The extract is washed with water once, drided over anhydrous sodium sulfated, and concentrated under reduced pressure. The residue is crystallized from ether to give 1.30 g of the titled compound in 63.7% yield.
mp. 144°-146° C.
[α] D +9.8° (c 0.997, 25° C., methanol),
[α] 365 +35.4° (c 0.997, 25° C., methanol),
IRνmax(nujol) 1516, 1246 cm -1
NMR (CDCl 3 ) δ1.48(3H, d, J=6 Hz), 2.21 (2H, m), 2.35(1H, m), 2.55(2H, m), 2.63(2H, m), 3.15(4H), 3.72(3H, s), 3.83(3H, s), 3.85 (3H, s), 6.7-6.85(5H), 7.0(2H, d, J=9 Hz).
Anal. Calcd. (%) for C 21 H 30 ClNO 3 : C, 66.39; H, 7.96; Cl, 9.33; N, 3.69; Found (%): C, 65.67; H, 8.04; Cl, 9.07; N, 3.96.
(3) Preparation of (+)-(R)-3,4-dihydroxy-N-[3-(4-hydroxyphenyl)-1-methyl-n-propyl]-2-phenylethylamine hydrochloride 6
A solution of 364 mg of the above mentioned trimethoxy compound 5 in dichloromethane is shaken with 10% aqueous solution of sodium hydroxide. The organic layer is washed with water, dried over anhydrous sodium sulfate, and concentrated to give 312 mg of the free amine.
A solution of this free amine is 9.5 ml of glacial acetic acid and 37 ml of 48% hydrobromic acid is refluxed for 4 hours under heating. The reaction mixture is evaporated to dryness under reduced pressure.
To the residue is added 15 ml of 4N-hydrochloric acid and the mixture is heated and then the reaction mixture is treated with active carbon. The resulting mixture is allowed to stand at room temperature overnight to give 203 mg of colorless prismatic crystals in 62.7% yield.
mp. 201°-203° C.
[α] D +10.8° (c 0.930, 24° C., Methanol)
[α] D +39.5° (c 0.930, 24° C., Methanol)
IRνmax(nujol): 3310, 1516cm -1 .
NMR(CD 3 OD) δ1.36(3H, d, J=7 Hz), 1.79(1H, m), 2.04(1H, m), 2.45˜2.95(4H), 3.10˜3.30(3H), 6.57(1H, dd, J=8.2 Hz), 6.65˜6.80 (4H), 7.04(2H, d, J=8 Hz).
Anal. Calcd. (%) for C 18 H 24 ClNO 3 : C, 63.99; H, 7.16; Cl, 10.49; N, 4.15; Found (%): C, 63.92; H, 7.22; Cl, 10.78; N, 4.22.
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This invention relates to an optically active (+)-secondary amine of the formula: ##STR1## wherein R 1 is a lower alkyl, and to a process for preparing a useful intermediate for the production of the optically active dopamine derivatives, namely, optically active (+)-primary amine of the formula: ##STR2## wherein R 1 is a lower alkyl, characterized by the reduction of said optically active (+)-secondary amine.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to nobel hydantoin derivatives, salts thereof, intermediates therefor and having an optical activity, a process for the prepartation of same, and medicines containing the derivative or salt as an effective ingredient to treat complications of diabetes.
The hydantoin derivatives and intermediates are shown by following formula.
Hydantoin derivatives ##STR4## wherein one of V and W is hydrogen and the other is a halogenomethyl group, 1H-tetrazol-5-yl radical, --COOR group,
in which R is hydrogen atom, an alkyl group, --(CH 2 CH 2 O)nCH 3 group (n is an integer of 1 to 113) or substituted phenyl, ##STR5## in which R 1 and R 2 are same or different independently, each is hydrogen atom, an alkyl group, substituted phenyl or --(CH 2 CH 2 O)nCH 3 group (n has the meaning as referred to) or R 1 may form a heterocyclic ring together with R 2 and nitrogen or oxygen atom, ##STR6## in which R 3 and R 4 are same or different independently and each is hydrogen atom or an alkyl group,
X is oxygen or sulfur atom, and Y and Z are same or different independently and each is hydrogen atom, a halogen atom, alkyl group, alkoxy group, alkylmercapto group, nitro radical or --NHR 5 , in which R 5 is hydrogen atom or an acyl group.
Intermediates ##STR7## wherein Y' and Z' are same or different independently, each is hydrogen atom, a halogen atom or alkyl group.
2. Related Arts
Racemic 3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid derivatives having the chemical formula same with that for the intermediates have been known [Jap. Unexamined Pat. Appln. Gazette No. 200991/1986, "J. Med. Chem." Vol. 14, No. 8, pages 758-766 (1971) and "Liebigs Ann. Chem." pages 1552-1556 (1971)].
According to the process disclosed in said Japanese official gazette, the racemic derivatives (II-a) are prepared as shown in following reaction formla, by brominating 4-chromanone derivative (VI), treating with triethylamine to remove hydrogen bromide and to form a 4-chromenone derivative (VII), treating the derivative with trimethylsilylcyanide to give cyano compound, and treating with concentrated hydrochroric acid to cause hydrolysis of the cyanide. ##STR8## wherein Y' and Z' are same or different independently and each is hydrogen atom, a halogen atom or alkyl group.
However, this process can not always be said as preferable one, since it requires the expensive reagent of trimethylsilylcyanide.
According to the process described in said J. Med. Chem., the racemic derivatives (II-b) are prepared as shown in the following reaction formula, by condensationally reacting 4-chlorophenol with α-bromo-γ-butylolactone to form the compound (VIII), oxidationally opening the ring with chromium trioxide to form the dicarboxylic acid (IX), and then treating with concentrated surfuric acid to cause a ring closure. ##STR9##
This process has also the disadvantage of that yield of the product is not so high of about 55 to 66%.
According to the process described in said Liebigs Ann. Chem., the racemic derivatives (II-c) are prepared as shown in the following reaction formula, by subjecting the monophenyl ester (X) of fumaric acid to Fries rearrangement, in the presence of aluminum chloride, and then causing a ring closure in sodium carbonate solution. ##STR10##
This process has disadvantages of that the synthetic yield of the raw material and yield of the Fries rearrangement reaction are low of about 30 to 52% and 16 to 50%, respectively.
Further, please note that each of the products obtained by such conventional processes has no optical activity and thus should be made into an optical active one, when the product is to be employed as the raw material to synthesize the hydantoin derivatives which are useful as the effective ingredient for medicines to prevent or cure the complications of diabetes.
Turning now to the diabetes, various studies have been made to seek compounds as effective ingredient for the medicine to prevent or cure the diabetes, which medicine can be administered in oral rout. As a result, various compounds of sulfonyl urea, mesooxalates, guanidine derivatives have been developed and various preparations containing one of the compounds have been marketed but each of them is of a mere symptomatic treating agent to a hyperglycoplasmia due to the diabetes. It has been known that there may be caused due to the diabetes specific chronic complications such as diabetic cataracts, diabetic neuropathy, diabetic retinopathy, diabetic nephrosis and the like but there is almost no effective agent for curing the complications and thus it may be said that no effective therapeutic system has been established.
Therefore, hitherto, various studies have also been made for developing an effective compound for curing such intractable diseases due to the diabetes but it is the fact that there is almost no success case. As one of the studies, there is a search on an anti- or inhibition substance to the enzymes of aldose reductase, since the enzyme reduces in vivo of human and other animals, aldoses such as glucose and galactose into corresponding polyols such as sorbitol and lactinol and it has been elucidated that said complications will appear when the polyols are accumulated at crystalline lens, peripheral nerve, kidney or the like in patients of diabetes or galactosemia ["Jap. J. Opthalmol." Vol. 20, page 399 (1976), "Int. Congr. Ser. Excerpta Med." Vol. 403, page 594 (1977), and "Metabolism" Vol. 28, page 456 (1979)].
Some of the inventors for this application have studied to find that following spiro-3-heteroazolidine derivatives and salts thereof are effective to the complications due to the diabetes (Jap. Pat. Appln. No. 41234/1985 early opened on Sept. 5, 1986 in Jap. Unexamined Pat. Appln. Gazette No. 200991/1986, which corresponding to U.S. patent application Ser. No. 835,823 and European patent application No. 86301530.1, respectively). ##STR11## wherein T is sulfur atom or hydrogen substituted nitrogen atom, U is oxygen atom, sulfur atom or an amino radical, one of V' and W' is hydrogen atom or an alkyl group and the other is hydrogen atom, 1H-tetrazol-5-yl radical, --COOR 6 ,
in which R 6 is hydrogen atom, an alkyl group, --(CH 2 CH 2 O)nCH 3 group (n is an integer of 1 to 113) or a substituted phenyl group, ##STR12## in which R 1 and R 2 are same or different independently, each is hydrogen atom, an alkyl group, substituted phenyl group, --(CH 2 CH 2 O)nCH 3 group (n has the meaning as referred to) or R 1 may form a heterocyclic ring together with R 2 and nitrogen or oxygen atom, ##STR13## in which R 3 and R 4 are same or different independently and each is hydrogen atom or an alkyl group,
X is oxygen or sulfur atom, Y" and Z" are same or different independently and each is hydrogen atom, a halogen atom, alkyl group, alkoxy group or alkylmercapto group, but there is no case of that one of V' and W' is hydrogen atom and the other is hydrogen atom or an alkyl group, when T is hydrogen substituted nitrogen atom and U is oxygen atom.
SUMMARY OF THE INVENTION
A basic object of the present invention is to provide a novel inhibition substance to aldose reductase to prevent an accumulation of polyols in vivo to, in turn, make prevention and curing of complications of the diabetes.
A specific object of the invention is to provide novel hydantoin derivatives and salts thereof as the inhibition substance to aldose reductase.
Another specific object of the invention is to provide a process for the preparation of the hydantoin derivatives and salts.
A still other specific object of the invention is to provide novel intermediates for preparing the hydantoin derivatives and salts, and a process for the preparation of the intermediates.
According to the invention, the basic and first specific objects can be attained by the hydantoin derivatives of the formula ##STR14## wherein one of V and W is hydrogen and the other is a halogenomethyl group, 1H-tetrazol-5-yl radical, --COOR group,
in which R is hydrogen atom, an alkyl group, --(CH 2 CH 2 O)nCH 3 group (n is an integer of 1 to 113) or substituted phenyl, ##STR15## in which R 1 and R 2 are same or different independently, each is hydrogen atom, an alkyl group, substituted phenyl or --(CH 2 CH 2 O)nCH 3 group (n has the meaning as referred to) or R 1 may form a heterocyclic ring together with R 2 and nitrogen or oxygen atom, ##STR16## in which R 3 and R 4 are same or different independently and each is hydrogen atom or an alkyl group,
X is oxygen or sulfur atom, and Y and Z are same or different independently and each is hydrogen atom, halogen atom, alkyl group, alkoxy group, alkylmercapto group, nitro radical or --NHR 5 group, in
which R 5 is hydrogen atom or an acyl group, and salts thereof.
Namely, it has been confirmed that the hydantoin derivatives shown by Formula I and the salts thereof show an inhibition of aldose reductase, which is better than that of the spiro-3-heteroazolidine derivatives disclosed in said Japanese official gazette and that a toxicity thereof is quite low.
In the compounds of Formula I, the term "alkyl group" may be straight-chain alkyl radicals, branched-chain alkyl radicals or cycloalkyl radicals. As examples for the straight-chain alkyl radicals, one having 1 to 6 carbon atoms, for instance methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl and the like can be listed. As examples for the branched-chain alkyl radicals, for instance isopropyl, isobutyl, s-butyl, t-butyl and the like can be listed. As examples for the cycloalkyl radicals, one having 3 or more carbon atoms, for instance cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like can be listed. As examples for the halogenomethyl group, fluoromethyl, chloromethyl, bromomethyl, iodomethyl and the like can be listed. The term of "halogen atom" may be fluorine, chlorine, bromine or iodine. The symbol "n" relates to the mean polymerization degree of ethylene glycol part of polyethylene glycol methyl ether. As exemplar values for the mean polymerization degree, 4, 7, 12, 16, 42 and 113 may be listed. As substituents for the substituted phenyl radical, o-, m- or p-chlorine, bromine atoms, methyl, methoxy and hydroxy radicals may be listed. As examples of the radical, when R 1 forms the heterocyclic ring together with R 2 and nitrogen atom or oxygen atom, pyrrolidinyl, morpholino, piperidino, piperazinyl and the like radicals can be listed. As examples for the alkoxy group and alkylmercapto group, those having a straight-chain alkyl group, for instance methoxy, ethoxy, n-propoxy, n-butoxy, n-pentyloxy, n-hexyloxy and the like as well as methylmercapto, ethylmercapto, n-propylmercapto, n-butylmercapto, n-pentylmercapto, n-hexylmercapto and the like can be listed, or those having a branched-chain alkyl group, for instance isopropoxy, isobutoxy, s-butoxy, t-butoxy and the like as well as isopropylmercapto, isobutylmercapto, s-butylmercapto, t-butylkmercapto and the like can be listed. As examples for the acyl group, acetyl, propanoyl, butanoyl and the like can be listed.
The salts of the hydantoin derivatives mean that acceptable in pharmacological field and with a cation of sodium, potassium, calcium, magnesium or the like.
According to the invention, the compounds of Formula I can be prepared through one of following routes.
Route A
A process wherein a compound of the formula ##STR17## wherein X, Y and Z have the meanings as referred to, and W" is a halogenomethyl group, 1H-tetrazol-5-yl radical, --COOR group, ##STR18## in which R, R 1 to R 5 have the meanings as referred to is reacted with a metal cyanide and ammonium carbonate. The reaction for this route can be shown following formula. ##STR19## wherein W", X, Y and Z have the meanings as referred to.
Route B
A compound of the formula ##STR20## wherein X, Y and Z have the meanings as referred to is reacted with a metal cyanide and ammonium carbonate as in said Route A to synthesize a compound of the formula ##STR21## wherein X, Y and Z have the menings as referred to and then this compound is lead into 2-carboxamide derivatives (I-c), 2-ester derivatives (I-d), 2-hydroxymethyl derivatives (I-e), 2-alkoxymethyl derivatives (I-f), 2-halogenomethyl derivatives (I-g) and 2-aminomethyl derivatives (I-h), as shown below and in accordance with manners known per se. ##STR22## wherein R, R 1 to R 5 , X, Y and Z have the meanings as referred to.
Regarding to the compounds (I) according to the invention, it can be estimated that two kind stereoisomers (diastereomers) will be produced due to 2- and 4-positioned asymmetric carbon atoms in the spiro[4H-1-benzopyran-4,4'-imidazolidine] ring. According to the process shown in said Route A, it has been confirmed that one of the isomers can be predominantly formed, the isomer can be isolated by simple operation of recrystallization, and the isomer shows higher pharmaceutical activity in inhibition of accumuration of sorbitol, galactitol and the like polyols. Namely, in the Route A, a forming ratio between the predominant isomer and the other isomers is about 5:1 to 10:1 and the former shows 10 times or more of the latter in inhibition of polyol accumuration.
In case of the Route B, each of single diastereomers of I-c, I-d, I-e, I-f, I-g and I-h can be prepared by using single diastereomer as the raw material, which is predominantly formed among the diastereomer mixture of the compound (I-b).
In both of the Routes A and B, the predominantly formed crystal (single diastereomer) is dl-compound which shows a relatively high activity but the inventors have tried an optical resolution thereof to find that each of the d- and l-compounds has the pharmaceutical activity and that the activity of d-compound is higher than that of the dl-compound is 2 times or more.
There are various methods to obtain optically active d- and l-compounds among the compounds (I), since those can be attained by subjecting the corresponding dl-compound to the optical resolution known per se, but one of preferable methods may be shown below.
A dl-compound among the compound (I) is treated in a conventional manner with a resolution agent such as brucine, cinchonine, quinine and quaternary salts thereof or the like optical active alkaloid, α-phenethylamine (d- and l-compounds), 3-aminomethylpinane (d- and l-compounds) or the like to obtain respective diastereomer salts and then the salts are separated in a conventional manner to obtain the optical active compounds (I). The method will be explained in more detail, as to the case of that cinchonine-methohydroxide or quinine-methohydroxide is employed as the optical resolution agent, dl-compound among the compounds (I) is dissolved in methanol, ethanol, acetone or the like organic solvent, quinine-methohydroxide solution in equivalent amount is added thereto, and then the mixture is concentrated in vacuo to obtain N-methylquinium salt of the corresponding compound, as an amorphous substance. The amorphous substance is dissolved in methanol, ethanol, isopropanol, acetone or the like organic solvent and the solution is left to stand to form crystals. The crystals are obtained through a filtration of the solution and subjected to recrystallization to obtain N-methylquinium salt of the d-compound. The salt was treated with hydrochloric acid and recrystallized from an organic solvent in a conventional manner to obtain the desired d-compound (I). While the mother liquor, from which the d-compound was filtered off, is concentrated to obtain N-methylquinium salts of the compounds mainly containing the 1-compound and thus the salts are treated with hydrochloric acid to obtain crystals of the compounds containing mainly the l-compound. The crystals are dissolved in methanol, ethanol, acetone or the like organic solvent, cinchonine-methohydrooxide solution in equivalent amount is added thereto, and the mixture is concentrated in vacuo to obtain N-methylcinchonium salts of the compounds containing mainly the l-compound. The salts are dissolved in methanol, ethanol, isopropanol, acetone or the like organic solvent and left to stand to obtain crystals which are recrystallized to obtain N-methylcinchonium salt of the l-compound. The salt is treated with hydrochloric acid and recrystallized from an organic solvent to obtain the desired l-compound (I).
According to said method, the d-compound is firstly obtained with use of quinine-methohydroxide as the resolution agent and then the l-compound is obtained with use of cinchonine-methohydroxide but this method can also be carried out by firstly obtaining the l-compound with use of cinchonine-methohydroxide and then obtaining the d-compound with use of quinine-methohydroxide.
The d- and l-compounds of compounds (I-c), (I-d), (I-e), (I-f), (I-g) and (I-h) can be obtained by carrying out a similar optical resolution with respect to the compounds (I-b) and (I-e) to obtain corresponding d- and l-compounds and then carrying out the synthesis as shown in the reaction formula for the Route B, with use of the d- or l-compound as the raw material.
Route C
A process wherein a compound of the formula ##STR23## wherein V, W, X and Y have the meanings as referred to, is nitrated in 8-position, if necessary reduced the introduced nitro radical into amino radical and if necessary acylated the amino radical.
The nitration can be carried out in a manner known per se, for instance with use of strong nitric acid under temperature of -30 to room temperature. The reduction of nitro radical into amino radical can also be carried out in conventional manner with hydrogenation in the presence of a suitable catalyst, for instance Pt, Pd, Raney nickel or the like. As the acylating agent, an acid halide, acid anhydride, active ester and the like reactive acid derivatives may be listed.
According to the invention, the second specific object of the invention can be attained by the optical active 3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid derivatives of the formula ##STR24## wherein Y' and Z' have the meaning as refered to.
The derivatives which can be employed as the raw material for preparing optical active hydantoin derivatives (I) can be prepared by reacting a compound of the formula ##STR25## wherein Y' and Z' have the meanings as referred to, with maleic anhydride, causing with a base a ring closure of the resulting compound of the formula ##STR26## wherein Y' and Z' have the meanings as referred to, activating the resulting compound of the formula ##STR27## wherein Y' and Z' have the meanings as referred to, reacting the compound with (S)-(-)-1-methylbenzylamine, subjecting the resulting diastereomer mixture of the formula ##STR28## wherein Y' and Z' have the meanings as referred to, to a fractional recrystallization, and then hydrolizing the resulting (d)- and (l)-compounds of the formula ##STR29## wherein Y' and Z' have the meanings as referred to.
It may, in general, be considered for the synthesis of the compound (IV) to utilize the acylation (Friedel-Crafts reaction) of the phenol derivative of the formula ##STR30## wherein Y' and Z' have the meanings as referred to, with maleic anhydride but no satisfactionary result can be obtained, since undesirable acylation to the oxygen atom of the phenol derivative will preferencially occur. In order to prevent the acylation to the oxygen atom, it necessary to protect the hydroxy radical of the phenol derivative. As the protecting radical, alkyl radical such as methyl radical is selected, in view of a cost and operability therefor. The protection by methyl radical can be easily and quantitatively carried out by using dimethyl sulfate.
Therefore, in the first step, the anisole derivative (III) formed by protecting hydroxy radical of the phenol derivative is subjected to the Friedel-Crafts acylation with maleic anhydride to form the compound (IV). The reaction conditions depend on the anisole derivative to be selected but are, in general, as follows.
It is preferable to use maleic anhydride in more than 1.1 times molar amount to the anisole derivative (III), so that the anisole derivative is fully exhausted. As a solvent, dichloromethane, carbon tetrachloride, 1,2-dichloroethane, carbon disulfide, nitrobenzene or the like may be employed. As a catalyst, Lewis acids such as aluminum chloride, boron trifluoride, boron tribromide and the like may be listed but it is preferable to use aluminum chloride in more than 2 times molar amount to maleic anhydride. The reaction temperature and time depend on the solvent selected but if dichloromethane is employed, the reaction will be completed in 0.5 to 3 hours under reflux temperature. During the reaction, demethylation (removal of protection radical) will occur to obtain the compound (IV) (Yield: 80 to 95%).
As the base to be used in the second step for ring closing the compound (IV) to make into the racemic 3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid derivative (II-a), sodium carbonate, potassium carbonate, sodium bicarbonate, sodium hydroxide, potassium hydroxide or the like may be employed but sodium bicarbonate is especially preferable among them. An amount of the base is sufficiently 1.01 to 2.0 equivalents. As a solvent, water, water/ethanol, water/methanol or the like polar solvent may be listed but water is most preferable. There is no groud to give a limitation on reaction temperature and the reaction smoothly proceeds at a temperature ranging from 10° to 100° C. The reaction completes by about 10 minutes, when the reaction is carried out at 100° C. The desired compound (II-a) can be obtained in relatively high yield of 90 to 95% by extracting same with a suitable organic solvent such as ethyl acetate, after completion of the reaction.
In the third step for activating the compound (II-a) and causing the reaction with (S)-(-)-1-methylbenzylamine to make into the diastereomer mixture (V-a), the activation can be carried out by converting the compound into its acid halide, in a conventional manner. As a halogenation agent therefor, thionyl chloride, phosphoric pentachloride or the like can be employed in an amount of 1 to 3 equivalent one. The activating reaction will proceed smoothly without use any solvent but as the solvent, benzene, dichloromethane, dichloroethane or the like may be employed. There is no limitation on the reaction temperature and if a solvent is employed, a temperature between 10° C. and boiling point of the solvent may be employed. After completion of the reaction, the solvent or excessive halogenation agent is distilled out to quantitatively obtain the activated compound (V) of acid halide, for instance acid chloride. The reaction between this acid halide and (S)-(-)-1-methylbenzylamine can be carried out by using the reactants in equimolar amount in a suitable solvent and in the presence of a base. As the base for this reaction, triethylamine, pyridine and the like may be listed but triethylamine is more preferable. As the solvent, dichloromethane, dichloroethane, N,N-dimethylformamide and the like may be listed but dichloromethane is more preferable. The reaction will, in general, be completed for about 1 hour, when the reaction is carried out at a temperature between 0° and 20° C. After completion of the reaction, the reaction mixture is washed by water to obtain the diastereomer mixture (V-a) with yield of 90 to 100%.
In the fourth step for fractionally recrystallizing the diastereomer mixture (V-a) to convert same into the optical active compound (V), ethanol and methanol and the like alcohols may be listed as the recrystallization solvent but ethanol is preferable, which is used 5 to 20 times in amount. By carrying out the recrystallization operation twice, (d)-type compound (V) having an optical purity of more 90% e.e. can be obtained with a higher yield of 70 to 80%. While, a similar recrystallization operation is carried out twice with use of the mother liquid to obtain (l)-type compound (V) having an optical purity of more 90% e.e. and with a higher yield of 70 to 80%.
In the last of fifth step for hydrolyzing the compound (V) to convert the same into the desired optical active compound of 3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid, as the hydrolyzing agent, an acid, for instance hydrochloric acid, bromic acid, sulfuric acid or the like mineral acid may be employed but hydrochloric acid is more preferable. As the solvent, methanol, ethanol, dioxane, acetic acid or the like may be employed but dioxane is more preferable. There is no specific limitation on the reaction temperature and time but the reaction will be completed for about 20 hours, when it carried out at 100° C. After completion of the reaction, an extraction is carried out with use of dichloromethane or the like organic solvent to obtain the desired compound (II) having an optical purity of more 99% e.e and with a higher yield of 85 to 95%.
The optical active hydantoin derivatives (I-b, I-c, I-d, I-e, I-f, I-g and I-h) can be synthesized by using the resulting optical active compound (II) as the raw material. Namely, a reaction of the optical active compound (II), metal cyanide and ammonium carbonate gives the optical active hydantoin compound (I-b). And, by using the resulting (d)- or (1)-type compound (I-b) as the raw material and carrying out the synthesis in accordance with the Route B, (d)- and (l)-type compounds of I-c, I-d, I-e, I-f, I-g and I-h can be obtained, respectively.
The d-type amido derivative (I-c) having a strong aldose reductase inhibition can be synthesized with a higher yield by using d-type compound (II) as raw material therefor. The d-type hydantoin derivative (I-b) derived from d-type compound (II) can be converted with a higher yield (97.1%) into d-type ester derivative (I-d). By reacting the resulting compound (I-d) with a compound of the formula ##STR31## wherein R 1 and R 2 have the meanings as referred to, in the presence or absence of a catalyst, the d-type compound (I-c) can be obtained with a higher yield of more than 90%. This method is quite useful for synthesizing the compound (I-c), since the yield thereof is higher than that in Route B wherein the compound is synthesized through the compound (I-b). Therefore, this method is named as Route D. ##STR32##
As a solvent for amidizing reaction of the compound (I-d), methanol, ethanol, n-propanol or the like lower alcohol, tetrahydrofuran, dioxane or the like cycroether, N,N-dimethylformamide or the like can be used. If necessary, ammonium chloride, sodium methoxide, sodium amide, butyllithium, sodium hydride or the like may be employed as a catalyst.
The reaction can be carried out at a temperature between 0° to 100° C. In case of the reaction with a lower amine, the reaction under conditions of room temperature, in methanol and in the absence of catalyst gives a especially preferable result.
In the manner similar to the above, l-type amido derivative (I-c) can also be obtained with a higher yield, in accordance with this Route D, by starting from 1-type compound (II) as raw material therefor.
EFFECTS OR ADVANTAGES OF THE INVENTION
The compounds (I) and salts thereof according to the invention, especially d-type as well as dl-type compounds and more particularly the d-type compounds show an excellent inhibition to aldose reductase and thus useful as an effective ingredient for medicines for preventing or curing complications of diabetes. Certain compounds (I) show a quite low toxicity (LD 50 =more than 5000 mg/kg), when the compound is administered in oral route.
FORM AS MEDICINES AND DOSING AMOUNT
There is no specific limitation, when the compound or salt according to the invention will be made into a medicine containing at least one of the compounds or salts, as effective ingredient. Therefore, the medicine may be of a solid form such as tablet, pill, capsule, powder, granules and suppository or a liquid form such as solution, suspension or emulsion, together with a conventional additive(s) and/or a carrier(s).
A dosing amount of the compound or salt for human depends on kind of the compound or salt per se to be selected, condition of illness, age of the patient, form of the medicine and other factors but in case for an adult, 0.1 to 500 mg/day and more particularly 1 to 150 mg/day are preferable.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will now be further explained with reference to Manufacturing Examples of the compounds and salts, Pharmacological Test Examples as well as Prescriptional Examples.
EXAMPLE 1
dl-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid
A mixture of potassium cyanide (16.1 g, 0.248 mol), ammonium carbonate (71.4 g, 0.744 mol) and dl-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid 26.0 g, 0.124 mol) in 237 ml of water was stirred at 65°-70° C. for 24 hours, and then at 80°-90° C. for 15 minutes. The reaction mixture was cooled to room temperature and acidified with concentrated hydrochloric acid. Resulting crystals were obtained through a filtration to give 30.6 g of a diastereomer mixture of 6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid (5:1 mixture) as pale yellow crystals. The crystals were recrystallized from water to give 20.4 g (58.8%) of the subject desired compound.
The compound was a single diastereomer without containing another diastereomer.
Melting point: 294°-298° C. (dec.).
IR spectrum (ν max KBr ) cm -1 : 1770, 1750, 1720.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.88-2.80 (2H, m), 5.23 (1H, dd), 6.83-7.38 (3H, m), 8.37 (1H, br.s), 11.07 (1H, br.s).
Mass spectrum (EI/DI) m/z: 280 (M + ), 262, 234, 219.
Elementary analysis: C 12 H 9 FN 2 O 5 ; Cal.: C, 51.43; H, 3.24; N, 10.00; Found: C, 51.15; H, 3.28; N, 9.98.
From the mother liquor, the other diastereomer of the subject compound was obtained.
In the evaluation of these diastereomers on the ability of reduction or inhibition of polyol increase in sciatic nerve of galactosemic rats, the potency of the major diastereomer (firstly obtained one) was higher than that of the minor diastereomer.
EXAMPLE 2
dl-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
(a) To a solution of dl-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid (150 g, 0.536 mol) (obtained through the process as described in Example 1) in 1.0 liter of anhydrous pyridine, silicon tetrachloride (66.6 g, 0.392 mol) was added below 10° C. After stirring the solution for 15 minutes at room temperature, dry ammonia gas was introduced in excess amount below 10° C.
The mixture was stirred for 12 hours at room temperature and then poured into 3.0 liter of methanol. Undissolved matter was filtered off and the filtrate was evaporated to dryness. To the residue, 1.2 liter of water were added. The mixture was stirred for an hour at room temperature. Resulting precipitate was obtained through a filtration and recrystallized from methanol to give 110 g (73.2%) of the subject desired compound.
Melting point: 286°-300° C. (dec.).
IR spectrum (ν max KBr ) cm -1 : 1770, 1720, 1670.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.83-2.67 (2H, m), 5.17 (1H, dd), 6.93-7.33 (3H, m), 7.57, 7.80 (1H, br.s), 8.47 (1H, br.s), 11.07 (1H, br.s).
Mass spectrum (EI/DI) m/z: 279 (M + ), 262, 235, 219
Elementary analysis: C 12 H 10 FN 3 O 4 ; Cal.: C, 51.62; H, 3.61; N, 15.05; Found: C, 51.79; H, 3.58; N, 14.98.
(b) To a solution of the diastereomer mixture (5:1) of 6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid (29.9 g, 107 mmol) (obtained through the process as described in Example 1) in 320 ml of anhydrous pyridine, silicon tetrachloride (20.7 g, 122 mmol) and dry ammonia gas were added as described in said Item (a) and the similar operation was carried out to obtain crystals. The crystals were recrystallized from ethanol to give colorless one (14.4 g, 48.5%) having physical properties same with those obtained in said Item (a).
From the mother liquor, further, another diastereomer of the subject compound was obtained, which has following physical properties.
Melting point: 285°-295° C. (dec.).
IR spectrum (ν max KBr ) cm -1 : 1765, 1724, 1660.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.95-2.68 (2H, m), 4.55 (1H, dd), 6.83-7.48 (3H, m), 7.58, 7.81 (2H, br.s), 8.98 (1H, br.s), 11.18 (1H, br.s).
Mass spectrum (EI/DI) m/z: 279 (M + ), 236, 193, 192, 165.
Elementary analysis: C 12 H 10 FN 3 O 4 ; Cal.: C, 51.62; H, 3.61; N, 15.05; Found: C, 51.57; H, 3.62; N, 15.01.
In the evaluation of these diastereomers on the ability of reduction or inhibition of polyol increase in sciatic nerve of galactosemic rats, the activity of the former crystals having the melting point of 286°-300° C. (dec.) was more than 10 times in comparison with that of the latter crystals having the melting point of 285°-295° C. (dec.).
EXAMPLE 3
Optical resolution of dl-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
(a) Preparation of d-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
To a suspension of dl-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide having the melting point of 286°-300° C. (dec.) (10.0 g, 35.8 mmol) (obtained through the process as described in Example 2) in 500 ml of methanol, an aqueous quinine methohydroxide solution (36.0 mmol) [J. Am. Chem. Soc., Vol. 63, page 1368 (1941)] was added dropwise under stirring in an ice bath. After stirring the mixture at room temperature for 2 hours, the mixture was evaporated in vacuo to dryness. Resulting pale yellow amorphous was dissolved in 150 ml of ethanol. The solution was concentrated to the volume of 100 ml under reduced pressure and then allowed to stand for 2 days.
Resulting crystals were obtained through a filtration and recrystallized from ethanol to give 5.02 g of N-methyl-quinium d-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide salt.
Melting point: 240°-241° C. (dec.).
[α] D 20 : -14.3° (methanol).
Elementary analysis: C 33 H 36 FN 5 O 6 : Cal.: C, 64.17; H, 5.87; N, 11.34; Found: C, 63.82; H, 5.87; N, 11.33.
The salt (4.87 g, 7.74 mmol) was dissolved in the mixture of 17 ml of ethanol and 4.1 ml of water. To the solution under stirring in an ice bath, 8.0 ml of 1N-hydrochloric acid solution were added and the mixture was stirred at room temperature for an hour. The reaction mixture was evaporated in vacuo to give crystalline mass, to which 97 ml of water were added.
After stirring the mixture at room temperature overnight, crystals deposited out therein were obtained through a filtration and recrystallized from ethanol to give 1.30 g of d-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide.
Melting point: 290°-291° C. (dec.).
[α] D 20 : +167° (methanol).
Elementary analysis: C 12 H 10 FN 3 O 4 ; Cal.: C, 51.62; H, 3.61; N, 15.05; Found: C, 51.73; H, 3.51; N, 14.99.
(b) Preparation of 1-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
The mother liquor, which was the filtrate after the filtration of the primary crystalline mass of N-methyl-quinium d-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide salt, was evaporated in vacuo to dryness. Resulting amorphous was dissolved in the mixture of 40 ml of ethanol and 10 ml of water and then 19 ml of 1N-hydrochloric acid solution were added dropwise to the solution under stirring in an ice bath. After stirring at room temperature for an hour, the solution was evaporated in vacuo to dryness. To the residue, 220 ml of water were added and the solution was stirred at room temperature overnight.
Resulting crystals (4.88 g) deposited out therein were obtained through a filtration. To a suspension of the crystals (2.84 g) in 100 ml of ethanol under stirring in an ice bath, an aqueous cinchonine methohydroxide solution (11.0 mmol) [J. Am. Chem. Soc., Vol. 41, page 2090 (1919)] was added dropwise. After stirring at room temperature for 2 hours, the solution was evaporated in vacuo to give an amorphous residue which was dissolved in 28 ml of isopropyl alcohol, followed by allowing to stand for 2 days. Resulting crystals deposited out therein were obtained through a filtration and recrystallized from ethanol to give 2.49 g of N-methyl-cinchonium 1-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide salt.
Melting point: 242°-243° C. (dec.).
[α] D 20 : +20.1° (methanol).
Elementary analysis: C 32 H 34 FN 5 O 5 ; Cal.: C, 65.40; H, 5.83; N, 11.92; Found: C, 65.07; H, 5.84; N, 11.82.
The salt (2.49 g, 4.23 mmol) was dissolved in the mixture of 10 ml of ethanol and 2.0 ml of water. To the solution under stirring in an ice bath, 4.5 ml of 1N-hydrochloric acid solution were added dropwise and the mixture was stirred at room temperature for an hour. The reaction mixture was evaporated in vacuo to give crystalline mass, to which 35 ml of water were added.
After stirring the mixture at room temperature overnight, crystals deposited out therein were obtained through a filtration and recrystallized from ethanol to give 880 mg of 1-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide.
Melting point: 290°-293° C. (dec.).
[α] D 20 : -169° (methanol).
Elementary analysis: C 12 H 10 FN 3 O 4 ; Cal.: C, 51.62; H, 3.61; N, 15.05; Found: C, 51.69; H, 3.52; N, 14.99.
EXAMPLE 4
dl-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid methyl ester
To a soluion of dl-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid (20.4 g, 72.9 mmol) (obtained through the process as described in Example 1) in 765 ml of methanol, 20.0 ml of concentrated sulfuric acid were added. The mixture was refluxed for 1.5 hours and then cooled to room temperature. Crystals deposited out therein were obtained through a filtration and dried to give 20.0 g (93.4%) of the subject desired compound.
Melting point: 291° C.
IR spectrum (ν max KBr ) cm -1 : 1790, 1745, 1730.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.92-2.85 (2H, m), 3.80 (3H, s), 5.40 (1H, dd), 7.00-7.43 (3H, m), 8.43 (1H, br.s), 11.10 (1H, br.s).
Mass spectrum (EI/DI) m/z: 294 (M + ), 262, 234, 192, 164, 137.
Elementary analysis: C 13 H 11 FN 2 O 5 ; Cal.: C, 53.06; H, 3.77; N, 9.52; Found: C, 53.07; H, 3.62; N, 9.56.
EXAMPLE 5
dl-6-Fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
To a suspension of lithium aluminium hydride (2.30 g, 0.06 mol) in 100 ml of tetrahydrofuran, a solution of dl-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid methyl ester (11.7 g, 0.04 mol) (obtained through the process as described in Example 4) in 100 ml of tetrahydrofuran was added at 5° C. After stirring the mixture for 20 hours at room temperature (15°-20° C.), the reaction mixture was poured onto 300 ml of cracked ice under stirring. While cooling the solution (10°-15° C.), the solution was acidified to pH 1 by adding concentrated hydrochloric acid and extracted with 400 ml of ethyl acetate. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and evaporated in vacuo to give a solid. The solid was recrystallized from methanol to give 8.70 g (82.0%) of the subject desired compound.
Melting point: 224°-225° C. (dec.).
IR spectrum (ν max KBr ) cm -1 : 3360, 1760, 1720
NMR spectrum (DMSO-d 6 ) δ ppm: 1.70-2.40 (2H, m), 3.50-3.86 (2H, m), 4.50-4.96 (1H, m), 4.50-5.20 (1H, m), 6.80-7.47 (3H, m), 8.46 (1H, br.s), 11.00 (1H, br.s).
Mass spectrum (EI/DI) m/z: 266 (M + ), 248, 228.
Elementary analysis: C 12 H 11 FN 2 O 4 ; Cal.: C, 54.14; H, 4.16; N, 10.52; Found: C, 53.98; H, 4.34; N, 10.35.
EXAMPLE 6
Optical resolution of dl-6-Fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
(a) Preparation of d-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
dl-6-Fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (25.0 g, 93.9 mmol) (obtained through the process as described in Example 5) was dissolved in 2.5 liter of ethanol and to the resulting solution, an aqueous quinine methohydroxide solution (96.1 mmol) was added dropwise, under cooling in an ice bath. After stirring the mixture at room temperature for an hour, the solvent was evaporated in vacuo to give 66.0 g of the residue, which was recrystallized from methanol twice to give 16.4 g of N-methyl-quinium d-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione salt.
Melting point: 235°-237° C. (dec.).
[α] D 20 : +5.7° (methanol).
Elementary analysis: C 33 H 37 FN 4 O 6 ; Cal.: C, 65.55; H, 6.17; N, 9.27; Found: C, 65.64; H, 6.33; N, 9.28.
The salt (16.0 g, 26.5 mmol) was added to the mixture of 610 ml of ethyl acetate and 17 ml of water, and then 17 ml of 16% aqueous solution of hydrochloric acid were added dropwise to the mixture under stirring same vigously in an ice bath. After stirring the mixture for 30 minutes, the organic layer was separated from the aqueous layer, and the aqueous layer was further extracted with ethyl acetate. Both of ethyl acetate layers were combined together, dried over anhydrous sodium sulfate and evaporated in vacuo to dryness. The residue was recrystallized from ethanol to give 6.32 g of d-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione.
Melting point: 188°-189° C.
[α] D 20 : +222° (methanol).
Elementary analysis: C 12 H 11 FN 2 O 4 ; Cal.: C, 54.14; H, 4.16; N, 10.52; Found: C, 54.29; H, 4.25; N, 10.53.
(b) Preparation of 1-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
The mother liquor, which was the filtrate after the filtration of the primary or predominant crystalline mass of N-methyl-quinium d-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzoyran-4,4'-imidazolidine]-2',5'-dione salt, was evaporated in vacuo to dryness. To the residue, 1.25 liter of ethyl acetate and 35 ml of water were added, and then 35 ml of 16% aqueous solution of hydrochloric acid were added dropwise to the mixture under stirring same vigously in an ice bath. After stirring the mixture for 30 minutes, the organic layer was separated from the aqueous layer, and the aqueous layer was further extracted with ethyl acetate. Both of ethyl acetate layers were combined together, dried over anhydrous magnesium sulfate and evaporated in vacuo to give 12.0 g of crystalline mass.
The crystalline mass (11.3 g, 42.4 mmol) was dissolved in 200 ml of ethanol, and an aqueous cinchonine methohydroxide solution (46.4 mmol) was added to the solution under strirring in an ice bath. After stirring the mixture at room temperature for an hour, the solvent was evaporated in vacuo to give the residue, which was crystallized from ethanol. The resulting crystals were obtained through a filtration and recrystallized from methanol to give 15.5 g of N-methyl-cinchonium 1-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione salt.
Melting point: 244°-246° C. (dec.).
[α] D 20 : +3.8° (methanol).
Elementary analysis: C 33 H 37 FN 4 O 5 ; Cal.: C, 66.88; H, 6.14; N, 9.75; Found: C, 67.04; H, 6.32; N, 9.82.
The salt (15.0 g, 26.1 mmol) was added to the mixture of 610 ml of ethyl acetate and 17 ml of water, and then 17 ml of 16% aqueous solution of hydrochloric acid were added dropwise to the mixture under stirring same vigously in an ice bath. After stirring at room temperature the mixture for 30 minutes, the organic layer was separated from the aqueous layer, and the aqueous layer was further extracted with ethyl acetate. Both of ethyl acetate layers were combined together, dried over anhydrous sodium sulfate and evaporated in vacuo to dryness. The residue was recrystallized from ethanol to give 6.31 g of 1-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione.
Melting point: 188°-189° C. (dec.).
[α] D 20 : -231° (methanol).
Elementary analysis: C 12 H 11 FN 2 O 4 ; Cal.: C, 54.14; H, 4.16; N, 10.52; Found: C, 54.31; H, 4.15; N, 10.54.
EXAMPLE 7
dl-2-Chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
To a solution of dl-6-fluoro-2,3-dihydro-2-hydroxymethylspiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (2.66 g, 10 mmol) (obtained through the process as described in Example 5) in 20 ml of N,N-dimethylformamide, thionylchloride (1.19 g, 10 mmol) was added. The solution was stirred at room temperature for 2.0 hours and further at 80°-85° C. for 4 hours. After cooling, thee reaction mixture was poured onto 100 ml of cracked ice and resulting precipitate was obtained through a filtration. The precipitate was partitioned between 70 ml of ethyl acetate and 50 ml of water. The organic layer was dried over anhydrous sodium sulfate and the solvent was evaporated in vacuo to give a pale yellow solid which was chromatographed on silica gel, eluted with ethyl acetate/n-hexane (1:1) to give 2.42 g (85.1%) of the subject desired compound.
Melting point: 212°-214° C.
NMR spectrum 8dmsoA-d 6 ) δ ppm: 1.86-2.42 (2H, m), 3.90-4.30 (2H, m), 4.76-5.23 (1H, m), 6.90-7.40 (3H, m), 8.46 (1H, br.s), 10.00-11.50 (1H, br.s).
Mass spectrum (EI/DI) m/z: 284 (M + ), 248, 219, 205, 177, 164, 137.
Elementary analysis: C 12 H 10 ClFN 2 O 3 ; Cal.: C, 50.63; H, 3.54; N, 9.84; Found: C, 50.77; H, 3.40; N, 9.71.
EXAMPLE 8
d-2-Chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
To a solution of d-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (600 mg, 2.25 mmol) (obtained through the process as described in Example 6-a) in 3.00 ml of N,N-dimethylformamide, thionylchloride (0.17 ml, 2.39 mmol) was added. The solution was stirred at room temperature for 3.0 hours and further at 80° C. for 3.0 hours. Thereafter, the operation as described in Example 7 was carried out to give 461 mg (71.8%) of the subject desired compound.
Melting point: 239°-240° C.
[α] D 20 : +216° (methanol).
Elementary analysis: C 12 H 10 ClFN 2 O 3 ; Cal.: C, 50.63; H, 3.54; N, 9.84; Found: C, 50.72; H, 3.49; N, 9.94.
EXAMPLE 9
1-2-Chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
The operation as described in Example 8 was repeated except that 1-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (600 mg, 2.25 mmol) (obtained through the process as described in Example 6-b) was employed as the starting material in lieu of the corresponding d-type compound. In this case, 492 mg (76.6%) of the subject compound were obtained.
Melting point: 239°-240° C.
[α] D 20 : -217° (methanol)
Elementary analysis: C 12 H 10 ClFN 2 O 3 ; Cal.: C, 50.53; H, 3.54; N, 9.84; Found: C, 50.46; H, 3.34; N, 9.86.
EXAMPLE 10
dl-2-Bromomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
To a solution of dl-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (3.6 g, 13.5 mmol) (obtained through the process as described in Example 5) in 28.0 ml of N,N-dimethylformamide, thionylbromide (3.47 g, 16.7 mmol) was added below 10° C. The mixture was stirred at room temperature for 2.0 hours and further stirred for 1.5 hours at 80° C. After cooling, the reaction mixture was poured onto 40 ml of cracked ice. Resulting aqueous solution was stirred for 30 minutes at room temperature and extracted with ethyl acetate. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and evaporated in vacuo to give a solid. The solid was recrystallized from the mixture of acetone nd n-hexane to give 3.40 g (77.3%) of the subject desired compound.
Melting point: 209°-211° c.
IR spectrum (ν max KBr ) cm -1 : 1780, 1740, 1495.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.87-2.43 (2H, m), 3.73-4.03 (2H, m), 4.73-5.20 (1H, m), 6.83-7.47 (3H, m), 8.53 (1H, br.s), 11.05 (1H, br.s).
Elementary analysis: C 12 H 10 BrFN 2 O 3 ; Cal.: C, 43.79; H, 3.06; N, 8.51; Found: C, 43.67; H, 3.02; N, 8.48.
EXAMPLE 11
d-2-Bromomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
To a solution of d-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (2.00 g, 7.51 mmol) (obtained through the process as described in Example 6-a) in 15.0 ml of N,N-dimethylformamide, thionylbromide (0.64 g, 8.27 mmol) was added. The mixture was stirred at room temperature for 2.0 hours and then refluxed for 1.5 hours. The reaction mixture was poured onto 67.0 ml of cracked ice and extracted with ethyl acetate. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and evaporated in vacuo. The resulting residue was chromatographed on silica gel, eluted with ethyl acetate/n-hexane (1:1) to give crystals. The crystals were recrystallized from ethyl acetate to give 1.74 g (70.4%) of the subject desired compound.
Melting point: 226°-227° C.
[α] D 20 : +193° (methanol).
Elementary analysis: C 12 H 10 BrFN 2 O 3 ; Cal.: C, 43.79; H, 3.06; N, 8.51; Found: C, 43.75; H, 2.80; N, 8.63.
EXAMPLE 12
1-2-Bromomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
The operation as described in Example 11 was repeated except that 1-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (2.00 g, 7.51 mmol) (obtained through the process as described in Example 6-b) was employed as the starting material in lieu of the corresponding d-type compound. In this case, 1.81 g (73.3%) of the subject desired compound were obtained.
Melting point: 226°-227° C.
[α] D 20 : -193° (methanol).
Elementary analysis: C 12 H 10 BrFN 2 O 3 ; Cal.: C, 43.79; H, 3.06; N, 8.51; Found: C, 43.50; H, 2.81; N, 8.53.
EXAMPLE 13
dl-6-Fluoro-2-fluoromethyl-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
To 15 ml of anhydrous tetrahydrofuran under argon atmosphere, diethylaminosulfur trifluoride (4.09 g, 25 mmol) and a solution of dl-6-fluoro-2,3-dihydro-2-hydroxymethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (3.99 g, 15 mmol) (obtained through the process as described in Example 5) in 80 ml of anhydrous tetrahydrofuran were added dropwise below -50° C. The mixture was then warmed to room temperature (25° C.) and stirred for 4.5 hours at room temperature (25°-30° C.). The solvent in the mixture was evaporated in vacuo and the residue was partitioned between water and ethyl acetate. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and evaporated in vacuo to dryness. The remaining residue was chromatographed on silica gel, eluted with ethyl acetate/n-hexane (1:1) to give 1.43 g (35.6%) of the subject desired compound.
Melting point: 183°-185° C.
IR spectrum (ν max KBr ) cm -1 : 1780, 1730, 1495.
Mass spectrum (EI/DI) m/z: 268 (M + ), 248, 219, 205, 197, 192, 177, 164, 137.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.83-2.43 (2H, m), 3.90-5.47 (3H, m), 6.80-7.43 (3H, m), 8.50 (1H, br.s), 11.03 (1H, br.s).
REFERENCE EXAMPLE
dl-2-Azidomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
A mixture of dl-2-chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (4.26 g, 15 mmol) (obtained through the process as described in Example 7), sodium iodide (600 mg, 4 mmol) and sodium azido (1.47 g, 23 mmol) in 20 ml of N,N-dimethylformamide was heated at reflux temperature for 1.5 hours and then poured onto 50 ml of cracked ice. The resulting precipitate was obtained through a filtration and then partitioned between ethyl acetate and water. The organic layer was washed with water, dried over anhydrous sodium sulfate, filtered and evaporated in vacuo to give a solid. The solid was chromatographed on silica gel, eluted with ethyl acetate to give 3.06 g (70.1%) of the subject desired compound.
Mass spectrum (EI/DI) m/z: (M + ), 248, 192.
NMR spectrum (DMSO-d 6 ) δ ppm: 2.00-2.40 (2H, m), 3.56-3.93 (2H, m), 4.83-5.26 (1H, m), 6.86-7.50 (3H, m) 8.48 (1H, br.s), 11.07 (1H, br.s).
EXAMPLE 14
dl-2-aminomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
To a suspension of 20% Pd-C (0.6 g) in 20 ml of 50% aqueous ethanol, a solution of dl-2-azidomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (3.0 g, 10 mmol) (obtained through the process as described in the Reference Example) in 160 ml of ethanol was added at room temperature. The mixture was hydrogenated for 16 hours at room temperature under atmospheric pressure. After filtration, the filtrate was evaporated in vacuo to give a solid. The solid was recrystallized from ethanol to give 2.5 g (84.0%) of the subject desired compound.
Melting point: 231°-233° C. (dec.).
IR spectrum (ν max KBr ) cm -1 : 1775, 1725.
Mass spectrum (EI/DI) m/z: 265 (M + ), 248.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.67-2.67 (2H, m), 2.80 (2H, d), 4.33-5.00 (1H, m), 4.83-6.00 (1H, br), 6.77-7.43 (3H, m).
EXAMPLE 15
d-6-Fluoro-2,3-dihydro-8-nitro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
d-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (2.00 g, 7.17 mmol) (obtained through the process as described in Example 3-a) was added to 10 ml of fuming nitric acid (specific gravity: 1.52) under stirring below -30° C. The reaction mixture was stirred below -15° C. for 40 minutes and poured onto 30 ml of cracked ice. Resulting crystals deposited out therein were obtained through a filtration and washed with water. The filtrate was further extracted with ethyl acetate and the organic layer was evaporated in vacuo to give an additional amount of crystals.
The crystals were combined together and recrystallized from methanol to give 2.02 g (87.1%) of the subject desired compound.
Melting point: 269°-270° C.
[α] D 20 : +274° (methanol).
IR spectrum (ν max KBr ) cm -1 : 1780, 1730, 1670, 1535, 1235.
Mass spectrum (EI/DI) m/z: 324 (M + ), 237.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.92-2.90 (2H, m), 5.10-5.50 (1H, m), 7.40-8.25 (4H, m), 8.60 (1H, br), 11.25 (1H, br).
Elementary analysis: C 12 H 9 FN 4 O 6 ; Cal.: C, 44.45; H, 2.80; N, 17.28; Found: C, 44.54; H, 2.68; N, 17.17.
EXAMPLE 16
d-8-Amino-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
To a solution of d-6-fluoro-2,3-dihydro-8-nitro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (1.40 g, 4.32 mmol) (obtained through the process as described in Example 15) in 40 ml of methanol, platinum (IV) oxide (140 mg) was added and the mixture was hydrogenated for 20 hours at room temperature under atmospheric pressure.
The catalyst was filtered off and the filtrate was evaporated in vacuo and the residue was recrystallized from the mixture of methanol and water to give 1.15 g (90.6%) of the subject desired compound.
Melting point: 240°-245° C.
[α] D 20 : +154° (methanol).
IR spectrum (ν max KBr ) cm -1 : 1770, 1735, 1680, 1495.
Mass spectrum (EI/DI) m/z: 294 (M + ).
NMR spectrum (DMSO-d 6 ) δ ppm: 1.67-2.80 (2H, m), 4.80-5.17 (1H, m), 5.70 (2H, br), 6.07 (1H, dd), 6.45 (1H, dd), 7.53 (1H, br), 7.95 (1H, br), 8.28 (1H, br), 10.98 (1H, br).
EXAMPLE 17
dl-6-Fluoro-2,3-dihydro-8-nitro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
dl-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (2.00 g, 7.17 mmol) (obtained through the process as described in Example 2) was added to 6 ml of fuming nitric acid (specific gravity: 1.52) under stirring at -30° C. the reaction mixture was stirred below -15° C. for an hour and poured onto 30 ml of cracked ice. Resulting crystals deposited out therein were obtained through a filtration and washed with water, dried and recrystallized from the mixture of N,N-dimethylformamide and methanol to give 1.98 g (85.3%) of the subject desired compound.
Melting point: above 300° C.
IR spectrum (ν max KBr ) cm -1 : 1780, 1735, 1690, 1530, 1240.
Mass spectrum (EI/DI) m/z: 324 (M + ), 237.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.92-2.90 (2H, m), 5.10-5.50 (1H, m), 7.40-8.25 (4H, m), 8.60 (1H, br), 11.25 (1H, br).
EXAMPLE 18
dl-8-Amino-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
To a solution of dl-6-fluoro-2,3-dihydro-8-nitro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (1.40 g, 4.32 mmol) (obtained through the process as described in Example 17) in 20 ml of N,N-dimethylformamide and 40 ml of methanol, platinum (IV) oxide (140 mg) was added and the mixture was hydrogenated for 20 hours at room temperature under atmospheric pressure.
The catalyst was filtered off and the filtrate was evaporated in vacuo and the residue was recrystallized from the mixture of N,N-dimethylformamide and methanol to give 1.17 g (92.1%) of the subject desired compound.
Melting point: 295°-above 301° C.
IR spectrum (ν max KBr ) cm -1 : 1770, 1725, 1675, 1495.
Mass spectrum (EI/DI) m/z: 294 (M + ).
NMR spectrum (DMSO-d 6 ) δ ppm: 1.67-2.80 (2H, m), 4.80-5.17 (1H, m), 5.70 (2H, br), 6.07 (1H, dd), 6.45 (1H, dd), 7.53 (1H, br), 7.95 (1H, br), 8.28 (1H, br), 10.98 (1H, br).
EXAMPLE 19
dl-2-Chloromethyl-6-fluoro-2,3-dihydro-8-nitro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
dl-2-Chrolomlethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (2.00 g, 7.4 mmol) (obtained through the process as described in Example 7) was added to 6 ml of fuming nitric acid (specific gravity: 1.52) under stirring at -30° C. The reaction mixture was stirred below -15° C. for 1.5 hours and poured onto 30 ml of cracked ice. Resulting crystals deposited out therein were obtained through a filtration, washed with water, dried and recrystallized from methanol to give 1.81 g (78.0%) of the subject desired compound.
Melting point: 210°-213° C.
IR spectrum (ν max KBr ) cm -1 : 1775, 1730, 1540, 1240.
Mass spectrum (EI/DI) m/z: 329 (M + ), 293
NMR spectrum (DMSO-d 6 ) δ ppm: 1.95-2.83 (2H, m), 3.90-4.10 (2H, m), 4.90-5.40 (1H, m), 7.58 (1H, dd), 7.97 (1H, dd), 8.57 (1H, br), 11.23 (1H, br).
EXAMPLE 20
dl-8-Amino-2-chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione
Toa solution of dl-2-chloromethyl-6-fluoro-2,3-dihydro-8-nitro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (1.40 g, 4.26 mmol) (obtained through the process as described in Example 19) in 40 ml of methanol, platinum (IV) oxide (140 mg) was added and the mixture was hydrogenated for 20 hours at room temperature under atmospheric pressure.
After 20 ml opf N,N-dimethylformamide was added to the mixture, the catalyst was filtered off and the filtrate was evaporated in vacuo to dryness. The residue was recrystallized from the mixture of N,N-dimethylformamide and methanol to give 1.09 g (85.8%) of the subject desired compound.
Melting point: 260° C.
IR spectrum (ν max KRr ) cm -1 : 3420, 3330, 1775, 1710, 1495.
Mass spectrum (EI/DI) m/z: 299 (M + ).
NMR spectrum (DMSO-d 6 ) δ ppm: 1.80-2.65 (2H, m), 3.78-4.10 (2H, m), 4.65-5.35 (3H, m), 6.08 (1H, dd), 6.45 (1H, dd), 8.40 (1H, br), 10.93 (1H, br).
EXAMPLE 21
d-8-Acetamido-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
To a solution of d-8-amino-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (700 mg, 2.38 mmol) (obtained through the process as described in Example 16) in 15 ml of pyridine, acetyl chloride (190 mg, 2.42 mmol) was added.
The reaction mixture was stirred at room temperature for 4 hours and then evaporated in vacuo to dryness. The residue was chromatographed on silica gel, eluted with chloroform/methanol (5:1) to give crystals. The crystals were crystallized from methanol to give 615 mg (76.9%) of the subject desired compound.
Melting point: 202°-203° C.
[α] D 20 : +136° (methanol).
IR spectrum (ν max KBr ) cm -1 : 1780, 1725, 1675, 1540, 1450.
Mass spectrum (EI/DI) m/z: 336 (M + ), 277.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.70-2.80 (2H, m), 2.20 (3H, s), 4.93-5.35 (1H, m), 6.78 (1H, dd), 7.73 (1H, br), 7.96 (1H, dd), 8.20 (1H, br), 8.43 (1H, br), 9.55 (1H, br), 11.10 (1H, br).
EXAMPLE 22
(E)-4-(5-Fluoro-2-hydroxyphenyl)-4-oxo-2-butenoic acid
Into 100 ml of 1,2-dichloroethane, maleic anhydride (11.3 g, 114 mmol) and anhydrous aluminum chloride (31.0 g, 228 mmol) were dissolved by heating at 50° C. for 15 minutes, and then p-fluoroanisole (12.6 g, 100 mmol) was added dropwise. The mixture was refluxed for an hour and then poured into 60 ml of concentrated hydrochloric acid with 400 g of cracked ice. Resulting crystals deposited out therein were obtained through a filtration, washed with water and dried in vacuo to give 16.0 g (80.0%) of the subject desired compound as yellow crystals.
Melting point: 189°-191° C.
IR spectrum (ν max KBr ) cm -1 : 1733, 1648.
NMR spectrum (DMSO-d 6 ) δ ppm:
6.70 (1H, d, J=16.0 Hz), 6.7-8.0 (3H, m), 8.00 (1H, d, J=16.0 Hz).
EXAMPLE 23
6-Fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid
Sodium bicarbonate (2.10 g, 25.0 mmol) was added to a suspension of (E)-4-(5-fluoro-2-hydroxyphenyl)-4-oxo-2-butenoic acid (5.00 g, 23.8 mmol) (obtained through the process as described in Example 22) in 200 ml of distilled water and the mixture was refluxed for 10 minutes. After cooling, the reaction mixture was acidified to pH 1.0 with concentrated hydrochloric acid and then extracted with ethyl acetate. The organic layer was dried over anhydrous sodium sulfate and evaporated in vacuo to give crude crystals which were recrystallized from the mixture of water and methanol to give 4.60 g (92.1%) of the subject desired compound as colorless crystals.
Melting point: 163°-164° C.
IR spectrum (ν max KBr ) cm -1 : 1755, 1650.
Mass spectrum (EI/DI) m/z: 210 (M + ), 165.
NMR spectrum (DMSO-d 6 ) δ ppm: 3.08 (1H, d, J=8.0 Hz), 3.10 (1H, d, J=6.0 Hz), 5.33 (1H, dd, J=8.0 and 6.0 Hz), 7.1-7.8 (3H, m).
EXAMPLE 24
d- and 1-N-[(S)-1-Methylbenzyl]-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxamide
Thionylchloride (71.5 g, 0.600 mol) was added to the solution of dl-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid (84.0 g, 0.400 mol) (obtained through the process as described in Example 23) in 840 ml of 1,2-dichloroethane. After refluxed for an hour, the reaction mixture was evaporated in vacuo to give crystals (91.0 g) of 6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carbonyl chloride. The crystals were dissolved in 50 ml of dichloromethane and resulting solution was added dropwise at 0° to 5° C. into a solution of (S)-(-)-1-methylbenzylamine (48.4 g, 0.400 mol) and triethylamine (40.5 g, 0.400 mol) in 800 ml of dichloromethane.
The mixture was stirred for an hour and then partitioned with water. Dichloromethane layer was separated, dried over anhydrous sodium sulfate and evaporated in vacuo to give crystals (124 g, 99.0%) of diastereomer mixture of N-[(S)-1-methylbenzyl]-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxamide.
The diostereomer mixture was recrystallized from 1 liter of ethanol twice to give 41.8 g (67.5%) of d-N-[(S)-1-methylbenzyl]-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxamide.
Melting point: 170°-172° C.
[α] D 20 : +5° (methanol).
Mass spectrum (EI/DI) m/z: 313 (M + ), 105.
NMR spectrum (CDCl 3 ) δ ppm: 1.48 (3H, d, J=7.0 Hz), 2.7-3.4 (2H, m), 4.8-5.5 (2H, m), 6.8-7.7 (9H, m).
The mother liquor, which was the filtrate after the filtration of the crystalline mass of d-N-[(S)-1-methylbenzyl]-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxamide, was evaporated in vacuo to dryness. The residue was recrystallized from 1 liter of the mixture of ethyl acetate and n-hexane (2:1) twice to give 24.4 g (39.4%) of 1-N-[(S)-1-methylbenzyl]-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxamide.
Melting point: 127°-128° C.
[α] D 20 : -108° (methanol).
Mass spectrum (EI/DI) m/z: 313 (M + ), 105
NMR spectrum (CDCl 3 ) δ ppm: 1.53 (3H, d, J=7.0 Hz), 2.7-3.4 (2H, m), 4.8-5.5 (2H, m), 6.8-7.7 (9H, m).
EXAMPLE 25
d-6-Fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid
A mixture of d-N-[(S)-1-methylbenzyl]-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxamide (127 g, 0.410 mol) (obtained through the process as described in Example 24), concentrated hydrochloric acid (600 ml) and 1,4-dioxane (800 ml) was refluxed for 2 hours. After cooling, the reaction mixture was extracted twice with dichloromethane.
The organic layer was dried over anhydrous sodium sulfate and evaporated in vacuo to give 72.9 g (85.5%) of the subject desired compound as colorless crystals.
Melting point: 175°-177° C.
[α] D 20 : +58° (methanol).
Mass spectrum (EI/DI) m/z: 210 (M + ), 165.
H-NMR spectrum (DMSO-d 6 ) δ ppm: 3.08 (1H, d, J=8.0 Hz), 3.10 (1H, d, J=6.0 Hz), 5.33 (1H, dd, J=8.0 and 6.0 Hz), 7.1-7.8 (3H, m).
Elementary analysis: C 10 H 7 FO 4 ; Cal.: C, 57.15; H, 3.36; Found: C, 57.10; H, 3.29.
EXAMPLE 26
1-6-Fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid
The operation as described in Example 25 was repeated except that 1-N-[(S)-1-methylbenzyl]-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxamide (110 g, 0.350 mol) (obtained through the process as described in Example 24) was employed as the starting material in lieu of the corresponding d-type compound. In this case, 68.2 g (92.4%) of the subject desired compound were obtained.
Melting point: 173°-175° C.
[α] D 20 : -56° (methanol).
Mass spectrum (EI/DI) m/z: 210 (M + ), 165.
H-NMR spectrum (DMSO-d 6 ) δ ppm: 3.08 (1H, d, J=8.0 Hz), 3.10 (1H, d, J=6.0 Hz), 5.33 (1H, dd, J=8.0 and 6.0 Hz), 7.1-7.8 (3H, m).
EXAMPLE 27
d-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid
The operation as described in Example 1 was repeated except that d-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid (54.8 g, 0.216 mol) (obtained through the process as described in Example 25) was employed as the starting material in lieu of the corresponding dl-type compound. In this case, 35.5 g (48.6%) of the subject desired compound were obtained.
Melting point: 146° C.
[α] D 27 : +194° (methanol).
IR spectrum (ν max KBr ) cm -1 : 3336, 1787, 1735, 1718.
Mass spectrum (EI/DI) m/z: 280 (M + ), 262, 164.
EXAMPLE 28
1-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid
The operation as described in Example 1 was repeated except that 1-6-fluoro-3,4-dihydro-4-oxo-2H-1-benzopyran-2-carboxylic acid (250 g, 1.19 mol) (obtained through the process as described in Example 26) was employed as the starting material in lieu of the corresponding dl-type compound. In this case, 202 g (48.6%) of the subject desired compound were obtained.
Melting point: 145° C.
[α] D 27 : -193° (methanol).
IR spectrum (ν max KBr ) cm -1 : 3338, 1787, 1735, 1716.
Mass spectrum (EI/DI) m/z: 280 (M + ), 262, 164.
EXAMPLE 29
d-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid n-propyl ester
A mixture of d-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid (5.0 g, 0.018 mol) (obtained through the process as described in Example 27), concentrated sulfuric acid (0.125 ml, 2.35 mmol), benzene (5 ml, 0.056 mol) and n-propyl alcohol (20 ml, 0.268 mol) was refluxed for 5.0 hours, while azeotropically removing water by setting a Dean-Stark trap. The reaction mixture was concentrated to half volume and partitioned between 100 ml of ethyl acetate and 50 ml of 5% aqueous solution of sodium bicarbonate. The organic layer was separated from the aqueous layer, dried over anhydrous sodium sulfate and evaporated in vacuo to dryness. To the residue, 50 ml of water were added and then the aqueous solution was stirred for an hour. Resulting crystals deposited out therein were obtained through a filtration and dried to give 5.60 g (97.1%) of the subject desired compound.
Melting point: 197°-200° C.
[α] D 26 : +165° (methanol).
IR spectrum (ν max KBr ) cm -1 : 3340, 3265, 1788, 1750, 1720.
Mass spectrum (EI/DI) m/z: 322 (M + ), 192.
Elementary analysis: C 15 H 15 FN 2 O 5 ; Cal.: C, 55.90; H, 4.69; N, 8.69; Found: C, 55.91; H, 4.66; N, 8.88.
EXAMPLE 30
1-6-Fluoro-2,3-dihyro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid n-propyl ester
The operation as described in Example 29 was repeated except that 1-6-fluoro-3,4-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid (5.0 g, 18 mmol) (obtained through the process as described in Example 28) was employed as the starting material in lieu of the corresponding d-type compound. In this case, 5.7 g (quantitative) of the subject desired compound were obtained.
[α] D 26 : -163° (methanol).
Elementary analysis: C 15 H 15 FN 2 O 5 ; Cal.: C, 55.90; H, 4.69; N, 8.69; Found: C, 55.98; H, 4.79; N, 8.67.
EXAMPLE 31
dl-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid n-propyl ester
The operation as described in Example 29 was repeated except that dl-6-fluoro-3,4-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid (5.0 g, 18 mmol) (obtained through the process as described in Example 1) was employed as the starting material in lie of the corresponding d-body compound. In this case, 5.7 g (quantitative) of the subject desired compound were obtained.
Melting point:
Mass spectrum (EI/DI) m/z: 322 (M + ), 192.
NMR spectrum (DMSO-d 6 ) δ ppm: 0.92 (3H, t), 1.68 (2H, hexlet), 2.00-2.90 (2H, m), 4.20 (2H, t), 5.38 (1H, dd), 6.90-7.50 (3H, m), 8.48 (1H, br.s), 11.10 (1H, br.s).
Elementary analysis: C 15 H 15 FN 2 O 5 ; Cal.: C, 55.90; H, 4.69; N, 8.69; Found: C, 55.93; H, 4.65; N, 8.87.
EXAMPLE 32
d-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid methyl ester
The operation as described in Example 4 was repeated except that d-6-fluoro-3,4-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid (35.0 g, 0.125 mol) (obtained through the process as described in Example 27) was employed as the starting material in lieu of the corresponding dl-type compound. In this case, 33.6 g (91.6%) of the subject desired compound were obtained.
Melting point: 340° C.
[α] D 20 : +186° (N,N-dimethylformamide).
IR spectrum (ν max KBr ) cm -1 : 3350, 3280, 1790, 1740.
Mass spectrum (EI/DI) m/z: 294 (M + ), 262.
NMR spectrum (DMSO-d 6 ) δ ppm: 1.92-2.85 (2H, m), 3.81 (3H, s), 5.40 (1H, dd), 6.90-7.40 (3H, m), 8.50 (1H, br), 11.12 (1H, br).
EXAMPLE 33
d-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
(a) To a suspension of d-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid n-propyl ester (1.00 g, 3.11 mmol) (obtained through the process as described in Example 29) in 5.0 ml of methanol, an excess amount of dry ammonia gas was perfused below 24° C. The mixture was stirred for 4.0 hours at 20°-24° C. and then evaporated in vacuo to dryness. To the residue, 10 ml of water were added. After stirring for an hour, the aqueous solution was acidified with 6N-hydrochloric acid solution. Resulting crystals were obtained through a filtration and dried to give 800 mg (90%) of the subject desired compound which had same physical properties with those of the crystals obtained in Example 3-a.
(b) The operation as described in said Item a was repeated except that d-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid methyl ester (30.0 g, 0.102 mol) (obtained through the process as described in Example 32) was emploed as the starting material in lieu of the n-propyl ester. In this case, 20.7 g (72.6%) of the subject desired compound were obtained as crystals which had same physical properties with those of the crystals obtained in Example 3-a.
EXAMPLE 34
1-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide
The operation as described in Example 33-a was repeated except that 1-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxylic acid n-propyl ester (5.75 g, 18 mmol) (obtained through the process as described in Example 30) was employed as the starting material in lieu of the corresponding d-type compound. In this case, 4.9 g (quantitative) of the subject desired compound were obtained [as crystals which had same physical properties with those of the crystals obtained in Example 3-b].
The invention will now be further explained with reference to Pharmacological Test Examples, and please note that Test Compounds and Control Compounds referred to in such Examples are as follows.
Test Compounds
A: dl-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (Example 2),
B: d-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (Examples 3-a and 33)
C: 1-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (Examples 3-b and 34),
D: dl-2-Chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Example 7),
E: d-2-Chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Example 8),
F: 1-2-Chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Example 9),
G: dl-2-Bromomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Example 10),
H: d-2-Bromomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Example 11),
I: 1-2-Bromomethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Example 12),
J: d-6-Fluoro-2,3-dihydro-8-nitro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (Example 15),
K: d-8-Amino-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (Example 16),
L: dl-6-Fluoro-2,3-dihydro-8-nitro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (Example 17),
M: dl-8-Amino-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (Example 18),
N: dl-2-Chloromethyl-6-fluoro-2,3-dihydro-8-nitro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Example 19),
O: dl-8-Amino-2-chloromethyl-6-fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Example 20),
P: d-8-Acetamido-6-fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2-carboxamide (Example 21).
Control Compounds
Q: dl-6-Fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione,
R: d-6-Fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione,
S: 1-6-Fluoro-2,3-dihydro-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione.
Pharmacological Test Example 1
The compounds according to the invention were tested for their ability to reduce or inhibit aldose reductase enzyme activity, in accordance with the method of Kador and Sharpless as described in "Biophysical Chemistry" Vol. 8, page 81 (1978) and using water soluble extracts of rat lenses. Results are given in following Tables 1 and 2 in terms of percent inhibition of enzyme activity with respect to the various concentrations of 10-10M. The selected control compounds are typical one disclosed in Japanese Unexamined patent application Gazette No. 53653/1978 introduced in the preamble of this specification. IC 50 represents the concentration of inhibitor which gives 50% inhibition.
Pharmacological Test Example 2
The compounds according to the invention were tested for their ability to reduce or inhibit polyol increase in the sciatic nerve of galactosemic rats. Rats were fed 30% galactose diet and were administered the compounds at the various doses of 0.4-50 mg/kg once a day for eight days. One day after the final administration (on 9th day), sciatic nerves were removed for galactitol determination. Results are given in following Tables 3 and 4 in terms of ED 50 which represents 50% effective dose. The selected control compounds are typical one described in the aforesaid Japanese unexamined patent application Gazette.
TABLE 1__________________________________________________________________________ Inhibition (%)Compound 10.sup.-8 M 3.3 × 10.sup.-8 M 10.sup.-7 M 3.3 × 10.sup.-7 M 10.sup.-6 M 3.3 × 10.sup.-6 10.sup.-5 IC.sub.50__________________________________________________________________________ (M)Testing compoundA 21 51 80 93 -- -- -- 3.2 × 10.sup.-8B 39 80 93 -- -- -- -- 1.4 × 10.sup.-8C -- -- -- -- -- -- 27 --D -- 28 53 78 -- -- -- 9.0 × 10.sup.-8E 21 38 66 -- -- -- -- 4.7 × 10.sup.-8F -- -- -- -- 28 52 74 2.9 × 10.sup.-6G -- 22 42 70 -- -- -- 1.3 × 10.sup.-7H -- 35 59 82 -- -- -- 6.8 × 10.sup.-8I -- -- -- -- 31 54 75 2.7 × 10.sup.-6Control compoundQ -- 10 17 46 71 85 -- 3.9 × 10.sup.-7R -- 15 34 61 80 88 -- 2.0 × 10.sup.-7S -- -- -- -- -- -- 32 --__________________________________________________________________________
TABLE 2__________________________________________________________________________ Inhibition (%)Compound 10.sup.-8 M 2.0 × 10.sup.-8 M 3.3 × 10.sup.-8 M 10.sup.-7 M 3.3 × 10.sup.-7 10.sup.-6 M IC.sub.50__________________________________________________________________________ (M)Testing compoundJ 35 69 82 -- -- -- 1.4 × 10.sup.-8K 27 -- 60 70 -- -- 2.5 × 10.sup.-8L 15 -- 50 88 -- -- 3.1 × 10.sup.-8M 13 -- 40 74 -- -- 4.4 × 10.sup.-8N -- -- 30 59 81 -- 7.6 × 10.sup.-8O -- -- -- 38 68 85 1.7 × 10.sup.-7P 30 56 69 -- -- -- 1.8 × 10.sup.-8Control compoundR -- -- 24 29 59 76 2.6 × 10.sup.-7__________________________________________________________________________
TABLE 3______________________________________Compound ED.sub.50 (mg/kg)______________________________________Testing compoundA 3.3B 1.3Control compoundQ 36.6R 18.0______________________________________
TABLE 4______________________________________Compound ED.sub.50 (mg/kg)______________________________________Testing compoundD 1.3E 0.6G 7.2H 2.2Control compoundQ 31.5______________________________________
As apparently seen from the results given in the Tables, the compounds according to the invention give fairly high reduction or inhibition of aldose reductase. Moreover, d and dl-type products according to the invention show superior effect and more particularly d-type product shows extremely high effect on reduction or inhibition of aldose reductase.
Pharmaceutical Agent Preparation Example 1 (Tablets)
Tablets for oral administration, each contains 50 mg of an active ingredient were prepared with following prescription and a method known per se.
______________________________________d-6-Fluoro-2,3-dihydro-2',5'-dioxo-spiro[4H--1-benzopyran-4,4'-imidazolidine]-2-carboxamide(Product of Example 3-a) 50 (g)Sodium citrate 25Alginic acid 10Polyvinylpyyrolidone 10Magnesium stearate 5______________________________________
Tablets, each of which contains the active ingredient of 1.0, 4.0, 5.0, 10, 25 and 100 mg, were prepared by varying the mixing amount thereof.
Pharmaceutical Agent Preparation Example 2 (Capsules)
Capsules for oral administration, each contains 10 mg of an active ingredient were prepared with following prescription and a method known per se.
______________________________________d-2-Chloromethyl-6-fluoro-2,3-dihydro-spiro[4H--1-benzopyran-4,4'-imidazolidine]-2',5'-dione(Product of Example 8) 10 (g)Lactose 70Corn starch 20______________________________________
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Hydantoin derivatives and salts thereof, intermediates therefor, process for the preparation thereof, and medicines containing the derivative, wherein said derivatives have the formula ##STR1## wherein one of V and W is hydrogen and the other is a halogenomethyl group, 1H-tetrazol-5-yl radical, --COOR group,
in which R is hydrogen atom, an alkyl group, --(CH 2 CH 2 O)nCH 3 group (n is an integer of 1 to 113) or substituted phenyl, ##STR2## in which R 1 and R 2 are same or different independently, each is hydrogen atom, an alkyl group, substituted phenyl or --(CH 2 CH 2 O)nCH 3 group (n has the meaning as referred to) or R 1 may form a heterocyclic ring together with R 2 and nitrogen or oxygen atom, ##STR3## in which R 2 and R 4 are same or different independently and each is hydrogen atom or an alkyl group,
X is oxygen or sulfur atom, and Y and Z are same or different independently and each is hydrogen atom, a halogen atom, alkyl group, alkoxy group, alkylmercapto group, nitro radical or --NHR 5 group, in which R 5 is hydrogen atom or an acyl group.
The derivatives and salts thereof are useful for the treatment of complications of diabetes.
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This application is the United States national phase application of Ukrainian Patent Application No. 2008 05098 filed Apr. 21, 2008 incorporated therein by reference.
FIELD OF THE INVENTION
The presented technical solution deals with medical equipment, particularly with tools for surgery and is specified for draining of cavities after various types of surgical operations.
BACKGROUND OF THE INVENTION
In surgery a necessity of long draining of cavities often arises. Drainage of various designs is used for this purpose, the appliances are inserted into the drained cavity, ensuring active or passive aspiration. The main and so far unsolved problem of prolong drainage of cavities remains maintaining of permeability of drainage and ensuring the natural process of gradual constriction of wound channel as the cavity heals. Unfortunately despite constant perfection of the design of drainage systems, the drainage opening after some time is obturated with fibrin's clot. In this case drainage is removed and a new drainage system is installed into the drained cavity. Unfortunately it is practically impossible to insert a new drainage into the drained cavity using the old wound passage. This is explained by two main reasons. Firstly, the wound passage is of winding shape on the spot of the removed drainage system and it is practically impossible to lead a new drainage through all its turns. Secondly, fibrin's clots that are found inside the passage of the removed drainage is fixed inside the cavity and is partially preserved inside the passage of the wound channel after the drainage system is removed. The remaining clots prevent insertion of a new drainage strictly along the old wound channel, it may be infected and promote inflammatory process inside the wound channel, decelerating the healing of the cavity and the wound channel. In such cases in order to obtain prolong drainage of cavities an old drainage is removed after it has been obturated with fibrin clots and a new drainage system is installed, using a new wound channel. Several problems arise here. Firstly, it is impossible to lead a new drainage along a new passage strictly to the spot where the end of the old drainage was, thus making the process of cavity's draining inadequate. Secondly, formation of a new wound channel will further traumatize the tissues and may provoke generalization of the infection inside the drained cavity. Thirdly, the presence of fibrin clot inside the old wound channel will promote the inflammatory process inside it.
The appliance for drainage of cavities through skin is known [V. G. Ivshin An appliance for drainage of cavity formation via skin//Surgery—1998.—No 8.—p. 49-50.], this appliance presents a needle with an external cannula, installed non-stationary upon it and drainage to be inserted into the drained cavity along a new wound channel, supervised by ultrasonic testing.
The drawback of this system is impossibility of its insertion along the old wound channel and the necessity to use expensive and technically complicated equipment.
Another design includes drainage tube [A. M. Moroz Drainage tube with centimeters points//Clinical surgery.—1969.—No 5—p. 35.], which presents a spherically closed end of children stomach pump. Before application all necessary holes are made in the tube and it is inserted into the desired depth. According to its author this tube can easily be substitutes, by means of a metal mandrel.
The main drawback of the drainage tube of such design is the absence of a butt hole, thus making the process of drainage ineffective. It is not possible to reinstall the drainage, using a mandrel, as specified by the author.
A model of a drain tube, functioning for a long time is also known [V.I. Shaposhnikov—A design of a drainage tube of a prolong action//Vestnik Khirurghii (Messenger of Surgery).—2002.—No 5—p. 81-83.], it was chosen as prototype which specifies the possibility of regulating the permeability of drainage by inserting a bead fixed on a fishing line, both ends of the line are drawn outside. By means of constant drawing of the bead backwards and forwards along the tube's body constant destruction of fibrin clots, precipitated into the drainage passage is performed, due to traction on the line's ends. The authors also specify periodic shift of the drainage system alongside its length, within 1-2 cm, 4-6 times a day.
The drawback of this design, chosen as a prototype is the necessity of location of both ends outside, thus making it impossible to apply it in the bulk of clinical situations, when drainage has to be inserted from one side only. Besides, the drained cavity may get infected when the bead is moved, through a piece of fishing line that was led outside. An organizational difficulty of application of such type of drainage that supposes constant bandaging (up to 6 times a day) may be considered another drawback.
The present invention solves the problem of ensuring the possibility of removing the clot inside the drainage opening, but fixed by one end inside the wound cavity during the drainage removal, as well as ensuring the possibility of reinstallation of the drainage with smaller inside diameter, strictly along the old wound channel, irrespective of length and direction of the latter.
SUMMARY OF THE INVENTION
The problem set is solved by fixing an additional tube of smaller diameter with an opening on a tube draining along its entire length, and upon the working end of drainage a unit for clot's destruction is installed, consisting of a cylindrical body, a tube with an opening, an opening, corresponding to an opening of an additional drainage tube and a spring with a splitter, located inside the body, the drainage having a working head with a diametrically located line inside it, connected by means of thread with the body of the splitter, besides inside the wall of the tube drainage and the splitter's unit a channel is made, inside of which there is a fixing unit of the splitter, the working end of which is inside the body of the splitter's unit and it fixes the splitter, while its opposite end is drawn to the outside surface of the drainage through the aforesaid channel and is equipped with a ring. The body of splitter's unit has an internal growing-through from on one side and an external growing-through from the other side, it is also equipped with internal thread on the side of the internal growing-through for ½ of its length, while the diameter of the body in the spot of the external growing-through is equal to the internal diameter of the tube drainage. The channel of splitter's fixing unit, inside the tube drainage and the channel of splitter's fixing unit inside the wall of the body of clots' splitting unit are located on the side, opposite to the place of fixation of an additional tube and the tube of the splitter's unit respectively, the channel of splitter's fixing unit, inside the body of the splitter is opened with an internal opening upon the surface of ledge's ring, formed by the difference between the diameter of the internal growing-through and the internal diameter of the body. The external diameter of the spring is equal to the internal diameter of the splitter's unit, while the diameter and the height of the fixing unit of the spring are equal to the width and depth of the body's slot, respectively. Clots' splitter is fixed to the spring in such a way, so that its axis is located at 90° angle with regard to the axis of the spring's fixing unit's, the protruding end of clots' splitter corresponds to the width of ring's ledge, formed by the difference between the diameter of the internal growing through and the internal diameter of the body, there being a possibility of its turning inside the body at the level of internal growing-through. The working head is made with an external growing-through, equipped with external thread for internal thread of the unit of clots' splitter, the length of the external growing-through being equal to ½ of the length of the internal growing-through of the unit of clots' splitter. The conductor is equipped with a plate and a handle and it has the working and directing ends, both ends being round in shape, while the conductor's plate is installed at 1.5-2.0 mm distance from the butt of the directing end of the conductor. The external surface of the tube drainage possesses slots with latches for the conductor and the fixing element of the splitter, respectively.
The novelty of this design is in the fact that the device ensures permeability of the wound channel after drainage is removed by means of clots removal from the drainage opening, clots being fixed by one end inside the wound's cavity, and by fixing such clots inside drainage. The new drainage may be reinstalled into the drained cavity strictly along the previously formed channel up to the healing of the latter.
BRIEF DESCRIPTION OF THE DRAWINGS
The essence of the presented technical solution is illustrated with the drawings, where:
FIG. 1 presents the longitudinal section of the drainage system,
FIG. 2 presents the side view of the drainage,
FIG. 3 presents the longitudinal section of the tube drainage,
FIG. 4 presents the front view of the tube drainage,
FIG. 5 presents the back view of the tube drainage,
FIG. 5 a presents the cross section view of the tube drainage 5 a,
FIG. 5 b presents the cross section view of the tube drainage 5 b,
FIG. 6 presents the upper view of the tube drainage,
FIG. 7 presents the bottom view of the tube drainage,
FIG. 8 presents the side view of the tube drainage, pictured from the side of the slot of the splitter's fixing element,
FIG. 9 presents the side view of the tube drainage, pictured from the side of the slot of the conductor,
FIG. 10 presents the cross section view of the cylinder of the clots' splitter unit,
FIG. 10 a presents the view of the cylinder of the clots splitter unit in 10 a section,
FIG. 10 b presents the view of the cylinder of the clots splitter unit in 10 d section,
FIG. 10 c the view of the cylinder of the clots splitter unit in 10 c section,
FIG. 11 presents side view of the cylinder of the clots splitter unit,
FIG. 12 presents the top view of the cylinder of the clots splitter unit,
FIG. 13 presents the bottom view of the cylinder of the clots splitter unit,
FIG. 14 presents the front view of the cylinder of the clots splitter unit,
FIG. 15 presents the back view of the cylinder of the clots splitter unit,
FIG. 16 presents the view of the spring with the clots splitter in longitudinal section,
FIG. 17 presents the side view of the spring with the clots splitter,
FIG. 18 presents the top view of the spring with the clots splitter,
FIG. 19 presents the front view of the spring with the clots splitter,
FIG. 20 presents the cross-sectional view of the working head,
FIG. 21 presents the side view of the working head,
FIG. 22 presents the front view of the working head,
FIG. 23 presents the back view of the working head,
FIG. 24 presents the cross-sectional view of the conductor,
FIG. 25 presents the side view of the conductor,
FIG. 26 presents the back view of the conductor,
FIG. 27 presents the splitter's fixing element in longitudinal section,
FIG. 28 presents the side view of the splitter's fixing element,
FIG. 29 presents the front view of the splitter's fixing element,
FIG. 30 presents the front view of the clots splitter's unit after the spring with the splitter were inserted into the cylinder of the clots splitter's unit,
FIG. 31 presents the front view of the clots splitter's unit at the moment when the splitter is turned in a counter-clockwise direction,
FIG. 32 presents the front view of the clots splitter's unit after the splitter was turned and was fixed anew by the protruded fixing element,
FIG. 33 presents the front view of the drainage with installed working head, after the splitter was turned and was fixed anew by the protruded fixing element,
FIG. 34 presents the front view of the clots splitter unit, pictured at the moment, when the splitter is returned into the previous position, after removal of the splitter's fixing element,
FIG. 35 presents the front view of the drainage with the working head installed after the clots splitter was returned into its previous position,
FIG. 36 presents the general view of the drainage, disassembled, in its isometric view.
DETAILED DESCRIPTION OF THE INVENTION
All drawings bear the same numbers for:
1 —the tube drainage; 2 —an additional tube; 3 —the unit of clots splitter; 4 —the working head; 5 —the conductor; 6 —the fixing element of the splitter; 7 —the working end of the tube drainage; 8 —the drainage openings; 9 —the opening of the additional tube; 10 —splitter's fixing element's channel inside the wall of the tube drainage; 11 —the opening of the channel of the splitter's fixing element on the external surface of the tube drainage; 12 —the opening of the channel of the fixing element in the butt of the tube drainage; 13 —fixing plates; 14 —holes, made in fixing plates; 15 —the slot for the conductor, made on the external surface of the tube drainage; 16 —the slot for the clots splitter's fixing element, made on the external surface of the tube drainage; 17 —growing-through of the additional tube, corresponding to the slot for the conductor; 18 —the latch, installed in the slot for the conductor; 19 —the latch installed in the slot for the fixing element of the splitter; 20 —the body of the clots splitter unit; 21 —the tube of the clots splitter unit; 22 —the opening in the tube of the clots splitter unit; 23 —the internal growing-through of the clots splitter unit; 24 —the internal thread of the internal growing-through of the clots splitter unit; 25 —the external growing-through of the clots splitter unit; 26 —the slot of the clots splitter unit; 27 —the channel of the splitter's fixing element, made inside the wall of the body of the clots splitter unit; 28 —the opening of the channel of the body of the clots splitter unit from the side of the growing-through; 29 —the ring of the ledge, formed by the difference between the diameter of the internal growing through and the internal diameter of the body of the clots splitter unit; 30 —the opening in the channel of the body of the clots splitter unit; pictured from the side of the external growing-through; 31 —the spring; 32 —clots splitter; 33 —spring's fixing element; 34 —the protruding end of the clots splitter; 35 —the beveled end of the working head; 36 —the external growing-through of the working head; 37 —the external thread on the external growing-through of the working head; 38 —the rod of the working head; 39 —the conductor's working end; 40 —the leading end of the conductor; 41 —the conductor's plate; 42 —the conductor's plate handle; 43 —the working end of the splitter's fixing element; 44 —the splitter's fixing element's ring; 45 —direction of turning of the clots splitter, when it is transferred into the working position; 46 —direction of turning of the clots splitter after the splitter's fixing element is removed.
The presented drainage design (See FIG. 1-9 , 36 ) consists of the tube drainage 1 , an additional tube 2 , fixed upon it, the unit of clots splitter 3 , the working head 4 , the conductor 5 and the splitter's fixing element 6 .
Six openings for drainage, of oval shape 8 , three on each side are made on the side surfaces of the tube drainage 1 ( FIG. 3 ) on the side of its working end 7 . Along the entire length of the additional tube 2 ( FIGS. 3-5 a ) an opening 9 was made. Inside the wall of the tube drainage 1 on the side opposite to the spot where the additional tube is fixed 2 a channel 10 of the splitter's fixing element 6 was made ( FIGS. 51 , 5 b ), which is opened on one side by a hole 11 on the external surface of the tube drainage 1 , and by a hole 12 on the side of the working end 12 on the butt end of the tube drainage 1 . Two fixing plates 13 ( FIG. 5 , 5 a , 6 - 8 ) with two holes 14 in each are fixed on the external surface of the tube drainage 1 , on the side, opposite to the working end 7 . Besides the external surface of the tube drainage 1 has the slot 15 for the conductor 5 and the slot 16 for the clots splitter's fixing element ( FIGS. 5 b , 6 - 8 ). The additional tube 2 also possesses growing-through 17 ( FIGS. 6 , 9 ), corresponding to the slot 15 for the conductor 5 . The slot 15 for the conductor 5 has a latch 18 ( FIGS. 6 , 9 ), and a latch 19 ( FIGS. 8 , 9 ) is installed in the slot 16 for the splitter's fixing element 6 .
Clots splitter's unit 3 consists of a body 20 , a tube placed on its surface 21 , with an opening 22 ( FIGS. 10-15 ). The tube of the clots splitter's unit 21 is the continuation of the additional tube 2 , having the same diameter, while the opening 22 of the tube 21 of the clots splitter's unit 21 coincides with the opening 9 of the additional tube 2 . Besides, the body 20 has got on one side an internal growing-through 23 with internal thread 24 for ½ of its length. On the other side of the body 20 there is an external growing-through 25 , the external diameter of the body 20 in the area of the external growing-through 25 being equal to the internal diameter of the tube drainage 1 . A slot 26 is made on the internal surface of the body 20 , on the side of the tube's fixing 21 , while on the opposite side a channel 27 is made inside the wall of the body for the splitter's fixing element, being the continuation of the channel 10 of the splitter's fixing element, made inside the wall of the tube drainage. The channel 27 is opened by the hole 28 on the ledge's ring 29 , which is formed by the difference in the diameter of the internal growing-through 23 and the internal diameter of the body 20 . The channel 27 ends on the side of the external growing-through 25 with an opening 30 , the diameter of which is equal to the diameter of the opening 12 of the channel of the fixing element in the butt of the tube drainage 1 . The unit of the clots splitter also contains the spring 31 with clots splitter 32 and the spring's fixing element 33 ( FIGS. 16-19 ). The external diameter of the spring 31 is equal to the internal diameter of the body 20 , the length of the spring's fixing element 33 being equal to the height of the slot 26 of the body 20 . The length of the clots splitter 32 is bigger than the diameter of the spring 31 and it corresponds to the internal diameter of the body 20 in the area of the internal growing-through 23 . The axis of the clots splitter 32 is located at 90° angle towards the axis of the spring's fixing element 33 . The protruding end 34 of the clots splitter 32 ensures fixing of the spring in the necessary position, by means of the splitters fixing element 6 .
The working head 4 ( FIGS. 20-23 ) presents a body with one end beveled at 60° angle on one end 35 and the external growing-through 36 , made on the other end, having external thread 37 for internal thread 24 of the internal growing-through 23 of the body 20 .
The end beveled at 60° angle 35 of the working head 4 ensures minimal injuring of tissues by the end of the drainage system, installed during an operation and it also minimizes traumas, caused to the wound channel, when a new drainage is inserted. The maximal external diameter of the working head 4 is equal to the external diameter of the tube drainage 1 and its internal diameter is equal to the internal diameter of the tube diameter 1 . The external diameter of the working head in the area of the external growing-through 36 is equal to the internal diameter of the body 20 of lots splitter in the area of its internal growing-through 23 . Inside the working head 4 a rod 38 is installed diametrically on the side of the external growing-through.
The conductor 5 ( FIG. 24-FIG . 26 ) presents a flexible rod of a round cross section, made of dense, elastic material and possesses a working end 39 and a leading end 40 . Both ends are rounded. The rounded working end 39 eliminates the possibility of tissues injury, when drainage is replaced. The plate 41 is fixed on the conductor on the side of the leading end 40 , a handle 42 being mounted on it. The diameter of the conductor 5 is equal to the internal diameter of the additional tube 2 and the internal diameter of the tube of the clots splitter's unit 21 . The plate's thickness 41 of the conductor 5 is equal to the width of an opening 9 of the additional tube 2 and an opening 22 of the tube 21 of the clots splitter's unit, while the plate's 41 height and width correspond to dimensions of the lot 15 , made on the body of the tube drainage 1 .
The splitter's fixing element 6 presents a flexible rod of a round cross section, it is made of a dense and elastic material its working end 43 has a flat butt ( FIG. 27-FIG . 29 ). A ring 44 is fixed on the opposite end of the fixing element 6 .
The drainage system and its elements may be made of the following materials: tubical drainage, additional tube made from medical silicone, block for clot cutting, working head, conductor, holder of cutter, cutter is made from medical steel.
The drainage works in the following way. Before a surgical operation drainage is put into the working state. For this purpose a body of the clots splitter's unit 20 is inserted into the tube drainage on the side of its working end 7 . The uniform diameter of the external growing-through 25 of the body 20 the clots splitter's unit and the internal diameter of the tube drainage 1 ensure their dense contact and fixing of the body 20 in the tube drainage. The body 20 being orientated in such a way, so that an opening of the additional tube 2 , fixing on the tube drainage should coincide with the opening of the tube 21 of the clots splitter's unit and the opening 12 of the channel 10 of the splitter's fixing element, made inside the wall of the tube drainage should coincide with the opening 30 of the channel 27 of the body. A spring 31 is inserted into the body 20 in such a way, so that the spring's fixing element should pass into the slot 26 of the clots splitter's unit. The clots splitter 32 here will be located inside the body 20 on the level of the internal growing-through 23 of the body (See FIG. 30-FIG . 35 ). Through the opening 11 , made on the external surface of the tube drainage 1 a fixing element of the splitter 6 is inserted and it is passed to the wall of the tube drainage through the channel 10 and channel 27 , made inside the body up to the level, when the working end 43 of the fixing element is on the level of the opening 28 of the body's channel on the side of its internal growing through. Clots ( 32 ) splitter 45 is turned by 270° angle in a counter-clockwise direction. The protruding end of the splitter 34 should be located behind the opening 28 of the body's channel. Holding the clots splitter 32 in such position, the splitter's fixing element 6 is moved in such a way, so that its working end 43 should keep the protruding end 34 of the splitter 32 in that position.
A working head 4 is inserted into the body 20 so that the thread 37 of the external growing-through of the head 36 should combine with the internal thread 24 of the internal growing-through 23 of the body. The 4 is turned in such a way, so the rod 38 of the working head 4 should be placed parallel with the clots splitter 32 . The splitter's ring 44 is turned, so that it will go into the slot 16 , made on the external surface of the tube surface. By placing the splitter's ring into the slot 16 a stable position of the working end of the fixing element 43 is ensured and consequently clots splitter 32 can be kept reliably in the desired position.
The splitter's ring 44 is kept inside the slot 16 by means of a latch 19 . Then a conductor 5 is inserted into the gap of the additional tube 2 , from the side of the opposite head and it is led throughout the entire additional tube 2 and the tube 21 of the unit of clots splitter. The conductor's plate 41 being led through the opening 9 of the additional tube and is to be placed opposite to the growing-through 17 inside the additional tube 2 and slot 15 . After that the conductor's plate 41 is turned and inserted into the slot 15 , where it is eventually fixed with a latch 18 . The location of the plate 41 in the slot 15 eliminates the possibility of distortion of the working end during the process of prolong staying of the drainage, thus guaranteeing the precise location of the end of the following drainage installation, which will replace the old one through the conductor 5 . Now the drainage is ready for work. The described preparation of drainage can be performed at a plant.
A set of drainage installations, of the design, described here, of equal length with different diameter of tube drainage 1 and the body 20 of the splitter's unit. The diameter of the additional tube 2 and the tube 21 of the clots splitter's unit and also the diameters of the channel 10 of the conductor's fixing element in the tube drainage 1 and the channel of the clots splitter's fixing element in the splitter's unit are equal for all drainage procedures. Only the first drainage set is supplied with the conductor 5 .
Drainage is used in the following way. After the surgical operation drainage is inserted into a cavity, which needs to undergo drainage. Drainage is fixed to skin by means of the openings 14 , made in the fixing plates 13 . Aspiration is carried out in an active or passive way both through the side openings 8 and through the opening in the working head 4 . After the drainage system has completed its work due to its obstruction with a clot or a piece of tissue, the system is replaced with a drainage set of smaller diameter. To perform it is necessary to remove drainage coupling to skin, after that the ring 44 of the splitter's fixing element is removed from the slot 16 and by traction through the ring 44 , the fixing element 6 is removed from the drainage. This results in the spring's 31 returning to its original location. The clots 32 splitter 46 is turned by 270° angle in a clockwise direction. As the result the clot is cut out between the splitter 32 and the head's rod 38 . After the turning the splitter is located perpendicular to the axis of the head's rod 38 , thus making it possible to retain the cut out clot inside the drainage opening. The conductor's plate 41 is removed from the slot 15 using the plate's handle 42 , after which, holding the conductor in its previous position, the drainage is removed from the cavity by means of the handle 42 . Then the leading end 40 of the conductor 5 is inserted into the opening of the tube 21 of the splitter's unit of the new drainage set with smaller diameter of the tube drainage and the new drainage is led up to the level where the old drainage has stood, along the conductor 5 . The rounded shape of the leading end 40 facilitates its insertion into the tube's opening 21 . The conductor 5 first passes inside the tube of the splitter's unit 21 and then inside the additional tube 2 up to the level of the growing-through 17 . After that the conductor's plate 41 is turned and it is placed into the slot 15 , where it is fixed by means of a latch 18 . a new drainage set is coupled to the skin through the openings 14 in the fixing plates 13 . Then the cavity undergoes drainage. In case of necessity the new drainage set is replaced by the subsequent sets of smaller diameters, using the methods described above. After the cavity has become smaller, as well as the diameter of the wound channel it may be possible to leave only the conductor 5 inside, which could be used for subsequent insertion of drainage a few days later. In case the conductor 5 is remained in the cavity it is to be fixed to the skin through the handle 42 . Besides, in case the drainage has to stand for a long time it is possible to replace the conductor 5 , prior to the removal of the last drainage.
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Drainage belongs to medical equipment, particularly to medical tools and is specified for drainage of cavities. Drainage comprises a first tube, an additional tube, which is fixed upon it, a unit of the clot's splitter and the splitter's fixing element. The additional tube has a smaller diameter with an opening, inside which the conductor is mounted, a unit of clots splitter is installed on the working end of the drainage, it comprises a cylinder, a tube with an opening, placed on it, which is the continuation of the additional tube of the drainage and a spring with a cutter inside the cylinder. A cutter is located diametrically inside the working head, while in the end of the wall of the first tube and the splitter's unit comprises a channel, inside which splitter's fixing element was led, its working end is inside the unit's cylinder and fixes the splitter. This design ensures the permeability of the wound channel after the drainage is removed and it is possible to reinstall drainage into the cavity strictly along the existing wound channel.
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DETAILED DESCRIPTION OF THE INVENTION
This is a continuation-in-part of application Ser. No. 255,129, filed May 19, 1972, now abandoned.
The catalyst of the present invention promotes two synthetic reactions as shown by the following equations: ##STR1##
The equation (1) stands for ammoxidation of isobutylene to form methacrylonitrile and the equation (2) for oxidative dehydrogentation of n-butene to form 1,3-butadiene.
Prior to describing the invention in detail, the conversion, selectivity and single pass yield of the present process are defined for the sake of brevity as follows: ##EQU1##
BACKGROUND OF THE INVENTION
It is known that isobutylene and n-butene are separately subjected to the vapor phase ammoxidation for synthesizing methacrylonitrile and vapor phase oxidative dehydrogenation for synthesizing 1,3-butadiene, respectively. The former case is described, for example, in Japanese Pat. Nos. 1613/66, 6897/66, 7771/66, 7854/66, 7856/66, 12731/66, 14093/66, 16778/66, 22476/67, 6045/68, 26288/68, 4092/69 and 28491/69, and the latter case is disclosed typically in Japanese Pat. No. 26842/68. However, no report has been known hitherto, as to the simultaneous preparation of methacrylonitrile and 1,3-butadiene by the vapor phase catalytic ammoxidation and oxidative dehydrogenation of mixed butane-butene.
Recently, the production of monomeric ethylene, which is one of the most important petrochemical starting materials, has been carried out in the so-called naphtha cracking center of the petrochemical complex, with the C 4 B-B fraction (containing the above-described mixed butane-butene together with butadiene) being formed as a by-product in large amounts. This C 4 fraction has heretofore been of little value except for the butadiene and used only as a fuel gas.
With a view to effectively utilizing individual components contained in the C 4 fraction, studies have been made individually for synthesis of methacrylonitrile by ammoxidation of isobutylene and for synthesis of 1,3-butadiene by oxidative dehydrogenation of n-butene and, as a result, several patents have been reported.
The processes of these patents require as starting gaseous material isobutylene and n-butene of high purity. Whereas, the constituents of the mixed butane-butene obtained as the B-B fraction, i.e. isobutane, n-butane, isobutylene, 1-butene, wis-2-butene and trans-2-butene are very similar to one another in their physical and chemical properties. Accordingly, separation and purification of these constituents are difficult and make it fairly expensive to produce starting materials of high purity.
Judging from the aspect of starting materials, it is apparent that the present process is advantageous wherein the mixed butane-butene is directly subjected as such to ammoxidation and oxidative dehydrogenation to yield simultaneously methacrylonitrile and 1,3-butadiene.
Thus, the present invention provides a novel and commercially advantageous process which enables the use of fairly low cost starting material, i.e. the C 4 fraction formed as by-product on cracking of naphtha, or a residuum obtained after extraction of 1,3-butadiene from said fraction (i.e. the mixed butane-butene).
The two products, methacrylonitrile and 1,3-butadiene, are quite different in chemical properties as the former is a nitrile compound and the latter a diolefin. They are different also in physical properties since methacrylonitrile boils at 90.3° C. and 1,3-butadiene at -4.41° C. This makes it possible to effect separation and purification of these compounds very easily by ordinary distillation, resulting in reduction of cost for the production of useful starting chemicals.
According to the present invention, it has been found that although ammoxidation of isobutylene alone produces methacrylonitrile in a single pass yield of 64.8%, the single pass yield of methacrylonitrile is increased to 75.1% by adding n-butene gas to the reaction system. It has also been found that addition of n-butene results in formation of butadiene and its single pass yield and selectivity are approximately as high as those obtained in oxidative dehydrogenation of n-butene alone.
Although it is not clear why the yield of methacrylonitrile is increased when the ammoxidation and oxidative dehydrogenation are carried out simultaneously using the mixed butene-butane as described above, it is thought that competition between the ammoxidation of isobutylene and oxidative dehydrogenation of n-butene may occur and this competition may decrease the concentration of active sites on the surface of the catalyst for the ammoxidation of isobutylene, and/or strongly active sites on the catalyst may be used for the oxidative dehydrogenation of n-butene, thereby avoiding excessive proceeding of the ammoxidation of isobutylene and resulting in increase in selectivity to methacrylonitrile.
In the catalyst used in the present invention, the numbers of individual atoms is preferably within the following ranges:
a: 3-10, b: 1-5, c: 0.6-2, d: 0-3, h: 0.04-0.8, f: 12 and g: 42-68.
The catalyst utilizable in the present invention can be prepared by adding to an aqueous solution of an appropriate molybdate such as ammonium molybdate, at least one of potassium, rubidium, and cesium compounds and then water-soluble iron, bismuth, cobalt, and magnesium compounds, adding, if necessary, a carrier to the resulting slurried suspension, evaporating the mixture to dryness, and treating the resulting cake at high temperatures ranging from 550° to 750° C for 4 hours in the presence of air or oxygen.
Used as the above-described potassium, rubidium, cesium, iron, bismuth, cobalt and magnesium compounds are, for example, nitrates of these metals.
The catalyst may be used as such, i.e. without any carrier to give an excellent yield, although, from the standpoint of catalyst strength, it is preferred to use a small amount of a carrier. Examples of such carriers include inert substances such as silica, silicon carbide and 2-alumina, although the silica is particularly preferred.
The catalyst may be used in the form of granules or tablets.
Although the catalyst may be used in a fixed bed, it is in general desired to use the catalyst in a fluidized or moving bed since the reaction is extremely exothermic.
As molecular oxygen used in the present invention, air is normally employed, although any oxygen-containing gases diluted with an inert gas, e.g. nitrogen which does not affect the desired reaction, may also be used.
Reaction temperatures adopted in the present process may preferably be within the range of from 300° to 500° C and more preferably from 350° to 480° C. The process may be carried out under either superatmospheric or subatmospheric pressure, although it is convenient to conduct the process under normal pressure.
Under real pressure and reaction temperature, contact time of a gaseous mixture consisting of the mixed butane-butene, ammonia and air with the catalyst, is within the range of 0.5-8 seconds, preferably 2-5 seconds.
The mixed gas to be passed through the catalyst is preferably composed of 1-5 moles of oxygen in the form of air and 1-5 moles of ammonia, per mole of effective olefin (i.e. isobutylene plus n-butene) in the mixed butane-butene, and more preferably 1-3 moles of oxygen in the form of air and 1-3 moles of ammonia per mole of the effective olefin. As the desired reaction is exothermal, it is preferred to add 1-30 moles of water in the form of steam.
The present invention will be illustrated in more detail by way of Examples. A carrier (SiO 2 ) is employed in all Examples except Example 19, with the carrier content in the carrier-containing catalyst being between 17 % and 18 % inclusive.
EXAMPLE 1
To a solution of 63.5 g. of ammonium molybdate in distilled water was added 0.230 g. of potassium nitrate with heating and stirring. A suspension of 17.6 g: as SiO 2 , of Aerosil (Trade name, Nippon Aerosil Co., Ltd.) in water was added to the mixture, and solutions of 61.1 g. of cobalt nitrate and 36.4 g. of ferric nitrate, each dissolved in distilled water, were added. To the resulting suspension was added a solution of 16.4 g. of bismuth nitrate in distilled water acidified with nitric acid and the mixture was stirred under heat and evaporated to dryness on a hot water bath. The residual dry cake was calcined at 700° C for 4 hours in a stream of the air and pulverized to a suitable grain size (about 20 mesh) for use in reaction.
The catalyst thus obtained was represented by a composition Co 7 .0 Fe 3 .0 Bi 1 .0 K 0 .7 Mo 12 O 49 . Fifty-five ml of the catalyst was filled in a stainless steel reactor of 20 mm i.d. and the reaction was carried out with the reactor immersed in a nitrate bath.
A molar ratio of the effective olefin: O 2 :NH 3 :H 2 O was 1:1.7:1.6:10.8. The effective olefin consisted of 48.5 mol % of isobutylene and 51.5 mol % of 1-butene. The contact time was about 3.8 seconds based on the reaction temperature.
The reaction product was analysed by way of gas-chromatography and found to contain besides methacrylonitrile and 1,3-butadiene as major products, acetonitrile, methacrolein, acetone, acrolein, acetaldehyde, hydrocyanic acid, cis-2-butene (i.e. isomer of 1-butene), trans-2-butene, formic acid, acetic acid, acrylic acid, methacrylic acid and the like formed as by-products.
The results were shown in Table 1.
Table 1__________________________________________________________________________Nitrate bath temperature, ° C 385 395 417 431Conversion of Mixed butene*,% 83.1 86.8 91.9 90.5Selectivity to MN+BD**, % 71.4 76.6 78.5 82.3Over-all yield of MN+BD, % 59.3 66.5 72.1 74.5Conversion of isobutylene,% 93.4 96.1 97.9 97.3Selectivity to methacrylonitrile,% 59.7 68.1 69.5 77.1Single Pass Yield ofmethacrylonitrile, % 55.8 65.5 68.0 75.1Conversion of 1-butene,% 73.4 78.2 86.2 84.1Selectivity to 1,3-butadiene,% 84.5 86.5 88.3 88.2Single Pass yield of 1,3-butadiene,% 62.0 67.6 76.1 74.2__________________________________________________________________________ ##STR2## ##STR3## ##STR4##In the foregoing equations, MN stands for methacrylonitrile and BD for
Ammoxidation of isobutylene alone was carried out using the catalyst as prepared in Example 1. A molar ratio of the isobutylene: O 2 :NH 3 :H 2 O was 1:3.3:3.6:22. The contact time was 4.0 seconds based on the reaction temperature. Other reaction conditions were the same as in Example 1. The results were shown as follows:
Conversion of isobutylene = 98.9 %
Selectivity to methacrylonitrile = 65.5 %
Single Pass yield of methacrylonitrile = 64.8%
EXAMPLE 2
A catalyst of the composition Co 7 Fe 3 Bi 1 Mg 1 K 0 .07 Mo 12 O 50 was prepared in the same manner as in Example 1 with the exception that magnesium acetate was further added.
Using the catalyst thus obtained, the reaction was carried out under the same conditions as in Example 1 except for the nitrate bath temperature. The results were shown in Table 2.
Table 2__________________________________________________________________________Nitrate bath temperature, ° C 377 390 401Conversion of mixed butene, % 82.0 87.0 91.4Selectivity to MN+BD, % 77.2 75.7 74.7Over-all yield of MN+BD, % 63.3 65.8 68.2Conversion of isobutylene, % 93.8 95.6 97.8Selectivity to methacrylonitrile, % 70.1 66.5 65.0Single pass yield of methacrylonitrile, % 65.7 63.5 63.5Conversion of 1-butene, % 71.0 78.9 85.6Selectivity to 1,3-butadiene, % 85.9 86.3 85.1Single pass yield of 1,3-butadiene, % 61.0 68.0 72.9__________________________________________________________________________
As was apparent from the results shown in Table 2, the optimal reaction temperature for the catalyst in this example was relatively low in comparison with that for the catalyst in Example 1, revealing higher catalytic activity of the former.
EXAMPLE 3
A catalyst of the composition Co 7 Fe 3 Bi 1 Rb 0 .07 Mo 12 O 49 was prepared in the same manner as in Example 1 except that rubidium nitrate was used in place of the potassium nitrate. Using the catalyst thus obtained, the reaction was carried out under the same reaction conditions as in Example 1 except for the nitrate bath temperature. The results were shown in Table 3.
EXAMPLE 4
A catalyst of the composition Co 7 Fe 3 Bi 1 Cs 0 .07 Mo 12 O 49 was prepared in the same manner as in Example 1 except that cesium nitrate was used in place of the potassium nitrate. Using the catalyst thus prepared, the reaction was carried out under the same reaction conditions as in Example 1 except for the nitrate bath temperature. The results were shown in Table 3.
EXAMPLES 5-13
Using the same starting materials as in Example 1 but varying their amounts used, catalysts of the following various compositions were prepared in a similar manner.
Example
5 Co 7 Fe 3 Bi 1 K 0 .4 Mo 12 O 49
6 co 7 Fe 3 Bi 1 K 0 .8 Mo 12 O 49
7 co 1 Fe 3 Bi 1 K 0 .07 Mo 12 O 43
8 co 9 Fe 1 Bi 1 K 0 .07 Mo 12 O 48
9 co 1 Fe 1 Bi 3 K 0 .07 Mo 12 O 43
10 co 14 Fe 1 Bi 1 K 0 .07 Mo 12 O 53
11 co 1 Fe 6 Bi 1 K 0 .07 Mo 12 O 48
12 co 7 Fe 3 Bi 1 K 0 .03 Mo 12 O 49
13 co 7 Fe 3 Bi 0 .5 K 0 .07 Mo 12 O 49
using these catalysts, the reaction was carried out under the same conditions as in Example 1 except for the nitrate bath temperature. The results were shown in Table 3.
TABLE 3__________________________________________________________________________Example No. 3 4 5 6 7 8 9 10 11 12 13 14__________________________________________________________________________Nitrate bath temperature, ° C 420 420 450 450 420 430 430 430 420 370 410 390Conversion of mixed butene, % 90.3 91.6 88.5 86.4 89.1 93.0 88.6 87.3 85.6 87.2 90.2 91.1Selectivity to MN+BD, % 79.5 77.2 79.5 79.2 74.5 75.2 66.5 70.9 66.0 69.6 67.5 73.5Over-all yield of MN+BD, % 71.1 70.8 70.3 68.4 66.4 70.0 59.0 62.0 56.5 60.6 60.9 67.0Conversion of isobutylene, % 96.5 95.1 94.5 91.3 92.3 97.1 94.7 91.3 90.1 94.6 97.5 92.1Selectivity to methacrylonitrile, % 70.3 69.6 70.3 71.2 65.3 65.4 56.1 66.7 57.3 59.9 55.3 67.4Single pass yield of methacrylonitrile, % 67.8 66.2 66.4 65.0 60.3 63.5 53.1 60.8 51.7 56.7 53.9 62.1Conversion of 1-butene, % 84.5 88.3 83.1 81.9 86.1 89.3 82.4 83.4 81.9 80.3 83.5 89.9Selectivity to 1,3-butadiene, % 89.0 84.8 88.9 87.7 84.2 85.2 78.6 75.7 74.6 80.5 80.9 80.1Single pass yield of 1,3-butadiene, % 75.1 74.8 73.9 71.7 72.4 76.1 64.7 63.1 61.1 64.6 67.5 72.0__________________________________________________________________________
EXAMPLE 14
A catalyst of the composition Co 7 Fe 3 Bi 1 Mg 3 K 0 .07 Mo 12 O 52 was prepared in the same manner as in Example 1 except that magnesium acetate was further added. The reaction was carried out under the same conditions as in Example 1 except for the nitrate bath temperature. The results were shown in Table 3.
EXAMPLES 15-18
Using the same starting materials as in Example 1 but carrying out 4-hour calcination at 550° C, 600° C, 650° C and 750° C, respectively, instead of 700° C, catalysts of the same composition as in Example 1 were prepared. Using each of the catalysts thus prepared, the reactions were carried out under the same conditions as in Example 1 except for the nitrate bath temperature. The results were shown in Table 4.
Table 4__________________________________________________________________________Example No. 15 16 17 18__________________________________________________________________________Calcination temperature, ° C 550 600 650 750Nitrate bath temperature, ° C 355 390 420 440Conversion of mixed butene, % 96.1 94.2 92.9 86.3Selectivity to MN+BD, % 63.0 73.5 79.2 73.6Over-all yield of MN+BD, % 60.6 69.2 73.5 63.5Conversion of isobutylene, % 95.9 97.4 96.5 94.9Selectivity to metha-crylonitrile, % 47.1 59.7 70.2 60.9Single Pass yield ofmethacrylonitrile, % 45.1 58.1 67.8 57.7Conversion of 1-butene, % 96.2 91.2 89.5 84.3Selectivity to 1,3-butadiene, % 78.2 87.4 88.1 81.8Single Pass yield of 1,3-butadiene, % 75.2 79.7 78.8 69.0__________________________________________________________________________
EXAMPLE 19
Using the same procedure as in Example 1 but excluding the use of SiO 2 as carrier, a catalyst of a general composition Co 7 .0 Fe 3 .0 Bi 1 .0 K 0 .07 Mo 12 O 49 was prepared. The reaction was carried out with the catalyst under the same conditions as in Example 1 except for the nitrate bath temperature. The results were shown as follows:
______________________________________Nitrate bath temperature, ° C 470Conversion of mixed butene, % 76.1Selectivity to MN+BD, % 78.7Over-all yield of MN+BD, % 59.9Conversion of isobutylene, % 81.3Selectivity to methacrylonitrile, % 70.1Single Pass yield ofmethacrylonitrile, % 57.0Conversion of 1-butene, % 71.3Selectivity to 1,3-butadiene, % 87.9Single pass yield of 1,3-butadiene, % 62.7______________________________________
EXAMPLE 20
The reaction was carried out using the same catalyst as in Example 1 and a spent B-B fraction as the mixed butene.
The spent B-B-fraction consisted of 48.5% of isobutylene, 1.6 % of iso-butane, 10.4 % of n-butane, 16.8% of 1-butene, 13.9 % of trans-2-butene and 8.80% of cis-2-butene.
Other reaction conditions were the same as in Example 1 except for the nitrate bath temperature. The results were shown in Table 5.
Table 5__________________________________________________________________________Nitrate bath temperature, ° C 430 450 470Conversion of mixed butene*, % 81.2 84.8 87.3Selectivity to MN+BD**, % 78.6 76.1 71.9Over-all yield of MN+BD***, % 63.9 64.5 62.8Conversion of isobutylene, % 96.7 97.5 98.1Selectivity to methacrylonitrile, % 73.5 70.1 64.2Single pass yield of methacrylonitrile, % 71.1 68.3 63.0Conversion of n-butene, % 62.1 69.1 74.3Selectivity to 1,3-butadiene, % 88.5 86.5 83.9Single pass yield of 1,3-butadiene, % 54.9 59.7 62.3__________________________________________________________________________Remarks: ##STR5## ##STR6## ##STR7##In the equations above, the term "effective olefin" was defined as
The reactions were carried out using the same catalyst as in Example 1 and the spent B-B fraction having the following composition as the mixed butane-butene:
______________________________________ Example Example Example Example 21 22 23 24______________________________________Spent B--B fractionisobutylene (%) 41.9 35.3 80.0 10.0isobutane (%) 3.2 4.8 0.6 2.8n-butane (%) 20.8 31.2 4.0 18.21-butene (%) 14.5 12.2 6.6 29.3trans-2-butene (%) 12.0 10.1 5.4 24.3cis-2-butene (%) 7.6 6.4 3.4 15.4______________________________________
Other reaction conditions were the same as in Example 1 except for the nitrate bath temperature. The results are shown in Table 6.
Table 6______________________________________Example No. 21 22 23 24______________________________________Nitrate bath temperature (° C) 450 450 430 470Conversion of mixed butene (%) 84.1 82.4 92.6 72.3Selectivity to MN+BD (%) 77.7 78.2 70.2 86.2Over-all yield of MN+BD (%) 65.3 64.4 65.0 62.3Conversion of isobutylene (%) 97.0 96.5 97.2 95.1Selectivity tomethacrylonitrile (%) 72.1 71.3 68.1 71.1Single pass yield ofmethacrylonitrile (%) 70.0 68.8 66.2 67.7Conversion of n-butene (%) 68.4 65.0 67.4 69.0Selectivity to1,3-butadiene (%) 87.1 87.3 86.7 89.1Single pass yield of1,3-butadiene (%) 59.6 56.8 58.4 61.5______________________________________
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This invention relates to a process for simultaneously preparing methacrylonitrile and 1,3-butadiene from a mixture of butanes and butenes (hereinafter referred to as a mixed butane-butene) consisting of isobutane, n-butane, isobutylene, 1-butene, cis-2-butene and trans-2-butene, in excellent selectivity and single pass yield. More particularly, this invention relates to a process for the simultaneous preparation of methacrylonitrile and 1,3-butadiene which comprises subjecting the mixed butane-butene, at high temperatures and in vapor phase, to ammoxidation and oxidative dehydrogenation with a gas containing ammonia and either air or oxygen, using a catalyst of the general formula:
CO.sub.a Fe.sub.b Bi.sub.c Mg.sub.d Q.sub.h Mo.sub.f O.sub.g
wherein Co is cobalt, Fe is iron, Bi is bismuth, Mg is magnesium, Mo is molybdenum, Q is at least one element selected from the group consisting of potassium, rubidium and cesium, O is oxygen, and a, b, c, d, f, g, and h are the number of atoms of Co, Fe, Bi, Mg, Mo, O and Q respectively, with a being a value of from 1 to 15, b from 0.5 to 7, c from 0.1 to 4, d from 0 to 4, f being 12, g being a value of from 39 to 72 determined naturally from the valences of other metal atoms and h from 0.01 to 1.0.
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TECHNICAL FIELD
The invention generally relates to systems and methods to reduce ascites caused by post-hepatic and intra-hepatic venous hypertension and by intrinsic liver disease. Specifically, the invention relates to a surgically applied method to relieve promptly severe ascites due to liver disease, in order to decrease the need for liver transplantations and for combined liver and kidney transplantations and to decrease the incidence of spontaneous bacterial peritonitis and renal failure in individuals with cirrhosis.
BACKGROUND OF THE INVENTION AND RELATED ART
Ascites has been known to occur in mankind for many centuries and chronic gross or large-volume ascites due to liver disease has usually been treated by repeated paracenteses, at times followed by colloid volume expansion or insertion of a transjugular intra-hepatic portosystemic stent shunt (Beers et al. 2006: b; Gines, Schrier 2009; Hyatt, Smith 1954; Moore et al. 2003; Panos et al. 1990). Spontaneous bacterial peritonitis is particularly common in cirrhotic ascites, (Beers et al. 2006: b; Gines, Schrier 2009; Garcia-Tsao 2001). In patients with refractory ascites from cirrhosis or who develop the hepatorenal syndrome, the survival prognosis is particularly very poor (Garcio-Tsoa 2001; Angeli, Merkel 2008; Moore et. al. 2003; Gines, Schrier 2009). Indeed, liver transplantation should be considered currently for all cirrhotic patients with gross or refractory ascites before the development of renal dysfunction and with a hepatic venous pressure gradient of 10 mm Hg or higher! (Moore et al. 2003; Gines, Schrier 2009).
Liver cirrhosis is a diffuse fibrotic disease characterized by regenerative nodules surrounded by dense fibrotic tissue (Beers et al. 2006: c). It is presently a leading cause of death world-wide Most cases arise from alcohol abuse or chronic hepatitis C infection in developed countries (Beers et al. 2006: c). Distortions in blood flow to nodules along with compression of hepatic venules contribute to portal hypertension. The surface of the cirrhotic liver is known to be commonly coarsely hob-nail in appearance and the liver size may be hypertrophic or atrophic. Various diseases and drugs cause liver cirrhosis, including those conditions with high venous pressure (intra-hepatic and post-hepatic), which may result from obstructive disease within the post-hepatic inferior vena cava (Budd-Chiari syndrome and in heart failure) (Beers et al. 2006: b, c, d). Heart failure can cause cardiac cirrhosis, including that from adhesive pericarditis in which ascites may be an early developed complication (ascites praecox) from central venous hypertension (Altschule 1954). Ascites and spontaneous bacterial peritonitis are commonly late complications of cirrhosis. Liver transplantation may be a last resort (Beers et al. 2006: c, d). Many patients presently die waiting liver transplants and there are complications from liver transplantations (Beers et al. 2006:e).
Most of the excess peritoneal fluid in cirrhotic ascites has been shown to originate from the liver (Freeman 1953; Mallet-Guy et al. 1954). Upon laparotomy, drops of liver tissue fluid or lymph has been seen to be formed constantly from the liver capsule (Glisson's capsule) (Hyatt, Smith 1954). The liver capsule becomes edematous in the ascites of experimental cirrhosis (Nayak et al. 1956). The hepatic lymphatic vessels are dilated and thickened in cirrhotic humans both with and without ascites (Baggenstross, Cain 1957). The ascites in cirrhosis may disappear spontaneously after several weeks or more in various mammals including man (Hyatt, Smith 1954; Nayak et al. 1956; Waugh 1958). This may occur despite portal and hepatic venous pressures (and sinusoidal pressures) remaining high, or paradoxically even higher than when ascites was present (Waugh 1958). Formerly, it was believed that increased collateral blood circulation developed which reduced pressure gradients and the ascites (Waugh 1958). At autopsy, Waugh observed, 2 and ½ years after canine ascites had disappeared spontaneously, the presence of marked increase in the lymphatic vessels within the superior region of the right dome of the diaphragm, which led from the very cirrhotic liver. Also, impermeability of saline through almost all of the lower regions of the collagenous fibrotic thickened liver capsule was found when saline was infused into the liver through the portal vein at higher hydrostatic pressure than present during life, while the hepatic artery and the vena cava immediately above the liver were both ligated (Waugh 1958). In contrast, the liver capsule of the normal dog was observed to be very thin, friable, and permeable to saline infused into the portal vein at similar pressure with the hepatic artery and vena cava just beyond the normal liver ligated (Waugh 1958).
Topical application of Eastman 910 adhesive diffusely to the surfaces of cirrhotic livers in animals with ascites from congestive cirrhosis resulted in an intensive connective tissue reaction within the liver capsules and incomplete or complete disappearance of the ascites (Belli 1963; Belli et al. 1964). Application of Eastman 910 to the liver capsules was performed as a complimentary procedure in 33 human patients with cirrhosis and ascites after termino-lateral porto-caval anastomoses were done. Reductions or complete resolutions of the ascites resulted in the patients who survived the procedures (Belli et al. 1966). Evaluation of the hepatopexy results with Eastman 910 was difficult because the porto-caval operations had been done just before the adhesive applications. No further studies with Eastman 910 application to humans with cirrhotic ascites apparently have been done since the work of Belli et al. in 1966. The animal and human work of Belli et al. in 1964 and 1966 has been overlooked apparently by medical professionals, surgeons, and gastroenterologists in the past few decades. The work appears to be not well known in the present art (Garcia-Tsao 2001; Moore et al. 2003; Gines, Schrier 2009). Eastman 910 is a cyanoacrylic ester compound which cures by binding in thermal reactions. Toxic reactions have been described with cyanoacrylate adhesives (Leggat et al. 2004; Leggat et al. 2007). By wrapping kidneys in cellophane but avoiding the renal pedicles, Page produced perinephritis with a fibro-collagenous hull and renal hypertension in dogs (Page 1939; Page 1940).
Collodion U.S.P. is a 4 percent solution of nitrocellulose (CAS No: 9004-70-0) (pyroxylin) in a mixture of 3 vols. of ether and 1 vol. of alcohol (Sollmann 1936). It is a syrupy liquid which dries rapidly. It is highly inflammable and should be stored in a cool environment. It is used as a liquid protectant to protect small wounds and it has been used in the absence of toxicity (Sollmann 1936; Lotterhos et al. 1978). It may be purchased in many pharmacies as an over the counter liquid. Collodion U.S.P. is produced by some chemical supply companies, e.g. Mallinckrodt Baker Inc., Philipsburg, N.J. Alternately, collodion liquid of nitrocellulose may be made by dissolving nitrocellulose in acetone (Sollmann 1936; Windholz et al. 1976). The boiling points of diethyl ether, ethyl alcohol, and acetone are, respectively, 34.6, 78.3, and 56.5 degrees Celsius (Windholz et al. 1976). Acetone N.F.and F.C. C. may be obtained at various chemical supply companies.
SUMMARY OF THE INVENTION
The object of the invention is to provide novel means to make promptly the capsules of cirrhotic livers relatively impermeable to liver tissue fluid or lymph in persons suffering from severe chronic ascites or refractory ascites. With such accomplishment, the incidence of spontaneous bacterial peritonitis and the need for repeat paracenteses should decrease. Also, the need for liver transplantations and combined liver and kidney transplantations should be reduced in individuals with chronic liver disease and ascites. To embody the means, a small model was employed which used soft, pliant leather chamois as a test membrane. It was measured for transudation of water at a pressure head of 15 cm. of water (11 mm. Hg). Topical brief application of Collodion U.S.P. or nitrocellulose in acetone, as the collodion liquid, to the inferior surface of the chamois membrane followed by solvent evaporation over the next several minutes at room temperature resulted thereafter in marked reduction of or complete prevention of the permeability of the membrane to water at such high hydrostatic pressure.
DETAILED DESCRIPTION OF THE INVENTION
Collodion in acetone as solvent was prepared by evaporation of the ether and alcohol in aliquots of Collodion U.S.P. at room temperature no higher than 30 degrees Celsius (86 degrees F.) for several hours and then redissolving the residual nitrocellulose to a concentration of 4 percent in acetone.[This solution could be optimally made more syrupy by redissolving the nitrocellulose in less volume of acetone.] As a working small model to measure liquid flux through a membrane at high hydrostatic pressure, transparent vinyl tubing about 40 cm. in length and ½ inch in internal diameter was used. A short hard nylon barb as nozzle of ½ inch internal diameter inserted inside the lower end of the tubing. A sheet of leather chamois covered the lower opening of the tubing nozzle. The chamois was kept tightly in place outside the nylon nozzle by a rubber O-ring, of number 14 and of ¾ inch in its unstretched internal diameter. [Leather chamois may be obtained in textile stores.] The chamois serving as membrane at its lowermost surface had an area of 159 sq. mm. exposed to liquid flux. Outflows of water were collected below this in a small beaker after water was placed into the superior end of the tubing Distilled water was used as the liquid medium. It was poured into the top end of the tubing and membrane outflow was allowed for several minutes before initial measurements of outflux of transudate at 15 cm. water pressure. Before outflux was measured initially and before topical application of collodion to the membrane, the flow of water was stopped by insertion of a number 13 glass stopper into the superior end of the tubing when the water length was about 16 cm. from the chamois membrane. [This maneuver was analogous to hepatic artery ligation for only a brief period in cirrhotic patients with portal hypertension (Taylor, Rosenbaum 1953).] Just before transudate was to be measured, the lower surface of the chamois was gently dried by gauze application. Two “coats” of collodion solution were applied by use of a saturated cotton swab or small paint-brush about 10 min. apart. Solvent evaporation followed each application. [The second application made the thin layer of nitrocellulose thicker and stronger.] Transudates was collected initially for less than 3 seconds immediately after removal of the glass stopper and for a whole one minute period after the second applications of collodion about 12 to 14 min. before. The collected amounts of water were weighed and the transudate rates were converted to ml. per minute at 15 cm. of water head pressure. Four runs were performed with a freshly used chamois membrane each time, both with use of Collodion U.S.P. and with use of the collodion containing acetone as solvent.
Summary of the results are tabulated in the following two EXAMPLES. Transudation of water at 15 cm. hydrostatic pressure averaged 166±13 ml./min. (mean & standard error) before Collodion U.S.P. application. Transudation was inhibited by 99.6±0.2 percent (mean & standard error) afterwards. Before use of nitrocellulose in acetone, the membrane transudate averaged 159±45 ml./min. The transudate rate was inhibited by 97.2±1.5 percent with use of nitrocellulose in acetone.
EXAMPLE 1
CHAMOIS TRANSUDATE RATES AT PRESSURE OF 15 CM.
WATER BEFORE AND AFTER USE OF COLLODION U.S.P.
BEFORE
AFTER
FLUX INHIBITION
(ml/min)
(ml/min)
(percent)
166 ± 13*
0.33 ± 0.22 *
99.6 ± 0.2 * p
* represents Mean ± SEM of 4 Runs.
p represents probability <0.001 by paired Student t-test.
EXAMPLE 2
CHAMOIS TRANSUDATE RATES AT PRESSURE
OF 15 CM. WATER BEFORE AND AFTER
USE OF COLLODION IN ACETONE * *
BEFORE
AFTER
FLUX INHIBITION
(ml/min)
(ml/min)
(percent)
159 ± 45 *
1.12 ± 0.6 *
97.2 ± 1.5 * p
* represents Mean ± SEM of 4 runs.
p represents probability <0.001 by paired Student t-test.
* * nitrocellulose in acetone was used.
The model demonstrations have clinical implications that the topical applications of Collodion U.S.P. and collodion solution as nitrocellulose in acetone, after several minutes of allowed evaporation, are able to prevent soon almost completely transudation of liquid through chamois membranes at pressure gradient of 15 cm. water (11 mm. Hg). This inventor proposes that collodion solution put on to the visible capsular surfaces of cirrhotic livers in mammals suffering from severe chronic ascites or refractory ascites, with evaporation over several minutes, will result soon in attenuation or absence of the ascites. In vivo, complete impermeability to liver fluid transudation at pressure gradient of 11 mm. Hg and higher may result from fibrotic reaction to the film of nitrocellulose in a few days, similar to renal capsule observations after cellophane (Page 1939; Page 1940). To this end, a laparotomy operation, perhaps performed laparoscopically (Beers et al. 2006 a), would be done with syrupy collodion liquid swabbed on to visible surfaces of the liver capsules (Glisson's capsules) with collodion-saturated cotton-swabs or small paint-brushes, with allowed evaporation of the liquid. Optimally, the application of collodion solution would be carried out during brief clamping of the hepatic artery to keep the capsular surfaces relatively dry of liver tissue fluid. Avoidance of application on to the common bile duct, portal vein, and hepatic artery at the hilar region would be recommended. Antecedently, a therapeutic paracentesis likely would be done.
While there has been shown and described what is considered to be preferred embodiments of the invention, it will be understood that various modifications could be made without departing from the scope of the invention. It is intended that the invention be not limited to the exact forms described and illustrated herein, but should be construed to cover modifications that may fall within the scope of the appended claims.
REFERENCES
Altschule, M. D., Physiology In Diseases Of The Heart And Lungs revised ed., Harvard University Press, Cambridge, Mass., (1954):p. 375.
Angeli P., Merkel C. “Pathogenesis and management of hepatorenal syndrome in patients with cirrhosis”. J. Hepatology 48: S93-S103 (2008).
Baggenstoss A. H., Cain J. C., “The hepatic hilar lymphatics of man their relation to ascites”. N. Engl. J. Med. 254: 531-535 (1957).
Beers M. H. et al., The Merck Manual of Diagnosis and Therapy 18 th ed., Merck Res. Labs. Whitehouse Station, N.J., (2006): a “Laparoscopy” p. 86; b “Ascites” pp. 188-189; c “Cirrhosis” pp. 215-219; d “Budd-Chiari syndrome” and “Veno-occlusive disease” pp. 232-234; e “Liver transplantation” pp. 1374-1376.
Belli L., [“New possibilities of influencing surgically the formation of ascites through application of Eastman 910 on the hepatic surface”], L'Ospedale maggiore 58: 647-652 (1963). [Article in Italian]
Belli L. et al., [“A new technic for the surgical treatment of ascites caused by stenosis of the inferior vena cava: hepatopexy by means of adhesives and plasticizing substances”] Lyon chirugical 61: 182-193 (1965).
Belli L., Forti D., [“Hepatopexy using tissue adhesives as a complementary procedure of termino-lateral portocaval anastomosis in the treatment of ascites. (immediate and remote results in 33 operated cases)”] J. Chir. (Paris) 92: 589-606 (1966). [Article in French]
Freeman S., “Recent progress in the physiology and biochemistry of the liver”. Med. Clin. North America 37: 107-124 (1953).
Garcia-Tsao G., “Current management of the complications of cirrhosis and portal hypertension: variceal hemorrhage, ascites, and spontaneous bacterial peritonitis”. Gastroenterology 120: 726-748 (2001).
Gines P., Schrier R. W., “Renal failure in cirrhosis” N. Engl. J. Med. 361: 1279-1290 (2009).
Hyatt R. E., Smith J. R., “The mechanism of ascites a physiologic appraisal”. Am. J. Med. 13: 434-448 (1954).
Leggat P. A. et al., “Toxicity of cyanoacrylate adhesives and their occupational impacts for dental staff”. Ind. Health 42: 207-11 (2004).
Leggat P. A. et al., “Surgical applications of cyanoacylate adhesives: a review of toxicity”. ANZ J. Surgery 77: 209-213 (2007).
Lotterhos W. E. et al., “Meeting of the panel on review of miscellaneous external OTC drug products twenty-third meeting Jan. 29 and 30, 1978”:—assessed on WWW/internet on Nov. 9, (2009).
Mallet-Guy P. et al., [“Etude Experimentale Des Ascites Stenoses veineuses post-hepatiques et transposition du foie dans le thorax”] Lyon chir (Paris) 49: 153-172 (1954). [Article in French]
Moore K. P. et al., “The management of ascites in cirrhosis: report on the consensus conference of the internal ascites club”. Hepatology 38: 258-266 (2003).
Nayak N. C. et al., “An experimental study of ascites produced after partial ligation of inferior vena cava”. Indian J. Med. Res. 44: 403-413 (1956).
Page I. H., “The production of persistent arterial hypertension by cellophane perinephritis”. J. A. M. A. 113:2046-2048 (1939).
Page I. H., “Demonstration of the liberation of rennin into the blood stream from kidneys of animals made hypertensive by cellophane perinephritis”. Am. J. Physiol. 130: 22-28 (1940).
Panos M. Z. et al., “Single, total paracentesis for tense ascites: sequential hemodynamic changes and right atrial size”. Hepatology 11: 662-667 (1990).
Sollmann T., A Manual of Pharmacology fifth ed. W.B. Saunders Co. Philadelphia (1936): p. 140.
Taylor F. W., Rosenbawm D. “The case against hepatic artery ligation in portal hypertension”. J.A.M.A. 151: 1066-1969 (1953).
Waugh W. H. “Local factors in the pathogenesis and course of experimental ascites”. J. Applied Physiol. 13: 493-500 (1958).
Windhholz M. et al. The Merck Index an encyclopedia of chemicals and drugs 9 th ed. Merck & Co. Rahway, N.J. (1976): p. 8, p. 31, p. 500-501, or p. 1039.
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A means is provided to make the capsules of cirrhotic or fibrotic livers relatively impermeable to liver tissue fluid or lymph in humans or other mammals suffering from severe chronic ascites or refractory ascites by application of collodion. The means will be useful to decrease the need for liver and combined liver and kidney transplantations.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Continuation of application Ser. No. 10/800,638, filed Mar. 16, 2004; which is a Continuation of application Ser. No. 10/101,112, filed Mar. 20, 2002, now U.S. Pat. No. 6,715,283; which is a Continuation of application Ser. No. 09/381,235, filed Sep. 13, 1999, now U.S. Pat. No. 6,449,949; which is a national stage of WO Application No. PCT/US97/03809, filed Mar. 12, 1997, all of which is hereby incorporated in its entirety herein by reference thereto.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an axle driving system in which a hydrostatic transmission (hereinafter referred to as an “HST”), axles and a power transmitting mechanism are integrally provided in a housing, and more particularly to an axle driving system in which the width of the portion of the housing which houses the HST and power transmitting mechanism is smaller than in conventional systems.
[0004] 2. Background Art
[0005] A conventional axle driving system houses the HST, axles and a driving gear train for interlocking the HST with the axles in a common housing. The HST is constructed so that a hydraulic pump is disposed on a horizontal portion of a center section which is L-like-shaped and a hydraulic—motor is disposed on the vertical portion of the same. The hydraulic motor is positioned to one side of the axle. The hydraulic pump and hydraulic motor are fluidly connected to each other by a closed fluid circuit formed in the center section. The hydraulic pump is driven by a prime mover provided on the vehicle so as to drive the hydraulic motor and then the axles through a driving gear train. Such a construction is disclosed, for example, in U.S. Pat. Nos. 5,163,293 and 5,335,496.
[0006] The hydraulic pump and hydraulic motor in the conventional technique, are disposed side-by-side and to one side of the axles. As such, the width of the HST is larger which results in the lateral width of the common housing for both the pump and motor also being larger. Furthermore, an output shaft of the hydraulic motor extends to one side of the vehicle to transmit power therefrom to a differential gear unit through gears of a driving gear train, so as to drive the axles. An unused space is formed at a side of the gear train and between the HST pump and the axles.
[0007] Further, when the HST and the driving gear train for driving the axles by the output shaft of the HST are housed in a common housing, a foreign object, such as iron powder produced by the driving gear train, may enter into the HST. This can adversely affect operation of the HST or various parts thereof.
BRIEF SUMMARY OF THE INVENTION
[0008] The axle driving system of the present invention is constructed so that the HST center section is formed in such a manner that the extended phantom plane of the motor mounting surface of the center section passes in the vicinity of the axis of the pump shaft of the hydraulic pump. The pump shaft extends substantially perpendicular to the axles. The motor shaft of the hydraulic motor extends substantially in parallel thereto. The hydraulic pump is disposed between the hydraulic motor and the axles. Hence, the width of the—housing is made smaller so as to be compact in size. The axle driving system, which is smaller in lateral width, is provided with a wide swinging space for the running wheels of the vehicle and is extremely effective for a vehicle having freely steerable wheels mounted thereon.
[0009] Further, the present invention divides the housing into two separate chambers for housing the HST and for housing a driving gear train and axles. A partition for dividing the two chambers is provided with an oil filter so that both chambers can be filled with common oil. This improves the durability of the HST and reduces the manufacturing cost.
[0010] The above and other related objects and features of the invention will be apparent from a reading of the following description of the preferred embodiments including the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
[0011] FIG. 1 is a partial cross-sectional plan view of a first embodiment of an axle driving system of the present invention, from which an upper half housing is removed;
[0012] FIG. 2 is a cross-sectional view looking in the direction of the arrows 2 - 2 in FIG. 1 ;
[0013] FIG. 3 is a cross-sectional view looking in the direction of the arrows 3 - 3 in FIG. 1 ;
[0014] FIG. 4 is a cross-sectional view looking in the direction of the arrows 4 - 4 in FIG. 1 ;
[0015] FIG. 5 is a cross-sectional view looking in the direction of the arrows 5 - 5 in FIG. 1 ;
[0016] FIG. 6 is a cross-sectional view looking in the direction of the arrows 6 - 6 in FIG. 1 ;
[0017] FIG. 7 is a top plan view of a center section of the present invention;
[0018] FIG. 8 is a side elevational view of the same;
[0019] FIG. 9 is a bottom plan view of the same;
[0020] FIG. 10 is a cross-sectional view looking in the direction of the arrows 10 - 10 in FIG. 7 ;
[0021] FIG. 11 is a cross-sectional view looking in the direction of the arrows 11 - 11 in FIG. 8 ;
[0022] FIG. 12 is a cross-sectional view looking in the direction of the arrows 12 - 12 in FIG. 8 ;
[0023] FIG. 13 is a cross-sectional view looking in the direction of the arrows 13 - 13 in FIG. 7 ;
[0024] FIG. 14 is a cross-sectional view looking in the direction of the arrows 14 - 14 in FIG. 7 ;
[0025] FIG. 15 is a cross-sectional rear view of a portion of the present invention surrounding a brake operating shaft;
[0026] FIG. 16 is a cross-sectional view looking in the direction of the arrows 16 - 16 in FIG. 15 ;
[0027] FIG. 17 is a cross-sectional view looking in the direction of the arrows 17 - 17 in FIG. 15 ;
[0028] FIG. 18 is a perspective view of the brake operating shaft and a biasing member of the present invention;
[0029] FIG. 19 is a plan view of a second embodiment of the axle driving system of the present invention from which an upper half housing is removed;
[0030] FIG. 20 is a cross-sectional view looking in the direction of the arrows 20 - 20 in FIG. 19 ;
[0031] FIG. 21 is a sectional view looking in the direction of the arrows 21 - 21 in FIG. 19 ;
[0032] FIG. 22 is a side view of an alternative embodiment of the center section of the present invention;
[0033] FIG. 23 is cross-sectional view looking in the direction of the arrows 23 - 23 in FIG. 22 ;
[0034] FIG. 24 is a cross-sectional view looking in the direction of the arrows 24 - 24 in FIG. 22 ; and
[0035] FIG. 25 is a cross-sectional view looking in the direction of the arrows 25 - 25 in FIG. 22 .
DETAILED DESCRIPTION OF THE INVENTION
[0036] Explanation will now be given on the entire construction of an axle driving system according to the present invention in which the housing thereof comprises an upper half housing 1 and a lower half housing 2 which are joined together along a horizontal, flat peripheral joint surface of each half housing. Along the joint surface of the upper and lower half housings is provided bearings for a motor shaft 4 and a counter shaft 26 . Axles 7 are disposed in parallel to the joint surface of the housing. The bearings for axles 7 are shifted upwardly from the joint surface and are disposed in upper half housing 1 so as to rotatably support axles 7 . Axles 7 are differentially coupled with a differential gear unit 23 . Each axle 7 projects outwardly from one end of left and right side walls of the housing, respectively.
[0037] The interior of the housing is divided by an inner wall 8 into a first chamber R 1 for housing therein an HST and a second chamber R 2 for housing therein (1) a driving gear train comprising a plurality of gears for transmitting power from motor shaft 4 to differential gear unit 23 , (2) differential gear unit 23 , and (3) axles 7 . Inner wall 8 comprises a longitudinal portion which is in—parallel to axles 7 and a perpendicular portion which extends at a right angle to the longitudinal portion of inner wall 8 . Both portions of inner wall 8 are continuously provided so that first chamber R 1 is disposed adjacent to second chamber R 2 . Inner wall 8 also comprises a vertical wall portion which extends downwardly from the interior of upper half housing 1 toward the joint surface of the housing and rising from the interior of second half housing 2 toward the same. The end surfaces of both the vertical wall portions of inner wall 8 abut against each other when both upper and lower half housings 1 and 2 are joined, thereby forming two divided, independent chambers within the housing.
[0038] The first and second chambers R 1 and R 2 are filled with lubricating oil which is used in common therewith to form an oil sump. As shown in FIG. 6 , an oiling lid 6 is provided on an upper wall of upper half housing 1 above differential gear unit 23 so as to enable operating oil to be supplied through lid 6 . As shown in FIG. 5 , an oil flow-through port 75 is mounted on a wall surface of upper half housing 1 constituting first chamber R 1 , so that first chamber R 1 and an external reservoir tank 10 fluidly communicate with each other through a piping 9 made of a rubber hose or the like so as to enable operating oil in the oil sump to be maintained at a predetermined amount. The amount can be adjusted by flowing an incremental volume of oil into reservoir tank 10 when the temperature of the oil rises when the HST is driven.
[0039] An oil filter 18 is disposed on inner wall 8 which partitions first chamber R 1 from second chamber R 2 . In a first embodiment, as shown in FIGS. 1 and 5 , oil filter 18 is disposed at the joint surfaces of the vertical portions of inner wall 8 to house therein the HST and right side axle 7 , thereby enabling oil to flow through oil filter 18 between first chamber R 1 and second chamber R 2 . Accordingly, oil provided in the housing can be used in common as operating oil for the HST and as lubricating oil for the gears and bearings. Also, when oil flows from second chamber R 2 into first chamber R 1 , harmful foreign objects such as iron powder, flowing into the HST is filtered by oil filter 18 .
[0040] First chamber R 1 is disposed in front of axles 7 and to the side of the geared transmission for transmitting power from motor shaft 4 to differential gear unit 23 , provided in the housing. A center section 5 of the HST is mounted in first chamber R 1 and is separate therefrom. Center section 5 is disposed in a manner such that its longitudinal direction is substantially perpendicular to axles 7 . The front portion forms a vertical surface 91 on which a motor mounting surface 41 is formed on which a hydraulic motor is disposed. The rear portion forms a horizontal surface 90 on which a pump mounting surface 40 is formed on which a hydraulic pump is disposed. Accordingly, the hydraulic pump is disposed between the hydraulic motor and axles 7 . A pump shaft 3 is supported vertically in the center of pump mounting surface 40 and is positioned between the hydraulic motor and axles 7 .
[0041] The axial piston type hydraulic pump of the present invention includes a cylinder block 16 which is rotatably, slidably disposed on pump mounting surface 40 of center section 5 . Pistons 12 are fitted into a plurality of cylinder bores and move in reciprocation through biasing springs. A movable swash plate 11 having a thrust bearing 11 a abuts against the heads of pistons 12 . At the center of movable swash plate 11 is formed an opening 11 b through which pump shaft 3 perforates. Pump shaft 3 also serves as an input shaft and is disposed along the rotational axis of cylinder block 16 and is not relatively rotatably retained thereto. The upper end of pump shaft 3 projects outwardly from the upper wall of upper half housing 1 and fixedly supports an input pulley 43 having a cooling fan 44 . Input pulley 43 is given power from a prime mover (not shown) of the vehicle to which the axle driving system is mounted through a belt transmission mechanism (also not shown).
[0042] The piston abutting surface of movable swash plate 11 is desirably slantingly movable from a horizontal state with respect to the rotational axis of cylinder block 16 , thereby enabling the amount and direction of discharged oil from the hydraulic pump to be changed. The rear surface of movable swash plate 11 is convex and the inner surface of a lid member 15 fixed to upper half housing 1 , which closes an opening in the upper wall, is made concave to match with the convex rear surface of movable swash plate 11 . Movable swash plate 11 is constructed to be of a cradle type which, when slantingly moved, slides while coming into close contact with the concave surface of upper half housing 1 .
[0043] In order to slantingly operate movable swash plate 11 , as shown in FIGS. 1 and 3 , a control shaft 35 extending in parallel to axles 7 is rotatably supported on the right side wall of upper half housing 1 opposite to the driving gear train for transmitting power to differential gear unit 23 . A control arm 38 is mounted onto one end of control shaft 35 outwardly extending from the housing. A swinging arm 39 is mounted to the other end of the same, inside the housing. The swinging arm 39 comprises a first arm 39 a and a second arm 39 b which extend radially from control shaft 35 . A projection 39 c is provided at the utmost end of second arm 39 b , as shown in FIG. 2 . Since control shaft 35 coincides at the axis thereof with the axis of slanting motion of movable swash plate 11 , it is possible to directly engage projection 39 c with a groove 11 d formed on a side surface of movable swash plate 11 . In such a construction, when control arm 38 is rotated longitudinally of the vehicle body, swinging arm 39 rotates longitudinally around control shaft 35 so as to enable movable swash plate 11 to be slantingly moved to thereby change the output of the hydraulic pump.
[0044] At the utmost end of first arm 39 a , opposite to projection 39 c , is disposed an engaging pin 39 d . A bush 51 is fitted onto control shaft 35 within the housing. A neutral position return spring 31 of the torsion coil type is fitted onto bush 51 . Both ends of neutral position return spring 31 cross and extend in the direction of first arm 39 a so as to put between both ends an eccentric shaft 33 mounted onto an inside wall of upper half housing 1 and engaging pin 39 a . Accordingly, when control arm 38 and swinging arm 39 rotate to change the speed of the vehicle, one end of neutral position return spring 31 is moved to widen a gap between both ends, but the other end of spring 31 is retained by the eccentric shaft 33 , so that control lever 38 is given a biasing force to return to a neutral position. When the operating force on control arm 38 is released, a restoring force generated at one end of neutral position return spring 31 holds engaging pin 39 d by eccentric shaft 33 in the specified neutral position. A portion of eccentric shaft 33 extending outwardly of the housing is formed into an adjusting screw and eccentric shaft 33 is preferably rotatably shifted therethrough, so that swinging arm 39 shifts around control shaft 35 , thereby enabling movable swash plate 11 to be adjusted to put it into an accurate neutral position.
[0045] Control arm 38 , as shown in FIG. 2 , is provided with an arm 38 b for connecting a shock absorber 73 . A vertical arm 38 a connects to a speed changing member (not shown), such as a lever or a pedal provided on the vehicle, through a link mechanism (not shown) on the vehicle. Arm 38 b is pivotally supported by a movable member of shock absorber 73 . A casing thereof is pivotally mounted onto a support plate 74 fixed to a lower surface of an axle housing portion of lower half housing 2 . Shock absorber 73 prevents control arm 38 from abruptly changing speed and also prevents the speed changing member (not shown) from abruptly returning to the neutral position when operating force is released so as to exert a sudden braking action onto the HST. Also, shock absorber 73 is positioned somewhat forwardly slanted and extends along the right side wall of upper half housing 1 straddling axles 7 , thereby effectively utilizing an otherwise unused or dead space surrounding axles 7 .
[0046] Pressurized oil discharged from the hydraulic pump is sent to the hydraulic motor through an oil passage in center section 5 . The hydraulic motor is constructed as shown in FIG. 4 . In detail, a cylinder block 17 is rotatably, slidably mounted on motor mounting surface 41 formed on vertical surface 91 of center section 5 . A plurality of pistons 13 are movably mounted in reciprocation in a plurality of cylinder bores in cylinder block 17 , through biasing springs. The heads of pistons 13 abut against a fixed swash plate 37 which is fixedly disposed between upper half housing 1 and lower half housing 2 . Motor shaft 4 is not relatively rotatably retained on the rotational axis of cylinder block 17 and extends substantially horizontally. One end of motor shaft 4 is supported in a bearing bore in motor mounting surface 41 of center section 5 . The other end is supported by a bearing 76 on inner wall 8 formed along the joint surfaces of upper half housing 1 and lower half housing 2 . The utmost end of motor shaft 4 enters into second chamber R 2 . Bearing 76 is a sealing bearing for partitioning first chamber R 1 from second chamber R 2 . An 0 -ring 77 is disposed between the outer periphery of an outer ring and inner wall 8 .
[0047] The driving gear train for transmitting power from motor shaft 4 to differential gear unit 23 , as shown in FIGS. 1 and 6 , comprises a gear 25 fixed onto motor shaft 4 where it enters into second chamber R 2 , a larger diameter gear 24 supported onto a counter shaft 26 and permanently engageable with gear 25 , a smaller diameter gear 21 supported on counter shaft 26 and integrally rotatable with larger diameter gear 24 , and ring gear 22 of differential gear unit 23 which is permanently engageable with smaller diameter gear 21 . Counter shaft 26 is disposed in second chamber R 2 adjacent to pump shaft 3 and perpendicular thereto. One end of counter shaft 26 is supported by a side wall of the housing at the joint surface of upper half housing 1 and lower half housing 2 . The other end is supported by inner wall 8 at the joint surface thereof. The rotational output speed of motor shaft 4 is reduced by larger diameter gear 24 , smaller diameter gear 21 and ring gear 22 so as to drive axles 7 through differential gear unit 23 . Larger diameter gear 24 on counter shaft 26 is disposed as close as possible to the outside surface of ring gear 22 and is overlapped axially therewith, thereby reducing the longitudinal length of the housing. In this embodiment, the HST is disposed to one side of the driving gear train at the right side thereof. At a further right side thereof is disposed a speed changing mechanism for the HST. The hydraulic pump thereof is positioned substantially in the lateral and longitudinal center of the housing. Differential gear unit 23 is disposed in an enlarged portion of the housing.
[0048] A brake disc 19 is fixed on the utmost end of motor shaft 4 in second chamber R 2 . As shown in FIGS. 1, 15 , 16 and 17 , a brake pad 29 and a wedge shaped member 70 are interposed between the upper portion of the front surface of brake disc 19 and the inner surface of upper half housing 1 and are supported thereto, movable only in the direction of the rotational axis of motor shaft 4 . In a space surrounded by inner wall 8 and the surface of brake disc 19 opposite to brake pad 29 (at the left side of brake disc 19 in FIG. 15 ), a biasing member 72 and a brake operating shaft 14 are disposed. Brake operating shaft 14 is vertically disposed and is rotatably supported by upper half housing 1 and lower half housing 2 . The upper end of brake operating shaft 14 projects upwardly from the housing and has a brake arm 27 fixed thereto. On an outside surface of an intermediate portion of brake operating shaft 14 in the housing is formed a flat cutout 14 a which is D-like-shaped when viewed in cross-section. Arch-like-biasing-member 72 is fitted into cutout 14 a and is restricted from axial movement by cutout 14 a and is guided at both sides by the inner surface of upper half housing 1 so as to be slidable only axially of motor shaft 4 . Accordingly, when brake arm 27 is rotated to the left or to the right, brake operating shaft 14 is rotated. One longitudinal end of cutout 14 a pushes the rear surface of biasing member 72 and brake disc 19 is interposed between brake pad 29 and biasing member 72 to exert a braking action on motor shaft 4 . Wedge member 70 abuts at the lower surface thereof against the upper end of an adjusting bolt 71 . Adjusting bolt 71 screws into lower half housing 2 and projects outwardly from lower half housing 2 , thereby screwably tightening a lock nut at the intermediate portion of bolt 71 for locking wedge member 70 . Wedge member 70 is raised or lowered in the housing as adjusting bolt 71 is rotated so as to advance or retract in the direction of the rotational axis of motor shaft 4 . As brake pad 29 is worn, the interval between brake pad 29 and brake disc 19 can be properly maintained by adjusting bolt 71 which is vertically disposed in lower half housing 2 .
[0049] Next, explanation will be given on the construction of center section 5 in accordance with FIGS. 7 through 14 . Center section 5 is larger longitudinally than conventional center sections. Center section 5 has three bolt bores 5 h which are open vertically between a front portion of center section 5 and a rear portion thereof. Center section 5 is fixed to upper half housing 1 through bolts. At the center of pump mounting surface 40 formed on horizontal surface 90 on an upper surface of a rear portion of center section 5 is formed a bearing portion so as to enable the lower portion of vertical pump shaft 3 to be rotatably supported therewith. Pump shaft 3 is perpendicularly disposed with respect to axles 7 . A pair of arcuate ports 40 a and 40 b are open at both sides of the bearing for supplying and for discharging oil from cylinder block 16 .
[0050] At the front portion of horizontal surface 90 is formed a vertical surface 91 , a phantom plane which includes vertical surface 91 crosses near the longitudinal axis of pump shaft 3 . Center section 5 is substantially L-like-shaped when viewed in cross section. As shown in FIG. 8 , a pair of arcuate ports 41 a and 41 b are also vertically open on motor mounting surface 41 formed on front vertical surface 91 , so that oil is adapted to be supplied to or discharged from cylinder block 16 through ports 41 a and 41 b . At the center of motor mounting surface 41 is provided a bearing for motor shaft 4 which is disposed in parallel to axles 7 .
[0051] In order to connect arcuate ports 40 a and 40 b on pump mounting surface 40 with arcuate ports 41 a and 41 b on motor mounting surface 41 , a first linear oil passage 5 a and a second oil passage 5 b are vertically and forwardly bored in a thick portion of center section 5 so as to reduce the lateral length of center section 5 .
[0052] Motor mounting surface 41 is positioned in front of the substantial center of pump mounting surface 40 so as not to increase the lateral length of the HST when the hydraulic motor is disposed thereon. A third linear oil passage 5 c crosses and communicates with an intermediate portion of second linear oil passage 5 b . Arcuate port 40 a on pump mounting surface 40 is, as shown in FIG. 14 , made thinner to communicate with first linear oil passage 5 a . Arcuate port 40 b is made deeper to communicate with third linear oil passage 5 c . Arcuate port 41 a at the upper portion of motor mounting surface 41 communicates with first linear oil passage 5 a . Arcuate port 41 b at the lower portion of the same communicates with second linear oil passage 5 b . Second linear oil passage 5 b communicates with third linear oil passage 5 c , whereby arcuate ports 40 a , 41 a , 40 b and 41 b communicate to form a closed fluid circuit so as to circulate operating oil between the hydraulic pump and the hydraulic motor.
[0053] Check valves 54 and 55 are disposed at the open ends of first linear oil passage 5 a and second linear oil passage 5 b and are closed with lids 64 , as shown in FIG. 10 . A lid 65 closes the open end of third linear oil passage 5 c . When subjected to pressure, lids 64 and 65 abut against projections 2 a and 2 b formed on the inner wall of lower half housing 2 . A first communication oil passage 5 d is vertically bored in center section 5 so as to communicate with inlet ports of check valves 54 and 55 . Oil passage 5 d communicates with a terminal end of a second communication oil passage 5 g which is horizontally bored in center section 5 . A fore end of second communication oil passage 5 g communicates with an inlet port 45 a into which discharged oil from a charging pump 45 is guided, as shown in FIG. 12 . A plug 66 , as shown in FIG. 9 , closes the open end of first communication oil passage 5 d.
[0054] Charge pump 45 , as shown in FIG. 3 , comprises a pump casing which has internal teeth for retaining the lower end of pump shaft 3 extending from, the horizontal lower surface of center section 5 and external teeth engageable with the internal teeth and which is brought into close contact with the horizontal lower surface of center section 5 . The pump casing is biased upwardly by a spring interposed between the lower surface of the pump casing and the inner bottom surface of lower half housing 2 and serving also as a relief valve for maintaining a specified value of pressure of oil discharged from charge pump 45 and filled in the closed fluid circuit. An annular oil filter 56 is disposed between the inner bottom surface of lower half housing 2 and the horizontal lower surface of center section 5 in a manner of surrounding charge pump 45 , thereby filtering operating oil taken therein.
[0055] As shown in FIGS. 5, 10 and 13 , in order to fill the closed fluid circuit with operating oil after the axle driving system is assembled, oiling pipes 52 and 53 are disposed on the horizontal lower surface of center section 5 . Oiling pipe 52 communicates with the deep portion of arcuate port 41 a through an oil passage vertically bored from the horizontal lower surface of center section 5 . Oiling pipe 53 directly communicates with second linear oil passage 5 b . Oiling pipes 52 and 53 are exposed at the lower ends thereof from the lower outer surface of lower half housing 2 and are closed by lids after the closed fluid circuit is filled with operating oil.
[0056] A by-pass operating arm 60 , as shown in FIG. 5 , is disposed above upper half housing 1 so as to open first and second linear oil passages 5 a and 5 b into the oil sump for idling axles 7 when hauling the vehicle. In detail, as shown in FIGS. 1 and 4 , by-pass operating arm 60 is fixed at the base thereof to a by-pass shaft 61 vertically, pivotally supported to an upper wall of upper half housing 1 . Bypass shaft 61 extends at the lower end thereof toward the surface of center section 5 opposite to motor mounting surface 41 and forms a flat surface at the periphery of the lower portion.
[0057] A through bore 5 f (see FIG. 8 ) is open on motor mounting surface 41 of center section 5 and is slightly above the center thereof and between accurate ports 41 a and 41 b . A push pin 62 is slidably supported by center section 5 in the direction of rotation of the axis of cylinder block 17 . Push pin 62 can at one end abut against a rotatably slidable surface of cylinder block 17 which comes into close contact with motor mounting surface 41 , and abuts at the other end against flat surface 61 a of by-pass lever shaft 61 .
[0058] When the vehicle is hauled, an operator operates by-pass operating arm 60 outside of the housing causing by-pass shaft 61 to rotate. Flat surface 61 a pushes push pin 62 toward cylinder block 17 . Push pin 62 releases cylinder block 17 from motor mounting surface 41 , and the closed fluid circuit communicates with the oil sump in the housing through arcuate ports 41 a and 41 b , thereby obtaining free rotation of motor shaft 4 .
[0059] Next, explanation will be given on a second embodiment of the present invention in accordance with FIGS. 19 through 25 , in which similar parts have been given the same reference numerals as used in the description of the first embodiment. In the second embodiment, the center section is formed in two pieces rather than in one piece as is center section 5 in the first embodiment. In this embodiment, center section 5 ′ is formed of a first piece 5 ′ a and a second piece 5 ′ b which are coupled together. On horizontal surface 90 of first piece 5 ′ a is formed pump mounting surface 40 . A pair of kidney-shaped ports 40 a and 40 b are open on pump mounting surface 40 . On a side surface of a vertical portion 91 of second piece 5 ′ b is formed motor mounting surface 40 , on which a pair of kidney-shaped bores 41 a and 41 b are open. Communicating oil passages 100 and 101 are bored in first piece 5 ′ a . The terminal ends thereof are open on the side surface. Inside second piece 5 ′ b are bored oil passages 102 and 103 which communicate with the pair of kidney-shaped ports 41 a and 41 b . The terminal ends of the passages 102 and 103 are open on the side surface. Oil passages 100 and 102 , 101 and 103 connect with each other through the joint surfaces when horizontal portion 90 is coupled with vertical portion 91 , thereby forming a closed fluid circuit for circulating therein operating oil between the hydraulic pump and hydraulic motor.
[0060] Center section 5 ′ is not provided with bolt insertion bores 5 h as shown in the first embodiment, but is sandwiched between upper half housing 1 and lower half housing 2 so as to be restrained from vertical and lateral movements, thereby being fixedly, positioned in the housing.
[0061] The advantages of a two-piece center section 5 ′ include that the manufacturing and processing costs and the number of assembly processes are reduced, which reduces the overall cost of the system. Further, fewer parts are required in that bolts for securing the center section in the housing are not required.
[0062] When oil leaks caused from the closed fluid circuit in center section 5 ′, oil in first chamber R 1 is taken into the closed fluid circuit through oil filter 56 and check valves (not shown). In this embodiment, control shaft 35 for slantingly rotating swash plate 11 of the hydraulic pump is vertically and rotatably supported by an upper wall of upper half housing 1 . Such construction for engaging control shaft 35 with swash plate 11 is the same as, for example, that described in U.S. Pat. No. 5,495,712 which is incorporated herein by reference thereto in its entirety.
[0063] As seen from the above description, the axle driving system of the present invention can be applied to drive the axles of a vehicle so as to sufficiently reduce the mounting space thereof. Vehicles on which this axle driving system may be used include agricultural working vehicles such as lawn and garden tractors, and transportation vehicles.
[0064] Although several embodiments have been shown and described, they are merely exemplary of the invention and are not to be constructed as limiting the scope of the invention which is defined by the appended claims.
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An axle driving system which houses in a housing thereof a hydrostatic transmission, axles, and a driving gear train for connecting output means of the hydraulic transmission and axles, so as to transmit power from a driving source to the hydrostatic transmission and to change the speed, thereby driving the axles. A first chamber therein contains the hydrostatic transmission and a second chamber therein contains the driving gear train. Both the first and second chambers are independent of each other so as to prevent a foreign object, such as iron powder produced in the driving gear train, from entering the hydrostatic transmission. The system includes an L-like-shaped center section on which the hydrostatic transmission is offset such that an imaginary plane which includes a motor mounting surface passes in proximity to the axis of a pump shaft. The pump shaft is disposed perpendicular to the axles. The motor shaft is disposed in parallel thereto. A hydraulic pump is positioned between the hydraulic motor and the axles, so that the housing for the hydrostatic transmission, axles and driving gear train, is smaller in width to thereby make the system more compact.
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This is a continuation of application Ser. No. 07/960,378 filed on Jan. 4, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to multi-ply paper formation. More specifically, this invention relates to two-wire, multi-ply paper formation. Still more particularly, this invention relates to two-wire, multi-ply web formation wherein the outer ply to be ply-bonded to the base ply of the multi-ply web, has its surface dewatered essentially by wire tension and centrifugal force.
1. Description of the Prior Art
In prior forming arrangements for forming a multi-ply paper web product, a relatively coarse base ply is first produced and a second, outer ply is produced to be brought into ply-bonding contact with the previously formed base ply. The outer ply, which is intended to form the outer surface of a printed container, such as a box, is formed of a finer grade of pulp stock so as to provide a smoother, higher quality surface. In order to form the outer ply at commercially desirable speeds, dewatering was effected through both of its surfaces before the outer ply was brought into ply-bonding contact with the base ply of the paper web sheet. This produces an acceptable paper product, mainly due to the quality of the pulp stock used to produce the outer ply, but the requirements of producing a better product with cheaper pulp, and the need to produce a better product at higher speeds regardless of pulp quality, or a combination of both, have necessitated the conception of an improved multi-ply web former having an outer surface which exhibits the desired printability, and feel and visual smoothness while having an inner surface which has better ply-bonding characteristics.
In prior apparatus, both sides of the outer ply were dewatered positively, that is, they were dewatered by the application of sub-atmospheric air pressure directly to both surfaces to enhance the removal of water through both of the web surfaces. When both surfaces are positively dewatered, fines and fillers in the pulp stock are urged outwardly in both directions to the respective surfaces of the web and removed during the dewatering process. Thus, while the web is rapidly dewatered, which was the desired effect, the fines and fillers which contribute so much to the ply bonding characteristics of the outer side of the web produced, were removed in large quantities which deleteriously effected web quality as well.
SUMMARY OF THE INVENTION
The aforementioned shortcomings, deficiencies and characteristics of the outer ply in a ply-bonded multi-ply paper web, and the resultant multi-ply paper product, have been obviated by this invention.
In this invention, the outer ply of a multi-ply web, which is sometimes referred to as a "white top liner", is produced by dewatering through one side of the web using only centrifugal force and the force of the tension of the forming wire over the web. The outer ply is formed in the general direction opposite to the direction of the traveling base ply to which it is ply bonded. The generally upwardly facing surface of the top ply is dewatered by the tension of its contact with the outer surface of the looped upper, outer forming wire the outer surface being arrayed concave downwardly as viewed from the outer side of the web over the forming zone, and held over the web which has been formed by the aqueous pulp stock slurry projected between the outer and inner forming wires. In addition, one, or more, water collection devices, such as water skimming slots, which may or may not be assisted by a vacuum, assist in removing water expressed inwardly of the outer forming wire. The fines and fillers in the pulp stock slurry are thus exposed to sub-atmospheric (vacuum) pressure only within the looped lower forming wire the inner surface of which is disposed in a generally concave downward direction over the forming zone for a relatively long distance. This affects the rate of water removal as well as permits the retention of a greater proportion of fines and fillers in the web, particularly the top surface of the web, due to the fact that migration of the fines and fillers through the lower surface of the web is hindered by the web fibers. The downwardly directed, relatively gentle dewatering through the lower surface of the outer web ply is effected by subjecting the ply to a sub-atmospheric pressure over a relatively long dewatering zone, which can take the form of a vacuum or suction box, or a plurality of spaced foil blades, or a combination of both.
Accordingly, it is an object of this invention to provide a method and apparatus for producing a multi-ply paper sheet having improved ply-bond characteristics.
Another object of this invention is to provide a method and apparatus for producing the outer ply of a multi-ply paper sheet wherein the surface to be ply-bonded is dewatered solely by centrifugal force, wire tension and gravity.
A feature and advantage of this invention is the provision of a white top liner in a multi-ply paper sheet, which sheet can be produced at improved speeds while exhibiting improved ply-bonding characteristics and a commercially desirable outer surface.
These and other objects, features and advantages of the invention will become readily apparent to those skilled in the art upon reading the following description of the preferred embodiments in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-elevational view of the former showing a foil box within the first wire for substantially the length of the forming zone between the throat and the turning roll.
FIG. 2 is a side-elevational view of the former showing a foil box followed by two suction boxes within the first, or lower, top ply forming wire.
FIG. 3 is a side-elevational view, similar to that shown in FIG. 1, but including a forming shoe within the lower top ply forming wire upstream of where the second, or upper, top ply forming wire comes into co-running engagement with the web over the first forming wire.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The convention used to describe the wires is always with reference to both sides of the same forming wire. Thus, for example, if the upper surface is described as convex upwardly, like , then the lower surface of the same forming wire in the same position is concave downwardly, like .
By the same convention, the opposite is also true. Thus, if the upper surface of a forming wire is concave upwardly, like , then the lower surface is convex downwardly, like .
As shown in FIG. 1, a first, lower looped top ply forming wire 10 is shown looped about guide rolls 12,12',12" and turning roll 14. Disposed within the first forming wire is a foil box 16 which has an outer contour defined by a plurality of foils 18 arranged to distend the first forming wire in a concave downwardly, (viewing the inner surface of the looped forming wire) or convex upwardly, shaped curve which defines a forming zone extending substantially between guide roll 12 and turning roll 14.
Disposed above the first, lower forming wire 10 is a looped second, upper forming wire 20 which is directed to travel in its looped path by guide rolls 22,22',22" and 22'".
Guide rolls 12,22 direct their respective forming wires 10,20 into a throat 24 which converges near the leading edge of foil box 16. In the embodiment shown in FIG. 1, the throat 24 extends to just after the beginning of foil box 16.
The second forming wire 20 is guided to remain over the first forming wire for a short circumferential distance over the surface of turning roll 14. Turning roll 14 is a suction roll having a vacuum chamber 26 extending between circumferentially spaced seals 28,30. The first and second forming wires are shown engaged for a short distance past the upstream vacuum chamber seal 28.
Positioned within the looped second forming wire 20 is a save-all 32, which can take the form of a so-called auto-slice. In either configuration, the save-all or auto-slice represents a blade, lip or slot 33 which is positioned in closely spaced adjacency, or even non-pressure contact, with the inner side of looped forming wire 20. More than one such lip or slot 33 may be used.
A headbox 34 is positioned to direct an aqueous slurry of stock fibers into the throat 24. Depending on operating parameters, such as machine speed, stock consistency and, possibly, the type of forming wires used, the headbox slice nozzle may be directed slightly toward one or the other of the forming wires.
Beneath the top ply former, which is the designation for the apparatus just described, is a base ply forming wire 36 on which a base ply web W B has been formed upstream of the top ply former by other means. A pivoted guide roll 38 wraps the base ply forming wire 36 around a portion of the periphery of the turning roll 14 beginning at a point over the trailing seal 30. The top ply web W T is thus brought into co-running engagement with the base ply web W B , and ply-bonding occurs between the webs during this period of contact. Transfer of the composite, multi-ply paper sheet so formed to the base ply wire 36 is assured by the application of vacuum pressure in transfer box 40.
A source of sub-atmospheric air pressure 42 is optionally linked to the foil box 16 to provide vacuum pressure to the lower side of the web being formed between the co-running forming wires 10,20 over the foil blades 18 in the foil box. Water is removed from the inner side of the looped second forming wire by a drain 44, and water is removed from within the looped first forming wire by drain 46.
In the various configurations shown in FIGS. 1-3, corresponding elements in each figure will be correspondingly numbered with a letter postscript to distinguish between corresponding elements in the various figures. Similarly, like elements within a particular figure will be distinguished by a different number of prime superscripts after each element number.
As shown in FIG. 2, the dewatering elements within the first forming wire 10a comprise a foil box 16a, and two vacuum boxes 17a,17a' The last forming box 17a', in the downstream direction, effects the transfer of the newly formed top ply web W T onto the first forming wire.
Within the looped second forming wire 20a, is a first auto-slice 48a following the foil box, and a second auto-slice 48a' intermediate the two vacuum boxes 17a,17a'. Both auto-slices have a leading lip 33a,33a' which is mounted in closely spaced adjacency, or non-pressure contact, with the inner side of looped forming wire 20a. A headbox 34a discharges an aqueous stock fiber stream into the throat 24a formed between the forming wires 10a,20a converging over guide rolls 12a,22a.
Turning roll 14a, which in this configuration is a plane surfaced roll with no vacuum chamber, brings the first forming wire around its surface and into co-running engagement with the base ply web W B being carried on base ply forming wire 36a.
In the embodiment shown in FIG. 3, a blade forming shoe 50 has been mounted within the first forming wire 10b upstream of the foil box 16b. The second forming wire 20b is brought into engagement with the web over the first forming wire 10b just prior to the beginning of their co-running travel over the foil box 16b. The first forming wire is guided onto the leading edge of foil box 16b by a guide roll 12b. The headbox 34b discharges an aqueous slurry of stock onto the first forming wire over the surface of guide roll 12b. As in the embodiment shown in FIG. 2, the second vacuum box 17b effects the transfer of the newly formed top ply web W T onto the first forming wire which is directed into ply-bonding contact with the base ply web W B to form the multi-ply web W in a manner similar to that described in conjunction with FIG. 2.
While the cross-sectional profile of the first forming wire contour over blade forming shoe 50, or forming board, may be substantially planar, or concave downward, (from the perspective of viewing the inner surface of the first forming wire 10b over forming shoe 50) the overall contour of the forming zone extending from before the leading edge of the forming shoe 50 to the trailing edge of vacuum box 17b' is concave downwardly (inner surface of the first forming wire)/convex upwardly (outer surface of the first forming wire) as shown which is similar to the configurations shown in FIGS. 1 and 2. The vacuum pressure beneath forming wire 10b is zero or low, regardless of how it is induced, so as to promote better formation, and improved web properties, such as directional strength.
In the embodiments shown in FIGS. 2 and 3, foil boxes 16a,16b and vacuum boxes 17a,17a',17b and 17b' are connected to a source of sub-atmospheric air pressure which are designated generally as 52a,52a',52b and 52b'. The profile contours of the wire-contacting surfaces of the foil boxes and vacuum boxes is concave downwardly (inner surface of the first forming wire 10a, 10b) /convex upwardly. (outer surface of the first forming wire 10a, 1Ob). While the surface of the foil boxes is defined by a series of spaced foils which are parallel and spaced in the machine direction and which extend in the cross-machine direction, the contours of the vacuum boxes are usually comprised of an arcuate surface which is perforated, such as with holes drilled through their covers, which permit the application of vacuum pressure to the underside of the first looped forming wire.
In operation, with particular reference to FIGS. 1 and 2, the headbox discharges an aqueous stock slurry into the throat between the co-running forming wires. Since the only application of sub-atmospheric air pressure to the fibrous stock slurry between the forming wires is provided by the foil box or vacuum boxes beneath the first forming wire 10,10a,10b, water is urged from the stock slurry outwardly and downwardly through the lower top ply web W T to within the looped first forming wire. Due to the tension of the second forming wire 20,20a,20b over the stock slurry over the first forming wire water is expressed outwardly through the top ply web W T being formed between the first and second forming wires and into the save-all 32, or auto-slices 48a ,48a', 48b,48b'. The water is also urged outwardly through the upper surface of the top ply web by centrifugal force and the force of gravity in the slightly down-turning portions of co-running forming wire travel in the generally horizontally disposed, concave downwardly forming zone (from the perspective of viewing the inner surface of the lower forming wire 10,10a,10b over the forming zone). The blades in the foil box 16,16a,16b, operating with or without sub- atmospheric vacuum pressure, urge the water gently to within the foil boxes. Downstream, at a point where the web is more dewatered, higher sub-atmospheric vacuum pressure is applied to vacuum boxes 17a',17b' to further dewater the top ply web through the lower surface thereof.
In the embodiment shown in FIG. 3, the headbox discharges the stock slurry onto the first forming wire and additional dewatering through the lower surface of the top ply web is effected by the blades 51 contacting the inner surface of the first forming wire over the forming shoe 50. This is substantially similar to the water removal operation at the beginning of a conventional fourdrinier.
In all of the embodiments, the application of sub-atmospheric air pressure solely to the lower side of the top ply web through the first forming wire urges the fines and any fillers in the stock slurry to migrate downwardly toward the lower surface of the top ply web. Thus, while some of the fines near the lower surface of the top ply web over the first forming wire are removed from the web, a relatively large proportion of the fines initially near the upper surface of the top ply web adjacent the second forming wire remain in the web during the dewatering effected by the sub-atmospheric air pressure. Not only do these fines remain in the web, but a relatively larger total proportion of the fines initially in the stock remain in the web due to the absence of any application of sub-atmospheric air pressure to the stock slurry between the forming wires through the second forming wire. In other words, the only forces urging water out of the upper surface of the top ply web are centrifugal force, forming wire tension and, in the slightly downwardly extending portion of forming wire travel in the substantially horizontally disposed forming section, gravity. Water expressed through the top (second) forming wire, therefore, need only be collected by the save-all or auto-slices; it is not urged through the top wire by these elements.
Thus, a relatively higher proportion of fines remain in the upper surface of the top ply web being formed, and it is this surface which is brought into ply-bonding contact with the upper surface of the base ply web W B over the turning roll. Since ply-bonding is enhanced by a higher proportion of fines in the surface of one, or both, of the webs at their interface, ply-bonding between the top ply web W T and the base ply web W B is promoted by this invention. This allows ply-bonding to be achieved at lower web moisture levels and faster machine speeds, or some combination of both.
In this invention, both upward (through the second forming wire) and downward (through the first forming wire) dewatering is effected, but the dewatering is controlled as described. More fines remain at or near the top surface of the top ply web for better ply bonding, and more fines and fibers remains in the whole top ply web due to the application of sub-atmospheric pressure on only the lower side through the first forming wire. In other words, the bottom of the top ply web is also of a higher quality. This promotes good top ply smoothness and printing properties in the composite multi-ply web W.
Naturally, variations in the method and apparatus described can be made without departing from the spirit of the invention and scope of the claims. For example, the throat can extend from upstream of the place where the top ply forming wires are guided to travel in substantially the same direction to where the wires converge. Also, while the foil boxes, and forming shoe, have been described as operated in conjunction with sub-atmospheric air pressure, it is contemplated that, under certain circumstances, they need not be so operated. Finally, it is to be understood that the terms web, sheet and paper include the term board.
|
A multi-ply paper web is formed by bringing a top ply liner into ply-bonding engagement with a base ply web (W B ) traveling on a base ply forming wire (36). The top ply liner (W T ) is formed between two co-running forming wires (10, 20) in a convex upwardly/concave downwardly curved, substantially horizontal forming zone. Dewatering in the forming zone is effected by applying sub-atmospheric air pressure solely beneath the lower surface of the top ply liner (W T ) being formed. Water is removed from the upper surface of the top ply liner (W T ) solely by wire tension, gravity and centrifugal force created by passing the co-running forming wires (10, 20) over the convex upwardly curved path of travel. This permits a greater concentration of pulp stock fines to remain in the upper surface of the top ply liner (W T ) to effect greater ply-bonding affinity with the base ply (W B ) when the two plies (W T , W B ) are brought together and bonded.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
TECHNICAL FIELD
The present invention generally relates to a compressor component having an airfoil and more specifically to an airfoil having a profile that is configured to improve performance of a gas turbine combustor.
BACKGROUND OF THE INVENTION
A compressor typically comprises a plurality of stages, where each stage includes a set of stationary compressor vanes which direct a flow of air into a rotating disk of compressor blades, where each stage of the compressor decreases in diameter, causing the pressure and temperature of the air to increase. Compressor components having an airfoil, such as compressor blades and compressor vanes, are held within disks or carriers and are designed to aid in compressing a fluid, such as air, as it passes through stages of blades and vanes of the compressor.
Axial compressors having multiple stages are commonly used in gas turbine engines for increasing the pressure and temperature of air to a pre-determined level at which point a fuel can be mixed with the air and the mixture ignited. The hot combustion gases then pass through a turbine to provide either a propulsive output or mechanical output.
Compressor components, such as blades and vanes, have an inherent natural frequency, and when the compressor component is excited, as can occur during normal operating conditions, the compressor component vibrates or moves at different orders of the engine's natural frequency. When the natural frequency of the compressor component coincides or crosses an engine order, the compressor component can start to resonate or vibrate in such away that it is excited and can cause cracking or failure of the compressor component.
SUMMARY
In accordance with the present invention, there is provided a novel and improved compressor component having an improved tip region optimized to improve the airflow coming off the compressor blade.
In an embodiment of the present invention, a compressor component has an attachment and an airfoil extending radially outward from the attachment, where the airfoil has a leading edge and a trailing edge, concave and convex surfaces, and a thickness based on the Cartesian coordinate values X, Y, and Z as set forth in Table 1, where Y is a distance measured radially from a root datum plane extending through the attachment of the blade.
In an alternate embodiment of the present invention, a compressor component is disclosed having an attachment and an airfoil extending radially outward from the attachment. The airfoil has an uncoated profile substantially in accordance with Cartesian coordinate values of X, Y, and Z as set forth in Table 1, where Y is a distance measured radially from a root datum plane extending through the attachment to which the airfoil is mounted. The X and Z values are joined by smooth connecting splines to form a plurality of airfoil sections and the sections are joined to form the airfoil profile.
In yet another embodiment, a compressor stator having an altered tip configuration and airfoil tilt in which the compressor stator comprises an attachment and an airfoil extending radially outward from the attachment with the airfoil having a thickness and extending to a generally planar tip.
Although disclosed as an airfoil that is uncoated, it is envisioned that an alternate embodiment of the present invention can include an airfoil that is at least partially coated with an erosion resistant coating, corrosion resistant coating, or a combination thereof. In this case, the coordinates of the airfoil as listed in Table 1 are prior to a coating being applied to any portion of the airfoil.
Additional advantages and features of the present invention will be set forth in part in a description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned from practice of the invention. The instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The present invention is described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a perspective view of a compressor component in accordance with the prior art;
FIG. 2 is an alternate perspective view of the compressor component of FIG. 1 having an airfoil in accordance with an embodiment of the present invention;
FIG. 3 is an alternate perspective view of the compressor component of FIG. 2 in accordance with an embodiment of the present invention;
FIG. 4 is yet another perspective view of the compressor component of FIG. 2 in accordance with an embodiment of the present invention;
FIG. 5 is an elevation view of a compressor blade depicting an airfoil in accordance with the prior art component overlaid with an airfoil in accordance with an embodiment of the present invention;
FIG. 6 is a cross section view of the airfoil of the present invention taken towards its tip region compared to a tip cross-section of the prior art airfoil;
FIG. 7 is a cross section view of the airfoil of the present invention taken towards its mid-span compared to a mid-span section of the prior art airfoil;
FIG. 8 is a cross section view of the airfoil of the present invention taken towards its base compared to a base section of the prior art airfoil;
FIG. 9 is a perspective view depicting overlays of the prior art compressor airfoil and the present invention in accordance with an embodiment of the present invention;
FIG. 10 is a set of Campbell diagrams depicting a comparison of operating frequencies for the prior art component and the present invention; and
FIG. 11 is a cross section view of a portion of a compressor including a portion of a diffuser.
DETAILED DESCRIPTION
The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different components, combinations of components, steps, or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies.
Referring initially to FIG. 1 , a prior art compressor blade 100 is depicted. The prior art blade 100 includes a cropped blade tip 102 . Because of critical aerodynamic crossings occurring in the airfoil at the tip of the blade 100 , vibrations within the airfoil caused a portion of the blade tip to crack and break off during operation. As a fix to this design flaw, suppliers proceeded to remove a portion of the blade tip during manufacturing in order to prevent the blade tip from cracking. However, this cropped blade tip, as shown in FIG. 1 creates a loss in both compressor blade efficiency and overall compressor efficiency.
The present invention seeks to overcome the shortcomings of the prior art, including the “cropped airfoil” configuration, by providing a redesigned airfoil portion of a compressor blade that eliminates the cracking of the blade tip and the need to remove a portion of the blade tip during manufacturing. Referring to FIGS. 2-4 , the present invention is directed towards a compressor component, such as a compressor blade, where the compressor component 200 has a redesigned shape to the airfoil 202 . While the general profile of the airfoil 202 has changed, the changes are most noticeable towards a tip 204 of the airfoil 202 , as can be seen in the comparison between compressor blades in FIG. 9 , where the solid line represents the present invention and the dashed line represents the prior art airfoil configuration.
An embodiment of the present invention also comprises an attachment 206 for securing the compressor component 200 to a disk (not shown). The airfoil 202 , which is preferably solid, extends radially outward from the attachment 206 and has a leading edge 208 and a trailing edge 210 with the trailing edge 210 spaced a distance from the leading edge 208 and separated by a concave surface 214 and convex surface 212 , as shown in FIG. 4 .
The airfoil 202 has an uncoated profile substantially in accordance with Cartesian coordinate values of Table 1, as set forth below, having a set of X, Y, and Z coordinates, where the Y coordinate extends in a radially outward direction from the attachment region. The airfoil 202 is formed by applying smooth continuing splines between the X and Z coordinate values at each Y distance to form an airfoil section. Example airfoil sections 216 , 218 , and 220 are depicted in FIGS. 6-8 . Then, each of the airfoil sections 216 , 218 , 220 , and others not depicted, but described in Table 1, are joined together smoothly to form the profile of the airfoil 202 . The coordinate values, which when taken together, generate the profile of airfoil 202 have a plurality of sections of data at spaced intervals in the Y direction that are measured from a datum plane B that is indicative of the center plane along root faces of the attachment 206 , as shown in FIGS. 2 and 3 . The datum plane B is located a distance of approximately 0.205 inches from the bottom surface of attachment 206 . The airfoil 202 extends a radial distance of approximately 3 inches and varies in its longitudinal length and thickness depending on the radial span.
A compressor component for a land-based compressor is typically fabricated from a relatively low temperature alloy since the air temperature of the compressor typically only reaches upwards of 700 deg. F. In an embodiment of the present invention, the compressor component 200 is fabricated from a lower temperature alloy such as a stainless steel alloy. The compressor component 200 can be fabricated by a variety of manufacturing techniques such as forging, casting, milling, and electro-chemical machining (ECM). For example, when milling or electro-chemical machining processes are used, the compressor component 200 is machined from bar stock.
Because of the limited precision of certain manufacturing techniques, the compressor component 200 has manufacturing tolerances for the surface profile of the airfoil 202 that can cause the airfoil 202 to vary by approximately +/−0.008 inches from a nominal state. In addition to manufacturing tolerances affecting the overall position of the airfoil 202 , it is also possible to scale the airfoil 202 to a larger or smaller airfoil size, approximately 80%-120% of its present size. However, in order to maintain the benefits of this airfoil shape and size, in terms of stiffness and stress, it is necessary to scale the airfoil uniformly in X and Z directions, but Y direction may be scaled separately.
While an embodiment of the present invention provides an uncoated compressor component 200 such as a compressor blade, it is possible to add a coating to at least a portion of the airfoil 202 in an alternate embodiment. A coating can be applied to the airfoil 202 in order to provide corrosion resistance protection to the material of the airfoil portion. In this embodiment, the coating would preferably be applied approximately 0.001-0.003 inches thick.
As one skilled in the art of blade and vane airfoil design will understand, the airfoils move at various modes due to their geometry and the aerodynamic forces being applied thereto. Should this excitation occur for prolonged periods of time at a natural frequency or order thereof, the airfoil 202 can fail due to high cycle fatigue as occurred in the prior art design. Such modes include bending, torsion, and various higher order modes. For example, a critical bending mode for the compressor component of the present invention is the chordwise bending mode initiated by vibrations imparted by upstream vanes (qty. 138) or downstream vanes (qty. 142). Where the seventh bending mode crosses either of these frequency ranges for a particular speed range, this creates an excitement in the blade causing it to cycle and eventually fail in high cycle fatigue. For the prior art airfoil configuration of blade 100 , the seventh mode crossed within a tolerance range of the 138 engine order (caused by the upstream vanes), as shown in FIG. 10 . This crossing is the root cause for the vibrations that led to failure of a portion of the blade tip and the temporary work around of cropping the blade tip in the prior art configuration. Referring to the plot of frequency versus percent speed for the present invention (compressor component 200 ), it can be seen that the seventh mode no longer crosses the engine orders of the upstream vane pack (138) or downstream vane pack (142), nor either tolerance range. As such, the present invention is no longer subjected to potentially damaging vibrations associated with the seventh mode and the blade tip will no longer crack due to this excitation.
TABLE 1
X
Y
Z
0.197
0.059
−0.907
0.170
0.059
−0.841
0.144
0.059
−0.775
0.117
0.059
−0.710
0.092
0.059
−0.646
0.067
0.059
−0.583
0.043
0.059
−0.521
0.021
0.059
−0.461
−0.001
0.059
−0.401
−0.021
0.059
−0.343
−0.039
0.059
−0.286
−0.057
0.059
−0.230
−0.072
0.059
−0.174
−0.087
0.059
−0.119
−0.099
0.059
−0.064
−0.111
0.059
−0.009
−0.120
0.059
0.047
−0.128
0.059
0.103
−0.134
0.059
0.159
−0.139
0.059
0.216
−0.141
0.059
0.275
−0.142
0.059
0.334
−0.140
0.059
0.394
−0.137
0.059
0.455
−0.131
0.059
0.517
−0.122
0.059
0.580
−0.111
0.059
0.644
−0.096
0.059
0.707
−0.079
0.059
0.770
−0.058
0.059
0.832
−0.032
0.059
0.892
−0.003
0.059
0.950
0.032
0.059
1.005
0.072
0.059
1.055
0.088
0.059
1.072
0.090
0.059
1.074
0.092
0.059
1.076
0.094
0.059
1.077
0.097
0.059
1.078
0.099
0.059
1.078
0.102
0.059
1.078
0.105
0.059
1.077
0.107
0.059
1.076
0.109
0.059
1.075
0.111
0.059
1.073
0.112
0.059
1.071
0.114
0.059
1.069
0.114
0.059
1.066
0.115
0.059
1.064
0.115
0.059
1.061
0.114
0.059
1.058
0.110
0.059
1.002
0.105
0.059
0.946
0.100
0.059
0.890
0.096
0.059
0.833
0.092
0.059
0.776
0.088
0.059
0.718
0.085
0.059
0.660
0.082
0.059
0.601
0.080
0.059
0.542
0.078
0.059
0.482
0.077
0.059
0.422
0.077
0.059
0.361
0.077
0.059
0.300
0.078
0.059
0.239
0.079
0.059
0.177
0.082
0.059
0.116
0.085
0.059
0.054
0.089
0.059
−0.007
0.094
0.059
−0.068
0.099
0.059
−0.130
0.106
0.059
−0.190
0.113
0.059
−0.250
0.120
0.059
−0.310
0.129
0.059
−0.370
0.138
0.059
−0.428
0.148
0.059
−0.486
0.158
0.059
−0.544
0.169
0.059
−0.600
0.181
0.059
−0.657
0.192
0.059
−0.712
0.204
0.059
−0.768
0.217
0.059
−0.822
0.229
0.059
−0.877
0.234
0.059
−0.898
0.235
0.059
−0.903
0.235
0.059
−0.907
0.234
0.059
−0.911
0.233
0.059
−0.914
0.231
0.059
−0.918
0.228
0.059
−0.920
0.225
0.059
−0.922
0.221
0.059
−0.924
0.217
0.059
−0.924
0.213
0.059
−0.924
0.210
0.059
−0.923
0.206
0.059
−0.921
0.203
0.059
−0.918
0.201
0.059
−0.915
0.199
0.059
−0.911
0.197
0.059
−0.907
0.129
0.322
−0.914
0.107
0.322
−0.848
0.085
0.322
−0.783
0.063
0.322
−0.718
0.043
0.322
−0.653
0.022
0.322
−0.590
0.003
0.322
−0.527
−0.015
0.322
−0.465
−0.032
0.322
−0.403
−0.048
0.322
−0.343
−0.063
0.322
−0.283
−0.076
0.322
−0.224
−0.088
0.322
−0.165
−0.099
0.322
−0.106
−0.108
0.322
−0.048
−0.116
0.322
0.010
−0.123
0.322
0.069
−0.128
0.322
0.127
−0.132
0.322
0.186
−0.134
0.322
0.245
−0.134
0.322
0.304
−0.133
0.322
0.364
−0.130
0.322
0.424
−0.126
0.322
0.484
−0.119
0.322
0.545
−0.110
0.322
0.606
−0.099
0.322
0.667
−0.086
0.322
0.727
−0.069
0.322
0.787
−0.050
0.322
0.846
−0.028
0.322
0.903
−0.001
0.322
0.958
0.029
0.322
1.011
0.064
0.322
1.060
0.078
0.322
1.077
0.080
0.322
1.080
0.083
0.322
1.082
0.085
0.322
1.084
0.088
0.322
1.085
0.091
0.322
1.085
0.093
0.322
1.086
0.096
0.322
1.085
0.098
0.322
1.084
0.101
0.322
1.083
0.102
0.322
1.081
0.104
0.322
1.079
0.105
0.322
1.076
0.106
0.322
1.073
0.106
0.322
1.070
0.106
0.322
1.067
0.106
0.322
1.064
0.102
0.322
1.007
0.098
0.322
0.951
0.094
0.322
0.895
0.090
0.322
0.838
0.086
0.322
0.780
0.082
0.322
0.722
0.079
0.322
0.664
0.076
0.322
0.605
0.073
0.322
0.545
0.071
0.322
0.485
0.069
0.322
0.424
0.067
0.322
0.364
0.066
0.322
0.302
0.065
0.322
0.241
0.065
0.322
0.179
0.065
0.322
0.117
0.066
0.322
0.055
0.067
0.322
−0.007
0.070
0.322
−0.068
0.072
0.322
−0.130
0.076
0.322
−0.191
0.080
0.322
−0.252
0.085
0.322
−0.312
0.090
0.322
−0.372
0.096
0.322
−0.431
0.103
0.322
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In addition to the structural improvements gained by the reconfigured airfoil shape of compressor component 200 , the present invention also helps to improve overall compressor performance by improving the performance at the compressor diffuser 300 . The compressor diffuser 300 , as one skilled in the art understands and as shown in FIG. 11 , receives the compressed air from an engine compressor at inlet region 302 and directs the air to the combustor(s). Due to the configuration of diffuser 300 and its support structure, efficiency losses are expected within the diffuser. In an embodiment of the invention, compressor component 200 is positioned in the last stage of rotating compressor blades and is the last point where it is possible to modify the total pressure profile along the height of the compressor section entering the diffuser. Efficiency losses at this stage are especially undesirable. Therefore, because of the improved airfoil configuration of compressor component 200 , especially at its blade tip, the last stage of compressor blades is able to impart additional energy to the compressor and improve efficiency in the diffuser. Based on the aerodynamic changes described above, an increase in overall efficiency of approximately 0.2% is expected across the compressor and diffuser.
In order to introduce more energy through this last stage of the compressor, it is necessary to energize the flow in the regions near the compressor walls, which requires a greater pressure rise at the blade tip and root sections. However, because of the boundary layer present in these same areas, increasing pressure in these locations can be difficult. Pressure can be increased by increasing the amount of turning in these regions, as shown in FIGS. 6-8 . To increase the turning, for a given airfoil chord length, the camber, or arc shape of the airfoil must be increased. However, with an increase in camber comes flow separation as the passing airflow approaches the airfoil trailing edge. To minimize flow separation for an airfoil with increased camber, the chord length of the airfoil must be adjusted wherever possible, as shown in FIGS. 5-8 . That is, geometric constraints of the compressor component 200 must be balanced with structural integrity constraints in order to improve overall compressor efficiency.
Due to the changes in the physical profile of compressor component 200 , the present invention airfoil profile also alters the natural frequency of the compressor component 200 . As a result previously-damaging engine crossings, especially with the 7 th mode, have been eliminated and are depicted by the Campbell diagrams of FIG. 10 .
The present invention has been described in relation to particular embodiments, which are intended in all respects to be illustrative rather than restrictive. Alternative embodiments will become apparent to those of ordinary skill in the art to which the present invention pertains without departing from its scope.
From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects set forth above, together with other advantages which are obvious and inherent to the system and method. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and within the scope of the claims.
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A compressor component having an improved airfoil profile so as to eliminate previously known vibratory issues in the blade tip is disclosed. By altering the airfoil profile throughout its span, the natural frequency of the airfoil is altered so as to not coincide with a critical engine order of the compressor. Further, the present invention provides a novel airfoil profile in accordance with the coordinates of Table 1.
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FIELD
Embodiments of the invention relate to methods and mechanisms to actuate components of downhole tools and, more specifically, downhole tools for oil, gas, geothermal, and horizontal drilling.
BACKGROUND OF THE INVENTION
Actuating downhole tools disposed in a well-bore is often accomplished by dropping a ball down a bore of a drill string to break shear pins, which upon breaking frees a valve to open or actuate a downhole tool, such as a reamer. Once the shear pins are broken, the downhole tool and, consequently, the drill string must be removed from the well-bore to replace them. Other disadvantages, such as an inability to reset the actuating mechanism of the downhole tool while the downhole tool is still in the well-bore are inherent in this type of design.
BRIEF SUMMARY OF THE INVENTION
In one aspect of the present invention, a downhole tool string component has at least a first end with an attachment to an adjacent tool string component and a second end spaced apart from the first end for attachment to another adjacent tool string component. The downhole tool string component includes a bore between the first end and the second end and a turbine disposed within the bore. An actuating assembly is arranged in the bore such that when actuated a clutch mechanically connects the actuating assembly to the turbine. When the actuating assembly is deactivated, the actuating assembly and turbine are mechanically disconnected.
The actuating assembly may move a linear translation mechanism, which may include a sleeve. The sleeve may have at least one port that is adapted to align with a channel formed in a wall of the bore when the sleeve moves. The actuating assembly may control a reamer, a stabilizer blade, a bladder, an in-line vibrator, an indenting member in a drill bit, or combinations thereof.
The actuating assembly may comprise a collar with a guide slot around a cam shaft with a pin or ball extending into the slot. When the collar moves axially, the cam rotates due to the interaction between the pin or ball and the slot. The cam shaft may be adapted to activate a switch plate, which is adapted to engage a plurality of gears. The actuating assembly may comprise at least one solenoid adapted to move a translation member in communication with a switching mechanism.
In some embodiments, the actuating assembly comprises a switching mechanism adapted to rotate a gear set in multiple directions.
The clutch may be a centrifugal clutch adapted to rotate with the turbine. The clutch may have at least one spring loaded contact adapted to connect the clutch to the shaft. The actuating assembly may be triggered by an increase in a velocity at which the turbine rotates, a decrease in the rotational velocity of the turbine, or a combination thereof. In some embodiments, the clutch may be controlled by a solenoid. The clutch may also be controlled over a wired drill pipe telemetry system, a closed loop system, or combinations thereof.
In another aspect of the present invention, a downhole tool string component has at least a first end with an attachment to an adjacent tool string component and a second end spaced apart from the first end for attachment to another adjacent tool string component. The downhole tool string component includes a bore between the first end and the second end and a turbine disposed within the bore. A turbine is disposed within the bore, the turbine being in mechanical communication with a linear actuator that is aligned with a central axis of the tool string component.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective diagram of an embodiment of a drill string suspended in a borehole.
FIG. 2 a is a perspective diagram of a portion of an embodiment of a tool string component that includes a reamer.
FIG. 2 b is a cross-sectional diagram of the embodiment of the tool string component illustrated in FIG. 2 a.
FIG. 3 is a cross-sectional diagram of another portion of the embodiment of the tool string component illustrated in FIG. 2 a.
FIG. 4 is a close-up cross-sectional diagram of the another portion of the embodiment of the downhole tool string component illustrated in FIG. 3 .
FIG. 5 is a close-up perspective diagram of the another portion of the embodiment of the downhole tool string component illustrated in FIG. 4 .
FIG. 6 is a perspective diagram of an embodiment of a switch plate for use in embodiments of the tool string component in a first position.
FIG. 7 is a perspective diagram of the embodiment of the switch plate illustrated in FIG. 6 in a second position.
FIG. 8 a is a close-up cross-sectional diagram of the portion of the embodiment of the downhole tool string component illustrated in FIG. 2 b in which a sleeve is in a first position.
FIG. 8 b is a close-up cross-sectional diagram of the portion of the embodiment of the downhole tool string component illustrated in FIG. 2 b in which a sleeve is in a second position.
FIG. 9 is a cross-sectional diagram of an embodiment of a downhole tool string component that includes a packer.
FIG. 10 a is a cross-section of an embodiment of a downhole drill string component that includes a solenoid-activated clutch.
FIG. 10 b is another cross-section view of the embodiment of a downhole drill string component that includes the solenoid-activated clutch illustrated in FIG. 10 b.
FIG. 11 a is a cross-section of an embodiment of a centrifugal clutch.
FIG. 11 b is a perspective cut-away of the embodiment of the centrifugal clutch illustrated in FIG. 11 a.
FIG. 12 a is a cross-section diagram of an embodiment of a downhole drill string component that includes an actuation assembly.
FIG. 12 b is a cross-section diagram of the embodiment of the downhole drill string component that includes the actuation assembly illustrated in FIG. 12 a.
FIG. 13 a is a cross-sectional diagram of an embodiment of a drill bit.
FIG. 13 b is a cross-sectional diagram of another embodiment of a drill bit.
FIG. 14 is a cross-sectional diagram of an embodiment of a reamer.
FIG. 15 is a cross-sectional diagram of an embodiment of a stabilizer in a drill string component.
FIG. 16 is a perspective diagram of an embodiment of a vibrator.
FIG. 17 is a perspective diagram of an embodiment of a turbine for use in a downhole tool string component.
FIG. 18 a is a perspective diagram of an embodiment of a plurality of blades of a turbine.
FIG. 18 b is a perspective diagram of another embodiment of a plurality of blades of a turbine.
DETAILED DESCRIPTION
FIG. 1 is a perspective diagram of an embodiment of a drill string 100 suspended by a derrick 108 in a well-bore or bore hole 102 . A drilling assembly 103 is located at the bottom of the bore hole 102 and comprises a drill bit 104 . As the drill bit 104 rotates downhole the drill string 100 advances farther into the earth. The drill string 100 may penetrate soft or hard subterranean formations 105 . The drilling assembly 103 and/or downhole components may comprise data acquisition devices adapted to gather data. The data may be sent to the surface via a transmission system to a data swivel 106 . The data swivel 106 may send the data to the surface equipment 110 . Further, the surface equipment 110 may send data and/or power to downhole tools, the drill bit 104 , and/or the drilling assembly 103 .
FIG. 2 a is a perspective diagram of a portion of an embodiment of a downhole drill or tool string component 201 with a reamer 200 . The reamer 200 may be adapted to extend into and retract away from a borehole wall. While against the borehole wall, the reamer 200 may be adapted to enlarge the diameter of the borehole larger than accomplished by the drill bit 104 at the front of the drilling assembly 103 , as illustrated in FIG. 1 .
FIG. 2 b is a cross-sectional diagram of the embodiment of the reamer 200 illustrated in FIG. 2 a . A sleeve 202 located within a bore 204 of the tool sting component 201 may comprise ports 203 . The ports 203 may be adapted to divert drilling mud that flows through the bore 204 when the ports 203 are aligned with openings 250 formed in a wall 202 a of the bore 204 . The diverted drilling mud may engage a piston 205 located in a chamber 251 otherwise isolated from the bore 204 when the ports 203 are not aligned with the openings 250 ; after the drilling mud passes through the chamber 251 the drilling mud is re-diverted back into the bore 204 of the tool string component 201 . As the drilling mud urges the piston 205 to extend, it may push the reamer 200 outward. A ramp formed in the reamer 200 may cause the reamer 200 to extend radially the piston 205 applies an axial force to the reamer 200 . The piston 205 and reamer 200 may stay extended by a dynamic force from the flowing drilling mud. The reamer 200 may be in mechanical communication with a spring 206 or other urging mechanism adapted to push the reamer 200 back into a retracted position in the absence of axial force exerted by the piston 205 while drilling mud is diverted into the chamber 251 . A reamer that may be compatible with the present invention, with some modifications, is disclosed in U.S. Pat. No. 6,732,817 assigned to Smith International, Inc., which is herein incorporated by reference for all that it contains.
When the sleeve 202 is moved along direction A such that the ports 203 and openings 250 misalign, the dynamic force provided by the flowing drilling mud is cut off and the reamer 200 retracts. In other embodiments, a pause in drilling mud flow may also cause the reamer 200 to retract. The sleeve 202 may be moved to realign and misalign the ports 203 with the openings 250 on command to control the position of the reamer 200 . In some embodiments, the ports 203 of the sleeve 202 is adapted to partially align with the openings 250 , allowing a flow less than a flow through fully aligned ports 203 to engage the piston 205 , thereby extending the reamer 200 less than its maximum radial extension. Further discussion and explanation of the mechanical structure and the process is made below in a discussion of FIGS. 8 a and 8 b.
FIG. 3 is a cross-sectional diagram of another portion of the embodiment of the downhole drill string component 201 . The drill string component 201 may comprise an actuating assembly 333 adapted to move the sleeve 202 axially along direction A. In some embodiments, the actuating assembly 333 is a linear actuator. The drill string component 201 may also comprise a turbine 400 in mechanical communication with the actuation assembly 333 wherein the turbine 400 may be involved in triggering and/or powering the actuation assembly 333 . The actuation assembly 333 may engage or disengage a plurality of gears 304 , such as a planetary gear system, adapted to move a linear screw member 1004 connected to the sleeve 202 .
FIGS. 4 and 5 disclose a turbine 400 located in the bore 204 of the drill string component 201 . As drilling mud is passed along a fluid path 402 in the drill string component 201 , the drilling mud flowing over one or more blades 400 a , illustrated in FIG. 5 , of the turbine 400 , thereby rotating the turbine 400 .
The turbine 400 is mechanically coupled to a shaft 412 a at a proximal end 412 b of the shaft 412 a . The shaft 412 a is mechanically coupled to a centrifugal clutch 502 at a distal end 412 c of the shaft 412 a . When drilling mud causes the turbine 400 to rotate, thereby rotating the shaft 412 a , the centrifugal clutch 502 also rotates. Once the centrifugal clutch 502 rotates sufficiently fast, the centrifugal clutch 502 engages a mount 501 , causing the mount 501 to rotate with the turbine 400 . (The operation of the centrifugal clutch is discussed in further detail below and in reference to FIGS. 11 a and 11 b .) As the mount 501 rotates, a plurality of weights 555 attached to a distal end 300 b of a pivotally attached bracket 300 a may be forced outward away from a central axis 210 of the drill string component 201 while a proximal end 300 c of the bracket 300 a moves to push in an axial direction A′ on a collar 503 coupled to a proximal end 401 b of a shaft 401 a located below the mount 501 . A driving gear 410 ( FIG. 5 ) disposed on a distal end 401 c of the shaft 401 a . Thus, the turbine 400 is mechanically coupled through the shaft 412 a , through a clutch 502 , to the shaft 401 a , and consequently the driving gear 410 .
The collar 503 may comprise a guide pin 557 that interacts with a guide slot 558 formed in a cam housing. When the collar 503 moves in an axial direction A′ it may rotate the cam 556 . The rotation of the cam 556 may move a switch plate 504 adapted to selectively place the driving gear 410 in contact with a plurality of gears 304 . When activated the plurality of gears 410 may transfer torque from the shaft 401 a to a linear screw member 1004 ( FIG. 4 ) attached to the sleeve 202 , as illustrated in FIG. 3 .
The guide slot 558 may comprise a section that causes the collar 503 to move in a first direction and another section that causes the collar 503 to move in a second direction away from the first direction. The direction that the collar 503 travels dictates how the driving gear 410 engages the plurality of gears 304 . In a preferred embodiment, the plurality of gears 304 is a planetary gear system that may control the direction that the gears within the planetary gear system rotate. A clockwise or counterclockwise rotation of the gears determines the forward or backward axial movement A of the linear screw member 1004 , as illustrated in FIG. 3 .
FIG. 6 discloses the switch plate 504 that moves the cam 556 in direction 560 as the collar 503 is advanced axially. The switch plate 504 may be positioned such that the driving gear 410 becomes engaged with a first set of gears 666 mounted to the switch plate 504 , thereby engaging the plurality of gears 304 . The engagement of the plurality of gears 304 may rotate a circular rack 567 in a direction 561 that drives a secondary gear set 678 adapted to turn the linear screw member 1004 , as illustrated in FIG. 3 .
As discussed above and in reference to FIGS. 4 and 5 , a decrease or slowing of the flow rate of the drilling mud and, consequently, the turbine 400 may cause the centrifugal clutch 502 to decouple the shaft 412 a from the shaft 401 a . When this occurs, the collar 503 , which may be in communication with a spring (not shown) adapted to urge the collar 503 back to its original axial position, moves axially towards the centrifugal clutch 502 , thereby disengaging the driving gear 410 from the plurality of gears 304 . With the driving gear 410 disengaged from the plurality of gears 304 , the plurality of gears no longer drive the linear screw member and the secondary gear set 678 and, consequently, the linear screw member 1004 remains in its last position before the plurality of gears were disengaged.
Referring now to FIG. 7 , should the flow of the drilling mud subsequently increase and, in turn, causing the rotational velocity of the turbine 400 and the shaft 412 a coupled thereto to increase, the centrifugal clutch 502 will recouple the shaft 412 a with the shaft 401 a . This causes the collar 503 to re-interact with the pin 557 in its guide slot 558 . The guide slot 558 is formed such that it will cause the cam 556 to push the driving gear 410 in a direction 562 into a position that causes the driving gear 410 to engage with a second set of gears 667 mounted to the switch plate 504 , thereby engaging the plurality of gears 304 . The engagement of the plurality of gears 304 may rotate a circular rack 567 in a direction 563 that drives a secondary gear set 678 to retract the linear screw member 1004 , as illustrated in FIG. 3 . Thus, the sleeve 202 (shown in FIG. 2 b ) attached to the linear screw member 1004 may be moved to extend or retract the reamer 200 .
FIG. 8 a , and in reference to FIG. 2 b and the related text, discloses an arrow 601 indicating the drilling mud flow through the bore 204 of the drill string component 201 when the ports 203 of the sleeve 202 are misaligned with the openings 250 , thereby preventing the flow of the drilling mud through the openings 250 .
FIG. 8 b discloses the ports 203 of the sleeve 202 aligned with the openings 250 . In this instance, drilling mud is partially diverted along a path 602 through the openings 250 and into a channel 608 in which the piston 205 is disposed. The drilling mud engages the piston 205 as discussed above in reference to FIG. 2 b , thereby causing the piston 205 to move the reamer 200 outward in a direction 603 due to an inclined ramp formed in the blade (discussed in relation to FIG. 2 b ).
FIG. 9 discloses a packer 800 that may be activated in a similar manner as the reamer described above.
FIGS. 10 a and 10 b are cross-sectional diagrams disclosing an embodiment of a downhole tool component 201 a that includes a solenoid activated clutch. A first solenoid 1002 and a second solenoids 1003 that acts in a direction opposite of the first solenoid 1002 are in mechanical communication with a translation member 1050 mechanically coupled to a shaft 1401 . The shaft 1401 is coupled to and rotated by a turbine, such as turbine 400 in FIG. 5 that is discussed above. The shaft 1401 is mechanically coupled to and, consequently, rotates a key gear 1099 . As reference to the drawings makes clear, the key gear 1099 is mechanically coupled through the shaft 1401 to the translation member 1050 . When the first solenoid 1002 is activated, it moves in a first axial direction A″, thereby moving the shaft 1401 and the key gear 1099 in the same direction as the first solenoid 1002 . When the second solenoid 1003 is activated ( FIG. 10 b ), it moves in a second axial direction A″ opposite the first axial direction, thereby moving the shaft 1401 and the key gear 1099 in the same direction as the second solenoid 1003 . Depending on the direction, the key gear 1099 will engage either a forward gear 1098 or a reverse gear 1097 , which will drive a plurality of gears 304 a , such as the plurality of gears 304 discussed above in reference to FIGS. 4 and 5 , to either extend or retract a linear screw member 1004 a , as above. The translation member 1050 may comprise a length adapted to abut a barrier to control its travel. The translation member 1050 may be biased, spring-loaded, or comprise an urging mechanism adapted to return the translation member 1050 , and, therefore, the key gear 1099 , to an unengaged position when a solenoid, such as first solenoid 1002 or second solenoid 1003 , is not energized.
The first solenoid 1002 and the second solenoid 1003 may be energized through either a local or remote power source. A telemetry system, such as provided by wired drill pipe or mud pulse, may provide an input for when to activate a solenoid. In some embodiments, a closed loop system may provide the input from a sensed downhole parameter and control the actuation.
FIGS. 11 a and 11 b disclose an embodiment of a centrifugal clutch 1502 , such as the centrifugal clutch 502 discussed above in association with FIGS. 4 and 5 . The centrifugal clutch 1502 comprises grippers 1100 attached to springs 1101 . In this embodiment, when the centrifugal clutch 1502 rotates sufficiently fast a centrifugal force may overcome the spring force and move the grippers 1100 away from a shaft 1412 . At lower rotational velocities the grippers 1100 bear down on the shaft 2401 rotationally locking them together. To engage the centrifugal clutch 1502 the flow of the drilling mud may be reduced; and to disengage the centrifugal clutch 1502 the flow may be increased.
FIGS. 12 a and 12 b disclose an embodiment of portion of a downhole drill string component 201 b that includes an actuation assembly 1333 comprising a turbine 1400 connected to a shaft 1412 . When a centrifugal clutch 1502 a is engaged as described above in reference to FIGS. 11 a and 11 b , the collar 1503 may be pushed forward in a similar manner as described above in reference to FIGS. 4 and 5 . In this embodiment, the collar 1503 may comprise a ball track 1111 adapted to receive a ball 1112 in communication with a cam 1556 . As the collar 1503 is pushed down, the cam 1556 rotates, which moves a translation member 1050 a . Movement of the translation member causes a key gear 1099 a coupled to a shaft 1401 a to engage with either a forward gear 1098 a or a reverse gear 1097 a as described above in reference to FIGS. 10 a and 10 b , which in turn either advances or retracts a linear screw member 1004 b.
FIG. 13 a is a cross-sectional diagram of an embodiment of a drill bit 104 a . The drill bit 104 a may comprise an actuating assembly 1500 a patterned after those described above. The assembly 1500 may be adapted to axially move an indenting member 1501 towards a cutting surface 2000 of the drill bit 104 a . The indenting member 1501 may be a steerable element, hammer element, penetration limiter, weight-on-bit controller, sensor, probe, or combinations thereof.
In the embodiment of a drill bit 104 b illustrated in FIG. 13 b , an actuating assembly 1500 b may be use to control a flow of drilling mud through a nozzle 1506 disposed in a face 2002 of the drill bit 104 b.
FIG. 14 is a cross-sectional diagram of an embodiment a downhole drill string component 201 c that includes a winged reamer 200 a , which may be pivotally extended away from downhole drill string component 201 c by using a linear screw member 1004 c.
FIG. 15 discloses an embodiment of a downhole drill string component 201 d that includes an actuation mechanism adapted to extend a stabilizer blade 1234 . As ports 203 a in a sleeve 202 a align with a plurality of openings 250 a , the flow of a drilling mud may be partially diverted to engage a piston 205 a adapted to push the stabilizer 1234 in a direction 603 a towards a formation.
FIG. 16 discloses an embodiment of a downhole drill string component 201 e that includes an in-line vibrator 1750 disposed within a bore 204 e of the drill string component 201 e . As a shaft 1401 b rotates due to activation of a clutch (not illustrated), an off-centered mass 1701 coupled to the shaft 1401 b is rotated. The in-line vibrator 1701 may reduce the drilling industry's dependence on drilling jars which violently shake the entire drill string when the drill string gets stuck in a well-bore. The in-line vibrator 1701 may successfully free the downhole drill string component 201 e and the drill string while using less energy than traditional jars. This, in turn, may preserve the life of the drill string components and its associated drilling instrumentation. In some embodiments, the use of the in-line vibrator 1701 may prevent the drill string from getting stuck in the well-bore in the first place. The distal end 1751 of the shaft 1401 b may be supported by a spider 1752 .
FIG. 17 discloses an embodiment of a downhole drill string component 201 f that includes a turbine 400 b with adjustable blades 1760 . A solenoid may be adapted to rotate a cam associated with the blades 1760 . By adjusting the blade 1760 , the revolutions per minute of the turbine 400 b may be changed, thereby activating or deactivating a centrifugal clutch, such as the centrifugal clutch 502 discussed above in reference to FIGS. 4 , 5 , 11 a , and 11 b.
FIGS. 18 a and 18 b disclose an embodiment of a plurality of blades 2004 a ( FIG. 18 a ), 2004 b ( FIG. 18 b ) of a turbine. The turbine blades 2004 a and 2004 b may be configured to produce higher torque at a lower RPM.
Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.
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In one aspect of the invention, a downhole tool string component has at least one end adapted to connect to an adjacent tool sting component and a bore adapted to accommodate a flow of drilling fluid. A turbine is disposed within the bore and an actuating assembly is arranged such that a clutch may mechanically connect and disconnect with the turbine.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for etching phosphate ore, comprising:
a digestion of phosphate ore by an aqueous solution of hydrochloric acid, which results in formation of an etching liquor consisting of an aqueous phase, in which calcium phosphate is in solution, and an insoluble solid phase which contains impurities, a first separation between the insoluble solid phase and the aqueous phase of the etching liquor, a preliminary neutralization of an aqueous medium containing calcium phosphate in solution to a first pH which is lower than the pH at which a significant part of this calcium phosphate in solution precipitates in the form of calcium monohydrogen phosphate (DCP), with precipitation of impurities, an isolation of the precipitated impurities from the pre-neutralized aqueous medium, a subsequent neutralization of said pre-neutralized aqueous medium to a second pH which is greater than the aforementioned first pH, with precipitation of DCP, and a second separation between the subsequently neutralized aqueous medium, which is an aqueous solution of calcium chloride, and the precipitated DCP.
2. The Prior Art
For a long time, methods have been known which provide for hydrochloric etching of phosphate ore (see patents U.S. Pat. No. 3304157, GB-1051521, ES-2013211 and SU-A-1470663 for example).
These methods have the drawback that they generally use, for etching purposes, a concentrated HCl solution of up to 20% and even 30% by weight. The ore to be used has to be of good quality, that is to say must have a high P2O5 content, and fine grinding of the ore is usually required, which increases the costs. During etching, a thermal shock is obtained which is due not only to the exothermic nature of the reaction but also to the dissolution energy which is released, and the insoluble materials are therefore difficult to separate since the liquor obtained is viscous and is loaded with organic materials originating from the ore. Given the high temperature and the concentration of the HCl solution, significant corrosion problems arise.
Also known is a hydrochloric etching method in which the ore is subjected to a first (limited) etching by dilute hydrochloric acid (see U.S. Pat. No. 3,988,420). The aim of this method is solely to dissolve within the rock, by means of this dilute acid, a substantial part of the calcium carbonate but the smallest possible amount of phosphate, which gives a solid phase enriched in P2O5 for the rest of the treatment.
Also known is a hydrochloric etching method as indicated in the introduction (see FR-A-2115244). This method consists in treating ores which contain very little phosphate, in a counter-current process, with several successive concentrations of hydrochloric acid. This process requires complex and expensive equipment to eliminate enormous quantities of sand and other insoluble materials which pollute this ore. This results in a loss of P2O5 during the treatment of the insoluble materials, and this loss has to be recuperated as much as possible by washing steps.
When a phosphate ore is digested in dilute HCl, two results determine the feasibility of the etching operation:
the yield of P2O5 in solution in the liquid phase. Any P2O5 which remains in the solid residue represents a loss and reduces the yield. This yield is expressed in % of P2O5 present in the treated ore. the level of purity of the end product, which increases as the amount of impurities dissolved in the liquid etching phase decreases. Within the meaning of the invention, the impurities are all the components (anions, cations and heavy metals, etc.) which are not water, P2O5 and calcium and chlorine ions. In the rest of the description, two elements will be selected as standards representative of the level of purity of the end product, namely fluorine and iron. In the text which follows, the end product will be calcium monohydrogen phosphate (DCP) in which the planned maximum content will be 0.2% for F and 0.05% for Fe.
It should be noted that the greater the yield of P2O5 in solution, the lower the degree of purity; this is because when all the P2O5 is dissolved, generally most of the impurities are also dissolved. A compromise must therefore be made between the desired level of purity for the end product and the minimum permitted yield of P2O5 in solution for the method to remain profitable, which is primarily determined by the cost of the raw material.
When the starting ore is of suitable quality, it has already been known to apply a method comprising a digestion of the phosphate ore by an aqueous solution of HCl having a concentration of at most 10% by weight, a separation between the insoluble materials and an aqueous phase containing phosphate ions, chloride ions and calcium ions, and a neutralization of the aqueous phase in order to precipitate DCP (see international patent application no. PCT/BE03/00111, not yet available to the public on the priority date of the present patent application).
This is because if conditions are stipulated whereby the minimum yield of P2O5 dissolved by dilute HCl is to be 75% and the minimum level of purity of the end product is 40%, it is possible to determine, as a function of one variable of the method, the conditions under which the method can be carried out. Such an example is shown on the graph in FIG. 1 , for a given phosphate ore. The percentages shown on the ordinate represent the level of purity of the end product (curve shown in solid line) and the yield of P2O5 in solution (curve shown in dashed line), and the graduation on the abscissa is that of a given variable of the method. In the shaded zone, between the two limit points A and B, are the conditions suitable for obtaining the minimum values mentioned above, in accordance with the teaching of the application PCT/BE03/00111.
FIG. 2 shows a similar graph, but for a different phosphate ore. It can be seen that, for this ore, it is not possible to achieve conditions under which both the minimum yield of P2O5 (point A) and the minimum level of purity (point B) can be met.
The object of the present invention is therefore to develop a hydrochloric etching method in which the ratio between the yield of P2O5 in solution and the level of purity of the end product is optimized so as to allow economically profitable etching of the ore, while carrying out this process using modern and simple equipment of justifiable expense.
SUMMARY OF THE INVENTION
According to the invention, this problem has been solved by a method as described in the introduction which comprises a digestion, in one step and in co-current, of phosphate ore having a P2O5 content of more than 20% by weight by an aqueous solution of hydrochloric acid having an HCl concentration of less than 10% by weight, and in which, in order to reach said first pH, said preliminary neutralization is carried out before said first separation in said etching liquor as aqueous medium containing calcium phosphate in solution, the isolation of the precipitated impurities taking place during said first separation of said insoluble solid phase, and said aqueous medium which has been pre-neutralized and subjected to said subsequent neutralization being formed of the separated aqueous phase resulting from the first separation.
Since the hydrochloric etching takes place in a dilute medium, which is therefore not viscous, the separation of the insoluble materials is easier and quicker to carry out, no heat is released during the etching operation, which advantageously takes place at ambient temperature, and the problems of corrosion by the hydrochloric acid are largely avoided.
A simple reactor which is equipped with a stirrer and operates at ambient pressure and temperature may therefore be sufficient for the treatment of the phosphate ore, and this therefore represents equipment of particularly favourable cost.
The effect of the preliminary neutralization is to promote a preliminary precipitation of heavy metals, in particular Fe and Mg, and of other impurities such as fluorine, so as to result in a permissible yield of P2O5 in solution during the etching process. The DCP thus obtained is particularly pure, more than could be expected by etching using dilute hydrochloric acid.
A significant part of the phosphate ions should be understood to mean that more than 10% of the dissolved P2O5 precipitates.
The aforementioned preliminary neutralization may take place for example in a separate vessel which is arranged immediately downstream of that used for digestion. Advantageously, the pH should be adjusted to a value of between 0.8 and 4, preferably between 1.3 and 1.5, so as to avoid as far as possible any premature precipitation of DCP. The precipitated heavy metals are thus advantageously separated in a single separation step with the insoluble components resulting from the etching.
The neutralizing agent according to the invention for the preliminary neutralization is preferably a strong base selected from the group consisting of the hydroxide, the oxide and the water-soluble salts of calcium, sodium, potassium and/or ammonium.
The digestion in particular and the entire hydrochloric etching process can preferably be carried out at ambient temperature. Temperatures of 20 to 80° C. can also be used.
Finally, the concentration of the aqueous HCl solution used for the etching is advantageously 3 to 8%, preferably 5 to 7.4%.
The dilute hydrochloric acid used in the method according to the invention may originate from any source. It is possible for example to obtain such dilute aqueous solutions of HCl on the market or as an effluent from another process. It is also possible to dilute concentrated hydrochloric acid, as commonly available on the market, in an aqueous phase. It is also possible to treat an aqueous solution of calcium chloride with sulphuric acid so as to precipitate calcium sulphate and isolate an aqueous HCl solution. Such an aqueous solution of calcium chloride can be obtained for example as an effluent from other processes, for example from certain processes for producing sodium carbonate.
In the method according to the invention, the insoluble phosphate resulting from the subsequent neutralization is calcium monohydrogen phosphate (DCP) having a very high level of purity and at the same time being rich in P2O5. Its P2O5 content may for example be 40 to 50% by weight, regardless of the ore used which at the start has a P2O5 content of more than 20% by weight. The phosphate ore may advantageously have a P2O5 content of 25 to 35% by weight.
During the subsequent neutralization, the pH is advantageously adjusted to a value of at least 4.5, preferably at least 5. At this pH, all of the phosphate ions in solution in the aqueous phase, in the form of calcium dihydrogen phosphate (MCP), pass to the insoluble DCP state. This neutralization is preferably carried out using a strong base selected from the group consisting of the hydroxide, the oxide and the water-soluble salts of calcium, sodium, potassium and/or ammonium.
According to one particular embodiment of the invention, the method comprises a treatment of said aqueous solution of calcium chloride with an aqueous solution of sulphuric acid, with formation of insoluble calcium sulphate, which precipitates, and of an aqueous phase based on hydrochloric acid, an isolation of the calcium sulphate precipitate, and an at least partial recycling, to the digestion step, of the aqueous phase based on hydrochloric acid, so as to form said aqueous solution of hydrochloric acid.
According to an improved embodiment of the invention, the method also comprises an additional neutralization of said aqueous solution of calcium chloride, by an addition of a neutralizing agent, so as to adjust this aqueous solution to a pH which is greater than the pH of the subsequent neutralization and so as to precipitate residual impurities, and an elimination of these impurities from said aqueous solution, a treatment of the latter with an aqueous solution of sulphuric acid, with formation of insoluble calcium sulphate, which precipitates, and of an aqueous phase based on hydrochloric acid, an isolation of the calcium sulphate precipitate, and a recycling, to the digestion step, of the aqueous phase based on hydrochloric acid, so as to form said aqueous solution of hydrochloric acid. By virtue of this step of the method, it is possible to precipitate all the undesired impurities, for example amphoteric metals, and to create a closed recycled system, without any gradual increase in the content of these impurities in the cycle.
Other information concerning the etching method according to the invention is given in the appended claims.
Other details and features of the method will also emerge from the following description of non-limiting examples, with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 show graphs which have already been described above.
FIG. 3 shows, in the form of a flowchart, one example of embodiment of a module for producing DCP, in which a method for etching phosphate ore according to the invention is carried out.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 3 , an extracted phosphate ore with a P2O5 content of 28 to 32% by weight is fed at 1 into a digestion vessel 2 , where it is subjected, in a single step, to etching in co-current by a solution of hydrochloric acid of around 5% by weight, which is added to this vessel via a conduit 3 . A phosphate ore as extracted is to be understood to mean that it has not been subjected to any calcination or to any fine grinding, in particular in mines where the extracted ore is in powdered form. If the ore is of volcanic origin, simple crushing may be provided to achieve a grain size of around 150 to 500 μm.
In the digestion vessel 2 , the dissolution of calcium phosphate is carried out at ambient temperature and it is rapid and intense, in the form of H3PO4 and soluble MCP.
It is then possible to introduce a neutralizing agent, such as hydrated lime for example, into a preliminary neutralization vessel 9 which is arranged downstream of the digestion vessel 2 and to which the latter is connected via the conduit 8 . This introduction of neutralizing agent is carried out via a conduit 10 , and it has the effect of maintaining in the vessel 9 a pH which will be for example between 1.3 and 1.5. At this high pH, the heavy metals, such as Fe, and other impurities, such as F, which have been dissolved from the ore by hydrochloric etching, are precipitated, and a suspension of solid particles is obtained. The cloudy liquid thus obtained is sent via the conduit 11 to a separation device 6 , for example a filter press, in which the solids, that is to say the insoluble materials resulting from the hydrochloric etching and the substances that have precipitated in the vessel 9 , are separated out together at 7 , following the advantageous addition of a suitable filtration adjuvant, known per se, and removed.
The liquid phase resulting from the separation contains, in dissolved form, phosphoric acid, monobasic calcium phosphate MCP, calcium chloride and some residual impurities.
The separated aqueous phase containing phosphate, calcium and chloride ions which leaves the separation device 6 via the conduit 12 is then transferred into a subsequent neutralization vessel 13 , in which dibasic calcium phosphate DCP is precipitated by introducing into the liquid phase, at 14 , a neutralizing agent of the same type as described above, for example calcium carbonate or milk of lime. Here, the pH will advantageously reach a value of around 5, at which all the MCP is converted to water-insoluble DCP.
In order to separate the precipitate, it is possible for example to evacuate the neutralized medium at 15 and to pass it in particular through a belt filter 16 , where the solid material is separated, that is to say a moist cake of DCP 17 , containing approximately 40-50% by weight of P205, determined on the dry product, 25-28% of Ca and minimal traces of impurities. The filtrate is removed at 18. It consists of an aqueous solution of CaCI2, which can easily be eliminated since it does not cause much pollution and can even easily be reused. Calcium chloride can be used for example as an antifreeze product on pavements.
During this hydrochloric etching, a yield of P2O5 in solution of more than 75%, preferably more than 90% and very advantageously more than 95% by weight can be obtained. Even with such a high etching yield, levels of purity which are greater than the required minimum values are achieved in the DCP obtained at 17 , for example a maximum content of F of 0.2% and of Fe of 0.05%.
Instead of removing the aqueous solution of CaCI2 which leaves the belt filter 16 , it is also possible to direct it via conduits 19 and 20 to a reactor 21 which is fed with an aqueous solution of sulphuric acid via the conduit 22 . In this reactor, which is stirred at a temperature of around 60° C. for one hour, formation of insoluble calcium sulphate is obtained, which precipitates in a highly pure form. Through the conduit 23 , the liquor resulting from the sulphuric etching is subjected to a separation step, for example by filtration at 24 . The solid phase formed of calcium sulphate is removed at 25 , and the liquid phase formed of an aqueous solution of highly pure HCl is sent back, via the conduit 26 , to the conduit 3 for supplying dilute hydrochloric acid.
Since sulphuric acid is more common and more readily available in large quantities than hydrochloric acid, this recycling makes it possible to further improve the hydrochloric etching yield, and even to provide said etching at locations where HCl is difficult to obtain.
Alternatively, before the sulphuric etching reactor, it is possible to pass the aqueous solution of CaCI2 leaving the belt filter 16 to an additional neutralization vessel 27 , passing via the conduit 28 .
In this vessel 27 , a neutralizing agent is once again introduced at 29 , preferably hydrated lime or calcium carbonate, so as to reach a pH of around 9-10, which has the effect of precipitating all the residual impurities such as amphoteric metals, etc. The suspension obtained is transferred via the conduit 30 to a separator 31 . The separated cake is removed at 32 , and the highly pure filtrate formed of CaCI2 in aqueous solution is led via the conduits 33 and 20 to the sulphuric etching reactor 21 .
It is of course also possible to envisage feeding the dilute hydrochloric acid source with an aqueous solution of CaCI2 resulting from another method, by optionally treating this aqueous solution beforehand by means of a sulphuric etching step, as in the reactor 21 , optionally after a neutralization as in the neutralization device 27 .
The invention will now be described in more detail on the basis of an example of embodiment, which is given by way of non-limiting example.
EXAMPLE
a. Use is made of phosphate ore of Syrian origin which has a P205 content of 30% by weight.
The etching of the ore is carried out in a batchwise manner using an aqueous solution having an HCl content of 7.4% by weight, at a temperature of 25° C. In this example, the digestion is carried out in co-current in a reactor equipped with a stirrer, and it takes around 30 minutes per batch.
The amount of HCl added is determined by a molar ratio between the HCl added to the ore and the Ca present in the latter (an HCl/Ca ratio=1 being defined as an addition of HCl such that all the Ca of the ore is dissolved in the form of CaCI2 in the aqueous phase). In this example, the etching of the ore is carried out at several HCl/Ca ratios varying from 0.6 to 0.9.
Following digestion, the suspension is filtered and the filtrate is subjected to a neutralization by hydrated lime so as to obtain a precipitated DCP cake.
Analysis of the yield of P2O5 in solution and of the contents of F and Fe++ in the DCP is then carried out, which gives the following results:
Fraction of
Yield of
ore in the
P205 in
form of
Fluorine in
solution
residue
DCP
Iron in DCP
Ratio HCl/Ca
% by weight
% by weight
% by weight
% by weight
0.6
80
55
0.41
0.06
0.7
92
52
0.48
0.064
0.8
95
48
0.65
0.096
0.9
96
47
0.78
0.12
As can be seen, although the yield of P2O5 in solution is entirely acceptable, the contents of Fe and F in the final DCP are too high (F>0.2% by weight and Fe>0.05% by weight).
b. Etching is carried out on the same ore. The etching of the ore takes place in a batchwise manner using an aqueous solution having an HCl content of 7.4% by weight, at a temperature of 25° C. In this example, the digestion takes around 30 minutes per batch and the molar ratio HCl/Ca is set at 0.9.
Before the first liquid/solid separation, the pH is controlled using hydrated lime so as to set different values, then filtration is carried out, followed by another neutralization to precipitate the DCP, which is separated in the form of a cake.
Analysis gives the following results:
Yield of P205 in
solution
Fluorine in DCP
Fe in DCP
pH
% by weight
% by weight
% by weight
0.6
95
0.79
0.12
1.3
78
0.25
0.05
1.5
77
0.074
0.04
1.7
67
0.047
0.036
1.9
54
0.055
0.036
As can be seen, by adjusting the pH to the range of 1.3 to 1.5 before filtration of the first liquid/solid separation, it is made perfectly possible to use an ore which, without pre-neutralization, could not be used, simply by etching with dilute hydrochloric acid. The yields of P2O5 in solution are still acceptable, and the level of purity obtained in the end product is excellent. A single step of separating impurities is required for this.
It should be understood that the present invention is in no way limited to this example of embodiment, and that many modifications can be made thereto without departing from the scope of the appended claims.
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A method for etching phosphate ores includes a single-pass digesting of ores which P 2 0 5 content is greater than 20% in weight by a hydrochloric aqueous acid solution having an HCI concentration less than 10% by weight with an etching solution formation and the separation of the insoluble solid phase and the aqueous phase of the etching solution. Preneutralization of the etching solution is accomplished by a neutralizing agent prior to the separation in such a way that the etching solution pH which is less than pH to which an important part of phosphate ions in solution precipitates in the form of calcium monohydrogen phosphate (DCP) is adjusted and in subsequently neutralizing the separated aqueous phase in such a way that a pure DCP is precipitated.
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This is a divisional of application Ser. No. 09/394,242 filed Sept. 13, 1999 now U.S. Pat. No. 6,538,265.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to a gallium nitride (GaN) compound semiconductor and to gallium nitride semiconductor light emitting diodes (LEDs) or semiconductor laser diodes. More particularly, the invention relates to LEDs or semiconductor lasers that include within their active region a layer of indium rich nitride. The presence of such an active layer within such a device can allow an LED or laser to output red light. This invention also relates to a method of manufacturing an active layer comprising an indium rich region and LEDs and lasers including such an active layer.
2. Description of the Related Art
Gallium nitride compound semiconductors and more specifically indium-aluminum-gallium nitride (InAlGaN) compound semiconductors are direct transition or direct bandgap semiconductors capable of efficiently producing high levels of luminosity. The bandgap of InAlGaN compound semiconductors can be adjusted between about 1.89 eV and about 6.2 eV by varying the composition of these semiconductors. Since the wavelength of output light varies with the bandgap of material within the active region for InAlGaN semiconductors, widely varying wavelengths of output light can be obtained by using different compositions of InAlGaN semiconductors in the active region of a light emitting device. Such devices are also considered to be good candidates for producing short wavelength light output. Few possibilities exist for producing short wavelength light output from a semiconductor device. Consequently, research has been directed to developing short and visible wavelength lasers and high luminosity light emitting devices employing gallium nitride compound semiconductors.
InAlGaN compound semiconductors are formed basically by combining in the deposition process the following binary compounds: gallium nitride (GaN), aluminum nitride (AlN) and indium nitride (InN). Gallium nitride is the most difficult of these materials to work with and has consequently been the subject of the most research. Gallium nitride has a high melting point of about 1700° C. and nitrogen has an extremely high equilibrium vapor pressure at the temperatures appropriate to growing gallium nitride, which makes growing single crystal gallium nitride difficult. Because of the difficulty of growing single crystal gallium nitride, advanced thin film growth techniques have been used, including hydride vapor phase epitaxial (VPE) growth or metal organic chemical vapor deposition (MOCVD). MOCVD has been studied extensively and can be applied to grow single crystal films of the binary compounds. Adding indium or aluminum during the growth of gallium nitride grows the ternary compound indium gallium nitride (In X Ga 1-X N) or aluminum gallium nitride (Al Y Ga 1-Y N). By using these ternary materials in the heterostructure active region of a light emitting device, the efficiency of light generation can be increased over simpler light emitting device structures. Furthermore, by forming a double heterostructure active region to more effectively confine both the injected carriers and the light generated in the active region, a high luminance semiconductor LED or a short wavelength semiconductor laser diode can be obtained.
By increasing the mole fraction X of indium in the compound, the bandgap of In X Ga 1-X N can be changed from about 3.4 eV, the bandgap of GaN, to about 1.89 eV, the bandgap of InN. Consequently, light-emitting devices can use In X Ga 1-X N in their active regions to produce visible light output. The ternary compound In X Ga 1-X N is obtained by simultaneously depositing gallium nitride and indium nitride while setting the deposition gas mixing conditions to achieve the desired composition.
The differences in the typical growth conditions for gallium nitride and indium nitride make growth of the ternary compound difficult. For example, higher quality crystalline gallium nitride films result from growth temperatures of over 1000° C., while a much lower temperature is appropriate to grow indium nitride crystals. For this reason, In X Ga 1-X N, with a high mole fraction X, is typically grown at a temperature well below the growth temperature for GaN (Appl. Phys. Lett. 59(18), p. 2251, Oct. 28, 1991). Research on the application of In X Ga 1-X N as the active layer for an LED emitting blue light, X=0.2, and green light, X=0.45, has been reported and such an LED has almost reached commercial production. (Jpn. J. Appl. Phys., Vol. 34 (1995), pp. L1332-L1335, part. 2, No. 10B, Oct. 15, 1995). However, if the proportion of indium in In X Ga 1-X N is increased for the purpose of emitting a larger-wavelength red light, the quality of crystals of InGaN degrades and the output intensity and conversion efficiency declines correspondingly. The difficulty of making InGaN of selected compositions has prevented from being successfully commercialized for longer-wavelength light emitting devices. InGaN LEDs with an emission wavelength of 594 nm are reported to have been developed, and this apparently is the longest wavelength ever achieved so far(Jpn. J. Appl. Phys., Vol. 37 (1998), pp. L479-L481, part. 2, No. 5A, May 1, 1998).
Indium aluminum nitride (In Y Al 1-Y N), formed from the constituents of InN and AlN, has also been studied and found to have potential for use as the active region material for an optical device emitting visible light. There is, however, a mismatch between the lattice constants of InN and AlN that makes it difficult to form heterostructures between these materials and that causes the ternary compound crystals to have internal strains. Also, there is a gap between the equilibrium vapor pressures for the two binary compounds InN and AlN. At the high temperature at which AlN crystals are typically grown, InN evaporates. This introduces further difficulty in growing In Y Al 1-Y N crystalline structures, as illustrated in T. Matsuoka, Proc. of ICN '97 at 20 (October 1997, Tokushima, Japan).
U.S. Pat. No. 5,780,876 to T. Hata describes the use of an evaporation preventing layer to prevent indium evaporation from an indium gallium nitride compound semiconductor. For example Al 0.05 Ga 0.95 N can be deposited at a reduced temperature over an In 0.2 Ga 0.8 N compound semiconductor layer to prevent indium from evaporating from the In 0.2 Ga 0.8 N active layer during subsequent processing. If not prevented, evaporation of indium from the active region leads to degradation of the interface between the active layer and the upper cladding layer. Such evaporation makes it difficult to control the crystal composition and thickness of the active layer.
Other efforts to facilitate the growth of heterostructures of InAlGaN have not yet been successful. For example, research on the microwave enhanced metal organic vapor phase epitaxial growth method, MOVPE, which would grow InN crystalline structures at lower temperatures, has been under way. At this time, the method has not been validated and the InN grown using this technique does not have satisfactory properties for efficient light emission.
Nitride compound semiconductors including indium have so far failed to realize their high potential for use as materials for the active regions of semiconductor devices emitting red light. Consequently, these materials have not yet achieved practical commercial use, due in large part to the fact that the technology for growing high quality crystal films of the indium-rich nitride compounds has not been established.
SUMMARY OF THE PREFERRED EMBODIMENTS
It is an object of the present invention to provide an indium-rich nitride compound for use as an active layer in an optical device to permit the device to emit red light, to provide LED and semiconductor laser employing such nitride compound, and to provide a method for manufacturing such nitride compound.
A preferred aspect of the present invention provides a nitride compound semiconductor with a mixture of areas including areas where the composition is indium-rich and is expressed as In X1 Al Y1 Ga 1-X1-Y1 N (0<X1≦1, 0≦Y1≦1) and other areas where the composition is aluminum-rich and is expressed as In X2 Al Y2 Ga 1-X2-Y2 N (0<X2<X1≦1, Y1<Y2≦1).
Another aspect of the present invention provides a nitride compound semiconductor light emitting device having a stack of layers including an active layer, the composition of each layer being expressed as In X Al Y Ga 1-X-Y N (0≦X≦1, 0≦Y≦1). The composition of the active layer preferably comprises areas where the composition is indium-rich and is expressed as In X1 Al Y1 Ga 1-X1-Y1 N (0<X1≦1, 0≦Y1≦1) and other areas where the composition is aluminum-rich and is expressed as In X2 Al Y2 Ga 1-X2-Y2 N (0<X2<X1≦1, Y1<Y2≦1).
Still another aspect of the present invention provides a method of manufacturing a nitride compound semiconductor light emitting device having a stack of layers. A first layer is grown at a first temperature to obtain an incomplete crystalline structure including both indium and aluminum with the composition expressed as In X Al Y Ga 1-X-Y N (0≦X≦1, 0≦Y≦1). The method grows a cap layer on the first layer to cover the first layer at a second temperature lower than the first temperature. The first layer is heated to a third temperature greater than the first temperature to cause the incomplete crystalline structure of the first layer to crystallize and to create separate areas of differing compositions. In preferred embodiments of the method, the material of the cap layer is selected as to be heat stable during the heating step.
Yet another aspect of the present invention provides a method of manufacturing a nitride compound semiconductor light emitting device having a stack of layers. The method grows a first layer at a first temperature to obtain an incomplete crystalline structure, including both indium and aluminum with the composition of the first layer expressed as In X Al Y Ga 1-X-Y N (0<X≦1, 0<Y≦1). The method then grows a cap layer on the first layer to cover the first layer, with the growth proceeding at a second temperature below the first temperature. The first layer is heated at a third temperature above the first temperature to cause the incomplete crystalline structures of the first layer to form an active layer. The material of the cap layer is selected to be stable during the heating step.
Another aspect of the invention provides a method of manufacturing a nitride compound semiconductor light emitting device with a stack of layers having a cladding layer. A first layer is grown on the cladding layer at a first temperature to obtain an incomplete crystalline structure including both indium and aluminum with the composition of the first layer expressed as In X Al Y Ga 1-X-Y N (0<X≦1, 0<Y≦1). The method grows a cap layer on the first layer to cover the first layer, with the cap layer grown at a second temperature below the first temperature. The first layer is heated at a third temperature above the first temperature to cause the incomplete crystalline structure of the first layer to form an active layer. The material of the cap layer is selected to be stable during the heating step.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention and many of its attendant advantages will be readily obtained by reference to the following detailed description considered in connection with the accompanying drawings, in which:
FIG. 1 is a cross-sectional view schematically illustrating a nitride compound semiconductor in accordance with the present invention.
FIG. 2 is a cross-sectional view schematically illustrating a semiconductor light-emitting device including a nitride compound semiconductor in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention provide an active region having a mixed composition InAlGaN semiconductor. Mixed composition here refers broadly to an active layer having different compositions within the layer. In refined embodiments of the invention, the mixed composition regions might be well defined; in other embodiments, the mixed composition regions may not be well defined. Most preferably, certain of the mixed composition regions are indium rich and others of the mixed composition regions are aluminum rich. This mixed composition structure arises, in preferred embodiments of the invention, as a natural consequence of the preferred growth technique. A mixed composition layer including indium rich regions is particularly useful as an efficient active region for outputting red light.
Other aspects of the invention provide preferred methods for producing an indium-rich InAlGaN active region or a device including such an active region. With these preferred methods, an incompletely crystalline layer of, for example, InAlN, is deposited at a first temperature on an appropriate nitride substrate. A cap layer is provided over the incompletely crystalline layer and a heat treatment is performed. Preferably the cap layer is stable to the temperature of the heat treatment and the temperature and duration of the heat treatment are sufficient to crystallize the incompletely crystalline layer so that it is transformed into an active layer. This allows an InAlGaN semiconductor having indium rich regions to be formed with reduced indium loss so that the semiconductor can be used as an active region of a light emitting device.
Embodiments of the present invention are described in further detail with reference to the drawings. FIG. 1 shows a cross-sectional view schematically illustrating the nitride compound semiconductor of the present invention. A stack of layers 10 according to this invention includes a gallium nitride (GaN) layer 100 , an indium aluminum nitride (InAlN) layer 101 formed on the GaN layer 100 , an aluminum gallium nitride (AlGaN) layer 102 formed on the InAlN layer 101 , and a gallium nitride contact layer 103 formed on the AlGaN layer 102 . In the illustrated embodiment, heterojunctions are formed between the GaN layer 100 and the InAlN layer 101 and between the InAlN layer 101 and the AlGaN layer 102 . Accordingly, the illustrated structure provides a double heterojunction with the InAlN layer 101 as an active layer, and both the GaN layer 100 and the AlGaN layer 102 as cladding layers. It is not essential to provide the lower GaN cladding layer within the stack of layers 10 . A layer of any other nitride compound semiconductor material can be used as long as it provides a suitably lattice-matched structure for growth of the InAlN crystalline structure. Alternatively, other types of substrates may be used for the growth of the InAlN layer 101 and the AlGaN layer 102 , so that only a single heterojunction is formed between the InAlN layer 101 and the AlGaN layer 102 . Regardless, it is preferred that the illustrated InAlN layer 101 be formed on a layer having a surface compatible with the growth of high quality InAlN films.
InAlN layer 101 plays a significant role in optical devices such as that illustrated in FIG. 1 , since InAlN layer 101 includes at least a portion of the active region of the light-emitting device. Here, the active region may be functionally defined as that portion of a semiconductor device in which carrier transitions take place to generate light. The structure of InAlN layer 101 , which comprises a mixed body with an indium-rich composition portion and an aluminum-rich composition portion, relates to a particularly preferred aspect of the present invention. Among other preferred aspects, the structure of InAlN layer 101 provides an active region well suited for the efficient production of light over a desired range of wavelengths. Methods described here that facilitate the reliable production of the InAlN layer 101 represent other particularly preferred aspects of the present invention.
Next, a method for manufacturing the InAlN layer 101 shown in FIG. 1 is described in greater detail as an illustration of preferred methods for manufacturing a nitride compound semiconductor in accordance with the present invention.
A stack of layers 10 which includes an InAlN layer 101 is preferably grown by metal organic chemical vapor deposition (MOCVD). Ammonia (NH 3 ), ionized nitrogen generated through plasma enhancement processes, or hydrazine (H 2 NNH 2 ) may be used as a source for nitrogen in the MOCVD growth process, and nitrogen preferably is used as a carrier gas. However, as mentioned above, because there is a mismatch in the lattice constants and the equilibrium vapor pressures between InN and AlN, it is difficult to grow a monocrystalline structure directly through use of conventional MOCVD techniques.
According to a preferred aspect of a method for manufacturing the nitride compound semiconductor of the present invention, an InAlN layer is grown on a GaN body at a first temperature, so that the InAlN layer is deposited as an incomplete crystal structure, but containing both indium and aluminum. At this stage it is preferred that some or all of the InAlN layer structure form either amorphous or minute multicrystal structures. In this regard, an incomplete crystal structure is one that may have one or more amorphous, polycrystalline, multiphase or nonuniform composition regions. An incomplete crystal structure stands in contrast to an epitaxial layer of sufficient crystalline quality to serve as the active region of an efficient light generating device. Subsequently, the method forms a cap layer over the InAlN layer, preferably directly on the InAlN layer, where the cap layer is preferably selected to be stable during a preferred subsequent heating step. The subsequent heating step most preferably is conducted at a temperature sufficient to at least partially crystallize portions of the InAlN layer. Thus, it is preferred that the cap layer be stable to a level of heat appropriate to transform the InAlN layer. After the cap layer has been formed, the method next applies heat to the InAlN layer to bring the temperature to a point higher than the first temperature to transform the InAlN layer to a mixed body of differing compositions. Due to the apparent thermodynamics of this ternary system, crystallization proceeds along with segregation of the ternary compound into indium rich regions and aluminum rich regions.
A still more detailed process for manufacturing preferred semiconductor layer structures is now described. The InAlN layer 101 is grown by MOCVD at about 500° C. on the GaN layer of FIG. 1 . It has been confirmed by observation that at this stage at least a portion of the InAlN layer comprises amorphous or minute multicrystals. Next, an AlGaN layer 102 is grown by MOCVD on the InAlN layer 101 at about 500° C. to cover the layer. Here, the AlGaN layer 102 is called the cap layer because it caps or covers the InAlN layer 101 . It should be appreciated that the temperatures listed here are exemplary and can be varied in the familiar manner. After formation of the cap layer, the temperature of the device is preferably increased to about 1000° C. and a GaN layer 103 is preferably grown on the AlGaN cap layer 102 , thereby completing the stack of layers 10 shown in this illustrated embodiment.
During the heat application process, the incomplete crystal structure in the InAlN layer 101 is subjected to heat annealing and hence the stabilization of the layer with respect to temperature will take place. Therefore, during the time the growth of the GaN layer 103 proceeds, the crystallization of the InAlN layer 101 advances and, at the same time within the same layer, the mixed regions develop including at least one indium-rich composition region and at least one aluminum-rich composition region. The separation of the regions is preferably maintained even after the temperature is brought down to room temperature. The layer 101 may contain Gallium and therefore, can become InAlGaN layer. The separation of the regions can still occur within the InAlGaN layer, but, the separation develops better without Gallium than with Gallium.
During the process, the AlGaN cap layer 102 , which is grown on the InAlN layer 101 , preferably also plays a significant role. If the temperature were to be elevated soon after the InAlN layer 101 is grown, the indium within the unstabilized structure of the InAlN layer 101 would cohere and combine to form In droplets. The high temperature would also help indium to evaporate, preventing the unstabilized structure of the as-deposited InAlN layer from forming the desired mixed composition discussed above. It has been found that, since the AlGaN cap layer 102 covers the InAlN layer 101 in this embodiment, the formation of a condensed In droplets can be prevented. The shielding effect of the cap layer facilitates the provision of an improved indium-rich composition and indium nitride compound within the illustrated structure. Also, by changing the patterning of the cap layer in accordance with a desired pattern for the formation of the nitride compound capable of emitting red light, the optical output of the device can be distributed to desired locations. In other words, because the cap layer is needed to produce the red light emitting nitride compound, the pattern of the cap layer determines the pattern of light emitted by the device. Therefore, a greater level of flexibility or freedom of design is provided for the illustrated type of nitride compound semiconductor device.
It can be inferred that the interplay of the InAlN layer 101 and the AlGaN cap layer 102 , including the growth of the latter layer on the former, has some effect on the crystallization process of the InAlN layer during the subsequent heat annealing step. At this time, however, the particular mechanism has not been elucidated. The AlGaN has been selected as the material for the cap layer in this embodiment of the invention because it is relatively stable with respect to heat at the high temperatures at which InAlN layer 101 is crystallized and forms separate composition regions.
It was observed that when the carriers in the stack of layer 10 are excited by means of an electron beam, red light was emitted from the indium-rich portion of the InAlN layer 101 . The phenomenon might be explained as follows. Carriers are excited and injected into the indium-rich composition regions since the indium-rich composition regions represent the smallest energy bandgap between the valence band and the conduction band in the stack of layers 10 . Therefore, by providing the stack of layers 10 according to the described method, a nitride compound semiconductor in accordance with an embodiment of the present invention was observed to emit red light. The ratio of indium to aluminum in the indium-rich regions of the InAlN layer 101 was determined to be approximately forty-nine to one (49:1) by energy dispersive X-ray (EDX) detection analysis.
Next, the nitride compound semiconductor light emitting device according to the invention will be described with reference to FIG. 2 of the drawings. FIG. 2 shows a schematic cross sectional view of the nitride compound semiconductor light emitting device 20 pursuant to preferred embodiments of the invention. The light emitting device 20 in FIG. 2 includes a sapphire substrate 201 , an n-type GaN layer 202 formed on the sapphire substrate 201 , an n-type AlGaN layer 203 formed on the GaN layer 202 as a first cladding layer, and a stack of layers 10 ′ formed on the AlGaN layer 203 .
The stack of layers 10 ′ preferably includes a nitride compound semiconductor 101 ′ produced in accordance with a preferred embodiment of the invention. In FIG. 2 , like elements have like references to those shown in FIG. 1 . The stack of layers 10 ′ further includes a p-type AlGaN layer 102 ′ formed on the nitride compound semiconductor 101 ′ and a p-type GaN 103 ′ formed on the AlGaN layer 102 ′, similar to the construction of the stack of layers 10 in FIG. 1 . The p-type AlGaN layer 102 ′ functions as a second cladding layer. The light emitting device 20 further includes an n-type electrode 204 provided on, but removed from, the n-type AlGaN layer 203 , the n-type GaN layer 202 , and a p-type electrode 205 formed on the stack of layers 10 ′. As shown in FIG. 2 , a portion of the GaN layer 202 is stripped off of the AlGaN layer 203 and the stack of layers 10 to provide the electrode 204 .
A method for manufacturing the light emitting device 20 according to the embodiment of the invention shown in FIG. 2 is now described.
After an n-type GaN layer 202 and an n-type AlGaN layer 203 are formed on the sapphire substrate 201 by the conventional method, the stack of layers 10 ′ is formed on the AlGaN layer 203 . The method of fabricating the stack of layers 10 ′ is generally the same as described above. The nitride compound semiconductor layer 101 ′ and the p-type AlGaN layer 102 ′ are grown, preferably by MOCVD at about 450° C., and the p-type GaN layer 103 ′ is grown, preferably by MOCVD at about 1000° C. Then, by means of conventional optical lithography using photoresist, a portion of the stacked layer above the GaN layer 202 along the perpendicular direction is selectively removed. After the photoresist is dissolved, ashed or otherwise removed, an n-type electrode 204 is provided on the GaN layer 202 . A p-type electrode 205 is also provided on the p-type GaN layer 103 ′, thus completing the light emitting device 20 as shown in FIG. 2 .
Just as described earlier with respect to the nitride compound semiconductor 10 in FIG. 1 , the inventor observed the emission of red light, with the wavelength of 630 nm and an output power of 0.5 mW at an operation current of 20 mA, from the InAlN layer 101 ′ in FIG. 2 when the appropriate voltage was supplied across the electrodes 204 and 205 . This indicates that the indium-rich composition region was properly formed in the InAlN layer 101 ′ and the injected carriers were effectively confined within the region.
While there has been illustrated and described what are presently considered to be preferred embodiments of a nitride compound semiconductor in accordance with the present invention and light emitting devices employing the semiconductor, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for devices thereof without departing from the true scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teaching of the present invention without departing from the central scope thereof.
Therefore, it is intended that this invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention include all embodiments falling within the scope of the appended claims.
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A nitride compound semiconductor light-emitting device having a stack of layers including an active layer for a light emitting device and a method of manufacturing the device is disclosed. The method includes the steps of growing a first layer on a substrate at a first temperature to obtain an incomplete crystalline structure including both indium and aluminum and having the composition expressed as In X Al Y Ga 1-X-Y N(0≦X≦1, 0≦Y≦1). The method grows a cap layer on the first layer to cover the first layer, with growth of the cap layer proceeding at a second temperature substantially equal to or below the first temperature. The first layer is heat treated at a third temperature above the first temperature to cause the incomplete crystalline structure to crystallize and to create areas of differing compositions, thus changing the first layer to an active layer. The material of the cap layer is selected to be heat stable during the heat-treating step.
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RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 08/980,419, filed on Nov. 26, 1997 now U.S. Pat. No. 5,831,866, which is a continuation of Ser. No. 08/655,843, filed on May 31, 1996 now U.S. Pat. No. 5,801,955, having a common inventor and having the same assignee as this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of circuit designs. More specifically, the present invention relates to the art of dealing with timing hazards when designing or validating circuits including level-sensitive storage circuit elements.
2. Background Information
In synchronous sequential circuits, the storage circuit elements (or registers) are basically controlled (or synchronized) by a periodic clock signal called the design source clock. The design source clock is very often combined with logic to generate derived clock signals such as gated or divided clocks. These derived clocks signals drive the input clock pin of the registers. The correct operation of the synchronous sequential circuit depends primarily on the fact that only transitions by the design source clock signal can cause register outputs to switch. Furthermore, when the design is implemented in hardware, the clock delay between the design source clock input and the input clock pins of the registers of the circuit must respect certain design tolerance constraints. More specifically, the clock skew, i.e. the difference between the input clock pin delay for two distinct registers, must be less than the time required to propagate data between these two registers. Otherwise, race conditions may be reached that will cause timing hazards such as hold time violations.
These timing hazard problems present themselves when designing or validating circuits in, for instance, cycle based simulation, hardware acceleration, and hardware emulation. The timing hazard problems are especially acute for hardware emulation, which is often employed to validate circuit designs prior to first silicon. Hardware emulation decreases the design development time by allowing a “real-time” verification ten thousand to one million times faster than software logic simulation. Thus, hardware emulation has become increasingly popular as complexity of circuit designs and the pressure to reduce time to market continue to increase.
A typical hardware emulation system includes a reconfigurable hardware emulator and circuit design “mapping” software which produces a hardware implementation of the circuit design to be emulated onto the hardware emulator system. This “mapping” software includes netlist translation, synthesis and technology mapping, and partitioning and routing for multiple electronically reprogrammable circuit based architectures, so that the mapping software can automatically produce a configuration file. The configuration file is downloaded to the hardware emulator to configure the emulator into a hardware prototype of the design. Unfortunately, all hardware emulators have limitations that constrain their performance. One of the most important problems involves meeting fundamental timing requirements of the original design, such as ensuring a minimal clock skew between registers controlled by clock signals directly connected or derived from the same design source clock input. Minimal clock skew ensures that a design operates properly by preventing hold time violations due to short paths between registers (latches or edge triggered flip-flops).
Existing hardware emulators typically provide a clock distribution network with zero-skew so that every register which is directly connected to such a distribution network can be clocked with a minimal clock skew. In existing hardware emulators, the design source clock signal is implemented by the clock distribution network so that the registers directly connected to the design source clock signal can behave properly, that is, without any hold time violations. The implementation of the design source clock by the clock distribution network will be referred to as “the master clock.”
When a clock is derived (gated or divided), the derived clock can no longer be routed over the clock distribution network. As a result, the minimal clock skew can no longer be guaranteed. Three techniques are commonly employed to solve this problem:
1) Hand patching of the original design to remove the gated and divided clocks.
2) Timing analysis of potential hold time violations and introduction of additional delays between registers after the partitioning and routing steps.
3) Pulling of the gated and divided clocks to the source of the clock distribution network.
These techniques suffer a number of drawbacks. The first technique is both time consuming and error prone. The second technique involves recompiling the design and may produce significant transformations in the circuit design, which in turn may result in new potential hold time violations and may lead to a time consuming compilation loop. The last technique is limited by the number of clock signals routed over the clock distribution network.
More recently, a new approach has been used to automatically solve the gated clock problem in the case of flip-flops that are controlled by a particular combinatorial logic gate set. In this approach, the structure of the gated clock combinatorial logic is identified. Then, the combinatorial logic is transformed so that the respective flip-flop is directly controlled by the master clock and the combinatorial logic provides a separate enable signal to the flip-flop. This approach, however, depends heavily on the way in which the clock signal is generated, i.e. the structure of the combinatorial logic. Furthermore, this approach is not applicable in the case of level sensitive storage circuit elements (i.e. latches).
As will be disclosed in more detail below, the present invention provides a new automated approach to remove timing hazards from a circuit design. The invention overcomes the prior art disadvantages, and provides a number of desirable advantages, which will be readily apparent to those skilled in the art. The invention is especially adaptable for use in a hardware emulator, although the invention is similarly applicable to cycle based simulation, hardware acceleration, etc.
SUMMARY OF THE INVENTION
An apparatus is programmed to automatically remove timing hazards from a circuit design. The apparatus identifies certain level sensitive storage circuit elements in the circuit design. The identified level sensitive storage circuit elements are those having timing hazards. The timing hazards arise as a result of skew, i.e. the difference in delay between the input clock pins of registers (one or both being a level sensitive storage circuit element). A skew, introduced by a gated or divided clock, cannot be assured to be within a design tolerance limit. Therefore, the program enables the apparatus to transform the identified level sensitive storage circuit elements so that each is directly controlled by the design source clock signal. Since the design source clock signal is mapped onto the clock distribution network, the apparatus allows the level sensitive storage circuit elements to behave properly. The transformation, however, is accomplished without altering the functionality of the circuit design. In effect, the apparatus automatically removes some or all of the timing hazards by determining the appropriate transformation for each of the identified level sensitive storage circuit elements. The apparatus can also be viewed as a way to minimize the number of clock signals within a design without altering the functionality.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will be described by way of embodiments, but not limitations, illustrated in the accompanying drawings in which like references denote similar elements, and in which:
FIG. 1 illustrates an overview of the present invention;
FIGS. 2 a - 2 b illustrate the general case and a simple case of clock gating timing hazards;
FIGS. 3 a - 3 b illustrate the general case and a simple case of clock dividing timing hazards;
FIG. 4 illustrates an example of multi-level timing hazards;
FIG. 5 illustrates one embodiment of the overall method steps of the present invention;
FIGS. 6 a - 6 b illustrate the target register and its equivalent employed to resolve timing hazards in accordance to the present invention;
FIGS. 7 and 8 illustrate one embodiment of the gated clock timing hazard resolution method steps of the present invention;
FIGS. 9 a - 9 i illustrate gated clock transformations for edge triggered registers (flip-flops);
FIG. 10 illustrates the transformed register from FIG. 2 b wherein the register is edge triggered;
FIGS. 11-13 illustrate one embodiment of the clock division timing hazard resolution method steps of the present invention for edge triggered registers;
FIG. 14 illustrates a hardware emulation system incorporated with the teachings of the present invention;
FIG. 15 illustrates one embodiment of the mapping software of FIG. 14 in further detail;
FIGS. 16-18 illustrate one embodiment of the emulator of FIG. 14 in further detail;
FIGS. 19 a - 19 i illustrate one embodiment of gated clock timing hazard transformations for level sensitive registers (latches);
FIG. 20 illustrates an example of a gated clock timing hazard for a level sensitive register;
FIG. 21 illustrates one embodiment of the transformed register of FIG. 20;
FIGS. 22-24 illustrate one embodiment of the clock division timing hazard resolution method steps for level sensitive registers;
FIG. 25 illustrates an example gated clock timing hazard from which only clock gating elements are extracted;
FIG. 26 illustrates the transformed register from FIG. 25;
FIGS. 27-29 illustrate a case 9 transformation for a level sensitive register.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, various aspects of the present invention will be described. However, it will be apparent to those skilled in the art that the present invention may be practiced with only some or all aspects of the present invention. For purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the present invention. However, it will also be apparent to one skilled in the art that the present invention may be practiced without the specific details. In other instances, well known features are omitted or simplified in order not to obscure the present invention.
Parts of the description will be presented in terms of operations performed by a computer system, using terms such as data, flags, bits, values, characters, strings, numbers and the like, consistent with the manner commonly employed by those skilled in the art to convey the substance of their work to others skilled in the art. As understood by those skilled in the art, these quantities take the form of electrical, magnetic, or optical signals capable of being stored, transferred, combined, and otherwise manipulated through mechanical and electrical components of the computer system; and the term computer system includes general purpose as well as special purpose data processing machines, systems, and the like, that are standalone, adjunct or embedded.
Various operations will be described as multiple discrete steps in turn in a manner that is most helpful in understanding the present invention. However, the order of description should not be construed as to imply that these operations are necessarily order dependent, in particular, the order of presentation.
Referring now to FIG. 1, wherein an overview of the present invention is illustrated. Shown is timing hazard remover 1000 of the present invention receiving circuit design 1002 as input, circuit design 1002 having timing hazards, processing the circuit design at the gate level, automatically detecting and removing the timing hazards from the circuit design, and then outputting circuit design 1004 with timing hazards removed. An example of circuit design 1002 is a synchronous sequential circuit having a number of registers (edge triggered flipflops and/or level sensitive latches or memories), and controlled by a periodic design source clock. Typically, the gate level design comprises a hierarchy or flattened gate-level netlist representing the circuit to be simulated. The various signals in a design are referred to as nets. A hierarchical netlist is made of a list of blocks, whereas a flattened netlist comprises only one block. A block contains components and a description of their interconnection using nets. Components can be reduced to combinatorial or sequential logic gates, or they may be hierarchical blocks of lower level. For example, components making up a gate level design may include primitive gates, such as AND, NAND, NOR, etc., or storage elements such as flipflops and latches. One example of a generic library of gate level components is GTECH, available from Synopsys, Inc. of Mountain View, Calif.
Examples of timing hazards in gate level designs include clock gating hazards and clock division hazards, to be more fully described below. Circuit design 1002 may include multiple levels of these timing hazards. Circuit design 1002 may be represented in any one of a number of machine readable manners well known in the art.
In one embodiment, timing hazard remover 1000 is a computer system programmed with logic for automatically removing clock gating and clock division timing hazards from a circuit design. As will be described in more detail below, timing hazard remover 1000 automatically removes timing hazards by transforming the registers in the circuit design. A computer system may be programmed with the logic in a variety of manners known in the art, including but not limited to representing the logic in executable instructions, and storing the executable instructions in a storage medium for execution by an execution unit of the computer system during operation. In one adaptation, the computer system is a component of a hardware emulation system, and the logic for removing timing hazards is programmed as an integral part of programming the computer system with logic for compiling and mapping the circuit design onto the logic and interconnect elements of the hardware emulation system.
Before we describe timing hazard remover 1000 in further detail, we will first describe clock gating and clock division timing hazards in more detail, including multi-level timing hazards.
FIGS. 2 a - 2 b illustrate the general case and a simple case of a clock gating timing hazard respectively. As shown in FIG. 2 a , register 1006 is clocked by a synchronization SYNC signal (hereinafter simply SYNC signal), which is generated by combinatorial logic 1008 based on a reference design source clock CK 1010 (hereinafter simply design source clock CK), outputs from other flip-flops 1012 , latches 1013 , memories 1014 and primary inputs 1015 . As a result of a hardware emulation, the amount of clock delay at the input clock pin for the SYNC signal (with respect to design source clock CK) may be different than the delay at other registers from which register 1006 receives input D or to which register 1006 provides output Q. This skew between delays cannot be guaranteed to be within the design tolerance limit. Obviously, in various variations of this general case, register 1006 may not have enable control signal LD, combinatorial logic 1008 may be very simple or very complex, combinatorial logic 1008 may use many flip-flop outputs and/or primary inputs, or may use only one of these outputs/inputs in its generation of SYNC. As shown in FIG. 2 b , combinatorial logic 1008 may simply be an AND gate 1018 , which generates the SYNC signal based only on the design source clock CK and one other input A (which could either be a register output or a primary input).
FIGS. 3 a - 3 b illustrate the general case and a simple case of clock division timing hazard respectively. As shown in FIG. 3 a , register 1020 is clocked by a SYNC 2 signal, which is generated by combinatorial logic 1022 based on outputs from flip-flops 1024 clocked by a SYNC 1 signal. As a result, even if SYNC 1 is the design source clock and not a derivative clock, the amount of clock skew between SYNC 2 and the synchronization signal for another register which depends on register 1020 or on which register 1020 depends cannot be guaranteed to be within the design tolerance limit. Obviously, in various variations of this general case, register 1020 and flip-flops 1024 may not have enable control signals LD, LD 0 -LDn, combinatorial logic 1022 may be very simple or very complex, combinatorial logic 1022 may use many or only one flip-flop output in its generation of SYNC 2 , and SYNC 1 may simply be CK or derived from CK. As shown in FIG. 3 b , combinatorial logic 1022 may even be null. In other words, register 1026 maybe controlled by SYNC 2 , which is the output of flip-flop 1028 , which is controlled by SYNC 1 .
FIG. 4 illustrates one example of multi-level timing hazards.
Register FFn 1030 is controlled by gated SYNCn signal generated by gate Gn 1032 . One of the inputs (Qn− 1 ) employed by gate Gn 1032 is output by a flip-flop FFn−1 1034 , which in turn is controlled by another gated SYNCn− 1 signal generated by another gate Gn− 1 1036 . The other input (An) employed by gate Gn 1032 is derived from lower level flip-flops synchronized by (ck, SYNC 0 , . . . , SYNCn− 1 ). The pattern continues until ultimately n levels later signal Q 0 is output by flip-flop FF 0 1038 controlled by gated SYNC 0 signal, which is generated by gate G 0 1040 using the design source clock CK as one of its inputs, and input A 0 as the other input. For convenience, we shall refer to the flip-flops clocked by the master clock as flip-flops situated at level 0, the flip-flops clocked by the outputs of the flip-flops of level 0 to be situated at level 1, and so forth. In other words, in general, flip-flops situated at level N+1 are clocked by outputs of flip-flops situated at level N or less than N.
Having now described clock gating and clock division schemes, we will now describe timing hazard remover 1000 in more detail.
FIG. 5 illustrates the method steps of one embodiment of timing hazard remover 1000 . As shown, during operation, timing hazard remover 1000 first resolves clock gating timing hazards in a circuit design, step 1042 . Upon resolving all the clock gating timing hazards in the circuit design, which will be described in more detail below, timing hazard remover 1000 logically organizes the clock division timing hazards into levels, step 1044 . If timing hazard remover 1000 is successful in organizing the clock division timing hazards into levels, step 1046 , timing hazard remover 1000 then proceeds to resolve the clock division timing hazards, which will also be described in more detail below, steps 1048 - 1056 . On the other hand, if timing hazard remover 1000 is unable to organizes the clock division timing hazards into levels, it terminates operation, steps 1046 and 1058 .
At step 1048 , timing hazard remover 1000 sets the current level to the next to lowest level, i.e. the first level of SYNC signals output by flip-flops directly controlled by the design source clock. Timing hazard remover 1000 then determines whether the next state of each SYNC signal is predictable, step 1050 . If the next state of each SYNC signal is predictable, timing hazard remover 1000 proceeds to resolve the clock division timing hazards, step 1052 . On the other hand, if the next state of at least one SYNC signal is not predictable, timing hazard remover 1000 terminates operation, step 1058 .
Upon resolving all clock division timing hazards for the current level, timing hazard remover 1000 determines if there are still additional levels of clock division timing hazards to be resolved, step 1054 . If the determination is affirmative, timing hazard remover 1000 sets the current level to the next level, step 1056 , and repeats steps 1050 - 1054 again. The process continues until it encounters a level wherein the next state has at least one SYNC signal which is not predictable, step 1050 , or until clock division timing hazards have been resolved for all levels, step 1054 .
Timing hazard remover 1000 will not be successful in logically organizing the clock division timing hazards into multiple logical levels if a synchronization signal depends on itself. This problem is known to those skilled in the art as a synchronization loop. The next state of a synchronization loop is unpredictable if an external primary input, a latch output or a memory output is connected to the clock dividing combinatorial logic generating the synchronization signal.
As described earlier, timing hazard remover 1000 resolves clock gating and clock division timing hazards by transforming the registers. More specifically, timing hazard remover 1000 transforms the registers controlled by gated/divided clocks into registers controlled by the design source clock and a complementary enable control. Before we proceed to describe these transformation operations in further detail, it should be noted that a register (edge triggered flip-flop or a level sensitive latch) controlled by a clock operating in conjunction with a multiplexer controlled by an enable signal may be made functionally equivalent to a register controlled by the same clock and a complementary enable control. FIG. 6 a illustrates a register 1060 controlled by a clock and a complementary enable control, whereas FIG. 6 b illustrates a register 1062 controlled by a clock, operating in conjunction with a multiplexer 1064 controlled by an enable signal. As it is apparent to those skilled in art, by providing the D input of register 1062 with a selected one of either the current state (feedback) or the next state of the D input using multiplexer 1064 as shown, register 1062 operating in conjunction with multiplexer 1064 is functionally equivalent to register 1060 .
FIG. 7 in conjunction with FIG. 8 illustrate the transformation steps performed by one embodiment of timing hazard remover 1000 to resolve a clock gating timing hazard. As shown in FIG. 7, timing hazard remover 1000 first extracts clock gating elements between the SYNC signal and the design source clock in step 1062 . This step is described in more detail below with respect to FIG. 25 . Next, timing hazard remover 1000 calculates a Boolean function F corresponding to the clock gating elements of the clock gating timing hazard, step 1064 . In one embodiment, a canonical representation of F is constructed using the well known Reduced Ordering Binary Decision Diagram (ROBDD). In alternate embodiments, a truth table representation of F, which is another canonical representation, could be used. Next, timing hazard remover 1000 calculates F ckn and F ck , step 1066 , where SYNC=CkN . F ckn +Ck. F ck , and F ckn and F ck are the cofactors of F with respect to Ck, and equal to F(Ck=0) and F(Ck=1) respectively. (CKN stands for the Boolean complement of CK.) The relationship between SYNC, CK, F ckn and F ck is specified by the well known Shannon's formula. Then, timing hazard remover 1000 transforms the registers in accordance to the values determined for F ckn and F ck , step 1068 . F ckn and F ck can take the value 0, 1, or X, where X stands for non-constant functions.
To determine if a Boolean function is equal to 1 (tautology checking) or 0 (antilogy checking) is well known in the art. In one embodiment, it can be solved by computing a canonical representation such as ROBDD.
FIG. 8 illustrates the various values F ckn and F ck can take on. There are nine possible pairs of values {0, 0}, {1, 0}, {X, 0} etc. FIG. 8 also shows the corresponding value for SYNC for each of the nine cases. The method of FIG. 7 and the table shown in FIG. 8 apply to gated clock timing hazards for both edge triggered registers, such as flip-flops, and level sensitive registers, such as latches. The transformations are not all the same, however, for edge triggered and level sensitive registers. Gated clock transformations for level sensitive registers are discussed below with respect to FIGS. 19-21.
FIGS. 9 a - 9 i illustrate the corresponding transformations performed for each of the nine cases for edge triggered flip-flops. For example, when F ckn and F ck are determined to be {0, 0} (case 1 ), since SYNC is suppose to always equal to zero, the flip-flop controlled by SYNC is transformed into a flip-flop controlled by the constant logic value zero (without a complementary enable control) (FIG. 9 a ).
When F ckn and F ck are determined to be {1, 0} (case 2 ), since SYNC is suppose to be equal to Ckn, the flip-flop controlled by SYNC is transformed into a flip-flop controlled by the inverted design source clock, which in turn is complemented by the original enable control signal LD only (FIG. 9 b ). (SYNC is not dependent on either cofactor.) When F ckn and F ck are determined to be {X, 0 56 (case 3 ), since SYNC is suppose to equal to CkN AND F ckn , the flip-flop controlled by SYNC is transformed into a flip-flop controlled by the inverted design source clock, complemented by an enable control which is F ck qualified by the original enable control LD (FIG. 9 c ), and so forth. The fact that case one and case five employ the constant logic value zero and one respectively is not a problem, because by virtue of their constancy, there is no excessive clock skew problem, and therefore no potential timing hazards.
The most complicated case is case nine, where F ckn and F ck are determined to be {X, X}. In that case, the clock gating combinatorial logic is replaced by a multiplexer controlled by a divided clock for selecting either F ckn for F ck , as SYNC. (LD is unmodified.) The divided clock will have the same frequency as the design source clock. The divided clock is derived by introducing a generated clock that is twice as fast as the design source clock, and dividing the double frequency clock. The new clock division timing hazard and LD are in turn resolved subsequently with the other clock division timing hazards, in steps 1044 - 1058 in FIG. 5 .
In sum, timing hazard remover 1000 resolves clock gating timing hazards by transforming each flip-flop controlled by a gated clock into a flip-flop controlled by either the design source clock of the circuit design, the inverted design source clock, the design source clock multiplied by two, or a constant logic value (0, 1).
The clocking control is complemented as appropriate by an enable control. The clocking control, the employment of complementary enable control, and if employed, the enable control are determined using a representation for a Boolean function corresponding to the clock gating circuit elements, and factoring into consideration whether the original flip-flop has an enable input or not. In some cases, depending on the complementary enable control employed, the programmed computer system further inserts an AND gate into the circuit design accordingly, to provide the appropriate complementary enable control.
FIG. 10 illustrates the transformed flip-flop for the simple clock gating timing hazard case illustrated in FIG. 2 b . Recall from FIG. 2 b , the clock gating combinatorial logic simply includes a single AND gate, thus the corresponding Boolean function F is F=A AND Ck. Therefore, F ckn and F ck equal 0 and X respectively, i.e. case 7 of FIG. 8 . Thus, the original flip-flop clocked by SYNC is transformed into a flip-flop clocked by the design source clock Ck, and complemented by F ck , which is equal to A (Ck=1). Since the original flip-flop did not have an enable control LD, F ck , which is A in the instant example, is provided to the transformed flip-flop without “qualification”, therefore resulting in the illustrated flip-flop.
Skipping now to FIGS. 19 a - 19 i , wherein nine gated clock transformations are shown for a level sensitive register. In the illustrated embodiments, the level sensitive register is a latch. In other embodiments, similar transformations may be employed for memories. FIGS. 19 a - 19 i correspond to the nine cases respectively of the Boolean function F, shown in FIG. 8 .
The level sensitive latch transformations shown in FIGS. 19 f and 19 h differ from the corresponding transformations for an edge triggered flip-flop shown in FIGS. 9 f and 9 h . The differences account for the different operational characteristics of the latch and the flip-flop. The output of a level sensitive register can change as long as SYNC is at the proper level. For instance, an active high latch will pass the D input through to the Q output as long as SYNC is high. That is, while SYNC is high, Q will follow D. When SYNC is low, the output will not change so that the last value on D at the time SYNC went low is “latched.” The output of the edge triggered flip-flop, in contrast, can only transition once in response to a SYNC transition. For instance, Q can only transition on rising clock edges.
FIG. 20 illustrates a simple example of a gated clock timing hazard for a level sensitive latch. In this example, the gating combinatorial logic includes a single OR gate. When A is 0, SYNC equals Ck. So, whenever Ck is high, Q follows D. When A is 1, SYNC equals 1, so that Q follows D irrespective of Ck. The corresponding Boolean function F is F=A OR Ck. When Ck=0, F=A. A is an indeterminate variable, indicated by X in FIG. 8 . When Ck=1, F =1. Therefore, F ckn and F ck are X and 1 respectively, which is case 6 of FIG. 8 . Case 6 corresponds to FIG. 19 f.
Accordingly, the transformation is shown in FIG. 21 . The original latch did not have an enable control E. Therefore, the transformed latch does not qualify the multiplexer select input by ANDing with E. Rather, the multiplexer is controlled directly by F ckn , which is equal to A in this case. The transformed latch performs exactly like the original latch. When A is 1, Q follows D. When A is 0, Q follows D only when Ck is high.
As with the edge triggered flip-flop, the most complicated latch transformation is for case nine, where F ckn and F ck are determined to be {X, X}, as shown in FIG. 19 i . As with the edge triggered flip-flop, the combinatorial logic cannot be transformed to eliminate the timing hazard. Instead, the gated clock timing hazard is transformed into a divided clock timing hazard. Then, the timing hazard will be resolved as a divided clock as discussed below with respect to FIGS. 27-29.
In sum, as with the edge triggered flip-flop, timing hazard remover 1000 resolves clock gating timing hazards by transforming level sensitive registers controlled by a gated clock into level sensitive registers controlled by one of the design source clock of the circuit, the inverted design source clock, the design source clock multiplied by two, or a constant logic value (0,1). The clocking control is complemented as appropriate by an enable control E. Some transformations for the level sensitive register differ from the transformations for the edge triggered flip-flop to account for the different operational characteristics of each. For instance, in cases 6 and 8 , the output of the latch is multiplexed with the input of the latch so that the output can change according to the level of the original SYNC signal, as opposed to changing in response to clock edges.
Next, we will discuss resolving divided clock timing hazards. Divided clock timing hazards are resolved differently for edge trigger registers and level sensitive registers. Resolving divided clock timing hazards for level sensitive registers will be discussed below with respect to FIGS. 22-24.
Referring back now to FIGS. 11-12, wherein together the figures illustrate the transformation steps performed by one embodiment of timing hazard remover to resolve a clock division timing hazard for an edge triggered flip-flop. As shown in FIG. 11, timing hazard remover 1000 first replicates the timing dividing combinatorial logic, step 1070 . Next, for each flip-flop that outputs for the clock dividing combinatorial logic, if the outputting flip-flop has an enable control LD, timing hazard remover 1000 inserts a corresponding multiplexer ( 1080 of FIG. 12) controlled by the original enable control LD to select either the current state (Qi) or the next state (Di) of the outputting flip-flop to output for the replicated clock dividing combinatorial logic; otherwise, timing hazard remover 1000 couples the next state (Di) of the outputting flip-flop to output for the replicated clock dividing combinatorial logic, step 1072 .
Then, timing hazard remover 1000 inserts a first AND gate ( 1082 of FIG. 12) to generate a logical AND of inverted SYNC 2 and the next state of SYNC 2 , step 1074 . If the original flip-flop has an enable control LD, timing hazard remover 1000 further inserts a second AND gate ( 1084 of FIG. 12) to qualify the output of first AND gate 1082 for transformed flip-flop ( 1086 of FIG. 12 ), otherwise, timing hazard remover 1000 provides the output of first AND gate 1082 to transformed flip-flop 1086 without “qualification”. Lastly, timing hazard remover 1000 couples SYNC 1 to the clock input transformed flip-fop 1086 , step 1078 .
In sum, timing hazard remover 1000 resolves clock division timing hazards by transforming each flip-flop controlled by a divided clock into a flip-flop controlled by the “parent” undivided clock and a complementary enable control. Timing hazard remover 1000 further inserts an AND gate into the circuit design to generate the complementary enable control using an inverted version and a predictive version of the divided clock. Timing hazard remover 1000 further inserts a replicated copy of the intervening clock dividing elements to generate the predictive version of the divided clock. Lastly, timing hazard remover 1000 further inserts a multiplexer for each input providing flip-flop coupled to the intervening clock dividing elements having an enable control, to correctly provide inputs to the replicated intervening clock dividing elements.
FIG. 13 illustrates the transformed flip-flop for the simple clock dividing timing hazard case illustrated in FIG. 3 b , wherein the register 1026 is an edge trigger flip-flop. Recall from FIG. 3 b , the clock dividing combinatorial logic is null, thus the replicated clock dividing combinatorial logic is also null. Since the outputting flip-flop 1090 did not have an enable control, its next state (SYNC 2 +) is provided directly to the replicated null clock dividing combinatorial logic. Next, AND gate 1092 is provided to generate the logical AND of inverted SYNC 2 and SYNC 2 +. Since the original flip-flop did not have an enable control, the output of AND gate 1092 is provided to transformed flip-flop 1094 as enable control without “qualification”. Finally, undivided clock SYNC 1 is coupled to the clock input of transformed flip-flop 1094
Skipping now to FIGS. 22-24, which illustrate the transformation steps performed by one embodiment of timing hazard remover 1000 to resolve a clock division timing hazard for a level sensitive latch. As shown in FIG. 22-23, in step 2210 , if latch 2386 includes an enable input LD, timing hazard remover 1000 adds AND 2384 to provide the logical AND of LD and the output of the combinatorial logic to the enable input of latch 2386 . If latch 2386 does not include enable input LD, timing hazard remover 1000 provides the output of the combinatorial logic directly to the enable input of latch 2386 . In step 2220 , timing hazard remover 1000 provides the logical invert of SYNC 1 (notation: SYNC 1 ′) to the clock input of latch 2386 . Next, in step 2230 , timing hazard remover 1000 inserts 2 to 1 multiplexer 2390 to select between the output of latch 2386 and the input D, wherein the enable input of latch 2386 is tied to the select of multiplexer 2390 .
In sum, timing hazard remover 1000 resolves clock division timing hazards by transforming each latch controlled by a divided clock into a latch control by the invert of the “parent” undivided clock and a complementary enable control. Timing hazard remover 1000 further inserts an AND gate into the circuit design to qualify the complementary enable control with the enable signal LD. Lastly, timing hazard remover 1000 inserts a multiplexer to select between the output of the latch and the input of the latch based on the input to the latch enable.
FIG. 24 illustrates the transformation of the simple clock dividing timing hazard illustrated in FIG. 3 b , wherein the register 1026 is a level sensitive latch. Recall from FIG. 3 b that the combinatorial logic is null and that the register 1026 had no enable input signal LD. Therefore, the output of the dividing flip-flop 1028 can be provided directly to the enable input of register 1026 . SYNC 1 ′, the logical invert of SYNC 1 , is provided directly to register 1026 . Multiplexer 2410 selects between the output of register 1026 and the input D based on the value provided to the enable input of register 1026 .
FIGS. 25-29 illustrate some examples of gated clock and divided clock timing hazards and their transformations. In FIG. 25, register 2510 has a gated clock. As discussed above for FIG. 7, timing hazard remover 1000 first extracts the clock gating elements between SYNC and the design source clock. In the illustrated example, AND gates 2520 and 2530 are between SYNC and the design source clock. Gates 2540 and 2550 are not elements between SYNC and the design source clock and are therefore not included in the Boolean function F. Therefore, F=A AND (B AND CK). Fckn=F(CK=0)=0 and Fck=F(CK=1)=A AND B. A AND B is indeterminate X in the table in FIG. 8 . {0,X} is case 7. Case 7 is the same transformation for both edge trigger and level sensitive registers as shown in FIGS. 9 g and 19 g . The transformed register is shown in FIG. 26, wherein the gated timing hazard has been removed. Fck is provided to the enable input using AND 2600 . Signals A and B are generated by their respective gates just as in FIG. 25 .
FIG. 27 illustrates a simple example of the most complicated gated clock transformation, and FIG. 28 illustrates the resulting divided clock hazard. Latch 2710 has a gated clock timing hazard. The Boolean function F equals (A OR Ck) AND B. When B is 0, SYNC equals zero, and Q provides the latched value. When B is 1 and A is 1, SYNC equals 1, and Q follows D. When B is one, and A is zero, Q follows D when Ck is high. F ckn equals A and B, which is an indeterminate X. F ck equals B, which is also an indeterminate X. {X, X} is case 9 from FIG. 8 . As discussed above, case 9 cannot be resolved as a gated clock timing hazard. Rather, the latch is transformed into an equivalent latch with a divided clock timing hazard, as shown in FIG. 28. A generated clock that is twice as fast as the design source clock is provided to flip-flop 2830 and divided to provide a clock signal having the same frequency as the design source clock. Therefore, the same functionality could be obtained by providing the design source clock directly to the select line on multiplexer 2820 . In other words, flip-flop 2830 may not serve any functional purpose in the design and may be merely provided so that timing hazard remover 1000 will recognize it as a divided clock timing hazard.
The resulting divided clock timing hazard of FIG. 28 is resolved using the general divided clock timing hazard transformation shown in FIGS. 22 and 23 . FIG. 29 shows the resulting transformation of the level sensitive latch wherein the timing hazard has been removed and multiplexer 2920 has been added.
Having described the timing hazard remover of the present invention in detail, we now proceed to describe a particular adaptation of the present invention in a hardware emulation system, referencing FIGS. 14-18. Obviously, other adaptations are possible, and will be apparent to those skilled in the art.
FIG. 14 is a block diagram showing the hardware emulation system having the timing hazard remover of the present invention adapted therein. As illustrated, emulation system 10 includes host system 12 and emulator 14 . Host system 12 includes in particular circuit design mapping software 22 , whereas emulator 14 includes in particular emulation array and interconnect networks 16 , a configuration unit 18 and host interface 20 coupled to each other as shown.
Emulation array and interconnect networks 16 perform the conventional function of “realizing” and emulating a circuit design. Circuit design mapping software 22 performs the conventional function of mapping a circuit design onto emulator 14 for emulation, configuring emulator array and interconnect networks 16 through host interface 20 and configuration unit 18 . However, for the illustrated embodiment, circuit design mapping software 22 incorporates timing hazard remover of the present invention, allowing circuit design mapping software 22 to automatically remove timing hazards from a circuit design, before compiling and mapping the circuit design onto emulation array and interconnect networks 16 . In other words, host system 12 is programmed with logic for resolving timing hazards as an integral part of programming host system 12 with circuit design mapping software 22 .
Except for the logic for resolving timing hazards, host system 12 including the base functions of circuit design mapping software 22 , and emulator 14 , are intended to represent a broad category the respective elements found in conventional emulation systems.
FIG. 15 illustrates circuit design mapping software 22 , and the general flow of programming emulation system 10 in further detail. As shown, circuit design mapping software 22 includes design reader 128 , primitive converter 130 , timing hazard remover 131 , partitioner 132 , net listing interconnection generator 134 and PGA conversion tool 138 . Circuit design 126 is processed by design reader 128 , primitive converter 130 , timing hazard remover 131 , partitioner 132 , and netlisting and interconnection generator 134 to generate netlists 136 , which in turn is processed by PGA conversion tools 138 to generate PGA configuration files 140 and trace xref files 142 . PGA configuration files 140 are then used to configure emulator 14 to “realize” circuit design 126 on emulator 14 .
In one embodiment, primitive converter 130 includes an optimizer (not shown) for optimizing the circuit design 126 . Most importantly, timing hazard remover 131 automatically resolves clock gating as well as clock division timing hazard in circuit design 126 , recursively if there are multiple levels of timing hazards, as described earlier. As a result, when the transformed circuit is “realized” on emulator 14 , circuit design 126 can be emulated with the assurance that timing hazards will not be encountered.
FIGS. 16-18 illustrate one embodiment of emulation array and interconnect networks 16 in further detail. Emulator array and interconnect networks 16 are distributively disposed on a number of logic boards 26 , electrically connected to each other through an inter-logic board crossbar (x-bar) network (not shown) disposed in backplane (not shown), forming a single crate (not shown). In one embodiment, a crate includes six logic boards 26 . As shown in FIGS. 16-17, each logic board 26 comprises a plurality of FPGAs 30 and inter-FPGA x-bar network (stage 1) 32 coupled to each other. For the illustrated embodiment, FPGAs includes 24 FPGAs, and inter-FPGA x-bar stage 1 32 also “doubles” as interlogic board x-bar network stage 0, thereby requiring only inter-logic board x-bar network stage 1 (not shown) to be disposed on backplane. As shown in FIG. 17, each FPGA includes LE array 102 having multiple reconfigurable LEs, inter-LE crossbar (or x-bar) network 104 , and I/O pins 113 . For the illustrated embodiment, each FPGA has 64 I/O pins 113 . Each of I/O pins 113 can be statically configured to be either an input or an output pin. This static configuration can be accomplished in any of a wide variety of conventional manners, such as by way of a configuration register. Additionally, each FPGA also includes inter-FPGA x-bar network (stage 0 and stage 1) 114 a - 114 b . In other words, inter-FPGA x-bar network (stage 1) 114 b is actually distributively disposed on-chip inside each FPGA.
As in the prior art, LEs 102 are used to emulate circuit elements of a circuit design to be “realized” for emulation. Inter-LE x-bar network 104 interconnects the LEs within a single FPGA and the I/O pins of the FPGA. Inter-FPGA x-bar network stages 0 and 1 114 a - 114 b and 32 in turn interconnect FPGAs of a logic board 26 to each other, and to the logic board's interconnections to the backplane. In other words, LEs 102 are interconnected with a scaleable multi-level multi-stage x-bar network topology. This interconnection topology is described in detail in copending application, Ser. No. 08/542,519, entitled “An Emulation System Employing A Multi-Level Multi-Stage Network Topology For Interconnecting Reconfigurable Logic Elements”, assigned to the assignee with the present invention, which is hereby fully incorporated by reference.
Preferably, as shown for the illustrated embodiment, each FPGA also includes memory 112 and context bus 106 . Memory 112 facilitates usage of the FPGA to emulate circuit design with memory elements. For the illustrated embodiment, memory 112 uses 8-bit input and 8-bit output. Context bus 106 facilitates individual initialization and observation of the LEs. An FPGA including these and other useful debugging features is disclosed in copending application, Ser. No. 08/542,830, entitled “A Field Programmable Gate Array with Integrated Debugging Facilities”, assigned to the assignee of the present invention, which is also hereby fully incorporated by reference.
Each FPGA of FPGAs 30 is provided with a global clock signal, i.e. the same clock signal for all logic boards 26 , and an enable signal (EN). Furthermore, each FPGA further includes a clock generator 111 for generating at least a master clock (Clk 0 ) and a “doubled” (or ×2) master clock (Clk 1 ) for the LE array 102 , using the provided global clock. In one embodiment, an additional clock can be calculated and provided to the LE array in order to generate an inverted master clock.
FIG. 18 illustrates one embodiment of LEs 102 in further detail. As shown, for the illustrated embodiment, each LEs 102 include 128 reconfigurable LEs 200 . Each reconfigurable LE 200 includes a multiple input—single output truth table 202 , a pair of master-slave latches 204 - 206 , output multiplexer 208 , input multiplexer 210 , control logic 212 , and clock signal generation circuitry 230 . The enumerated elements are coupled to each other as shown.
Truth table 202 is used to generate a predetermined output in response to a set of inputs. For the illustrated embodiment, truth-table 202 has 4 inputs and 1 output. In other words, depending on the inputs, truth table 202 outputs 1 of 2 4 of predetermined outputs. Each of master-slave latches 204 - 206 is used to store an input value synchronously with its clock input. Furthermore, each of master-slave latches 204 - 206 can be asynchronously forced to one or zero depending on the values of set and reset. For the illustrated embodiment, the set and reset inputs are provided using the inputs 13 and 12 of truth table 202 .
Output multiplexer 208 , input multiplexer 210 and control logic 212 are used to control the manner in which truth table 202 and master-slave latches 204 - 206 are used. Output multiplexer 208 allows either the output of truth table 202 (by-passing master-slave latches 204 - 206 ) or the output of slave latch 206 (for level sensitive designs), or the output of master latch 204 (for edge sensitive designs) to be selected for output. The by-passed output is selected if truth table 202 is to be used standalone. When either the output of master or slave latch 204 or 206 is selected, input multiplexer 210 allows either the output of truth table 202 , the feedback from output multiplexer 208 , or an input value on context bus 106 to be provided to master-slave latches 204 - 206 . The feedback value is selected to “freeze” LE 200 , and the bus value is selected to initialize LE 200 . Thus, master/slave latches 204 - 206 operating in conjunction with multiplexer 210 may be configured to function as illustrated in FIG. 6 b.
Control logic 212 controls input multiplexer 210 and the set and reset values provided to master-slave latches 204 - 206 , in accordance to a set, a reset, an ENAB, a load (LDE) and a hold (HLD) value provided. Clock signal generation circuitry 230 is used to selectively provide one of a number of clock signals for master-slave latches 204 - 206 . Clock signal generation circuitry 230 generates the localized clock signal using selected ones of Clk 0 , Clk 1 , and a calculated clock from input 10 . In other words, the localized clock signals provided to master-slave latches 204 - 206 are generated by circuitry integrated with each LE 200 using inputs generated by the “on-chip” clock generator 111 or other LEs. Furthermore, the inter-board, inter-FPGA, and inter-LE clock skew is ensured to be smaller than the minimum propagation time between any two registers in emulation array and interconnect network 16 . Hence, there are no race conditions (short paths) between registers clocked by such signals. Lastly, LE 200 also includes buffer 214 a for outputting the selected output to inter-LE X-bar network 104 and buffer 214 b for outputting the selected output onto context bus 106 for direct observation outside each FPGA.
In sum, truth table 202 may be used in a standalone manner, or in conjunction with the corresponding master-slave latches 204 - 206 . Enhanced LE 200 is suitable for “level sensitive” as well as “edge sensitive” circuit design emulations. Additionally, beside the “normal” current output of truth table 202 , each LE 200 can be individually initialized. Each LE 200 can also be caused to output the same output over and over again, as if it is frozen. Furthermore, LEs 200 are individually and directly observable outside each FPGA. In other words, there are no “hidden nodes”. The state of each “node” is directly observable outside the FPGA, without requiring the reconfiguration and time consuming re-compilation of circuit design mappings normally performed under the prior art.
Thus, a method and apparatus for removing timing hazards in a circuit design has been described. While the method and apparatus of the present invention has been described in terms of the above illustrated embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described. The present invention can be practiced with modification and alteration within the spirit and scope of the appended claims. The description is thus to be regarded as illustrative instead of restrictive on the present invention.
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An apparatus is programmed to automatically remove timing hazards from a circuit design. The apparatus identifies certain level sensitive storage circuit elements in the circuit design. The identified level sensitive storage circuit elements are those having timing hazards. The timing hazards arise as a result of potential skews between the reference signal for the circuit design and the synchronization signal controlling each storage circuit element. A skew, introduced by a gated or divided clock, cannot be assured to be within a design tolerance limit. Therefore, the program enables the apparatus to transform the identified level sensitive storage circuit elements into level sensitive storage circuit elements controlled by synchronization signals that do not have potential skews with respect to the reference signal of the circuit design. The transformation, however, is accomplished without altering the functionality of the circuit design. In effect, the apparatus automatically removes some or all of the timing hazards by determining the appropriate transformation for each of the identified level sensitive storage circuit elements.
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TECHNICAL FIELD
[0001] This invention is directed to charge transport layers in a photoconductor, which comprises a hydrazone or aryl amine transport molecule and additives to reduce room light fatigue.
BACKGROUND OF THE INVENTION
[0002] An electrophotographic photoreceptor essentially comprises a charge generation layer (CGL) and charge transport layer (CTL) coated on a suitable substrate. The substrate may be an aluminized MYLAR polyester or an anodized aluminum drum (termed a PC drum). An aluminum drum can be coated with a suitable sub-layer and/or a barrier layer, derived by dispersing metal oxides in a polymer binder.
[0003] The charge generation layer comprises pigments or dyes selected from phthalocyanines, squaraines, azo compounds, perylenes etc. The pigment or dye may be dispersed or dissolved in a suitable solvent, with or without a polymer binder. The use of polymer binder helps improve the dispersion stability and improve the adhesion of the CGL to the core or other substrate. However, depending on the type of polymer binder being used, the sensitivity of the photoreceptor may be affected.
[0004] As printers are expected to perform at speeds of 30-50 pages-per-minute, it becomes imperative that the photoconductor charge and discharge at very short time intervals. The time frames required for 35 ppm, for example could relate to an expose-to-develop time in the order of 40-80 ms. Hence, there is a growing need to identify systems that improve the electrophotographic properties without compromising on other properties such as adhesion, fatigue, and the like.
[0005] Also, with a move towards faster systems, the drive towards lower cost becomes more demanding. One area where cost can be lowered is by using a cartridge that does not have a shutter for the photoconductor drum. Optionally, a separation of function can be envisioned wherein the photoconductor may be a part of the printer and not the toner cartridge. In this case, the photoconductor may be highly susceptible to exposure to room light, when the toner cartridge is replaced. Most photoconductor formulations are sensitive to the effect of room light (eg. fluorescent light).
[0006] As shown in this invention, the exposure to room light (fluorescent light) can cause severe fatigue (electrical and the related print) in the PC drum. This results in a print defect pattern. This invention addresses possible methods of mitigating any fatigue or deterioration in electrophotographic properties brought about by exposure to room light.
[0007] The acetosol yellow 5GLS of this invention is also known by the trademark SAVINYL YELLOW and as Colour Index Solvent Yellow 138. It is an ingredient of a more-than-twenty-year-old patent, specifically U.S. Pat. No. 4,362,798 to Anderson et al.
[0008] The foregoing U.S. Pat. No. 4,362,798 and U.S. Pat. No. 6,544,702 to Haggquist et al. disclose the use of acetosol yellow 5GLS as a room light fatigue mitigant, in a hydrazone transport. U.S. Pat. No. 5,545,499 (Balthis et al., Lexmark International, Inc.) discloses hydrazone charge transport.
[0009] JP 06-161123 A, published Jun. 7, 1994, (Mita Ind Co.) claims the use of cyclopentadienone type compound in the sensitive layer.
[0010] JP 64-040835 A, published Feb. 13, 1989 (Toshiba Corp.) describes the use of a tetraphenylcyclopentadienone in a N-ethylcarbazole hydrazone transport layer coated on a charge generating layer comprising of a tau-type phthalocyanine and polyvinylbutyral. In addition, a suitably substituted cyclohexenedienone is also disclosed.
DISCLOSURE OF THE INVENTION
[0011] This invention comprises a photoconductor member having a charge generation layer, a charge transport layer having a hydrazone or amine charge transport molecules and having as room-light fatigue protective additives acetosol yellow 5GLS and an electron acceptor compound selected from tetraphenylcyclopentadienone or 9-fluorenenone.
[0012] The total amount of room light fatigue additive mixture is at least 1% by weight, and no more than 5% by weight of the total weight of the charge transport layer. Preferably amounts are 2% to 4% by weight of the total weight of the charge transport layer.
[0013] When the charge transport molecule is a hydrazone, at least 1% by weight of acetosol yellow 5GLS of the total weight of the charge transport layer is mixed with the tetraphenylcyclopentadienone or fluorenone in a weight ratio of 1:1 to 3:1.
[0014] When the charge transport molecule is arylamine, at least 1% by weight of acetosol yellow 5GLS of the total weight of the charge transport layer is mixed with the tetraphenylcyclopentadienone or flourenone also in a weight ratio of 1:1 to 3:1.
DESCRIPTION OF THE INVENTION
[0015] The need for higher sensitivity photoconductors geared towards laser printers that are capable of outputs exceeding 30-50 ppm (pages-per-minute) relates to higher efficiencies for the charge generation/charge transport molecules. Along with the higher sensitivity, the stability of the photoconductor drums towards exposure to fluorescent light or room light is critical. In most cases, the charge transport layer is adversely affected when exposed to room light.
[0016] The electrophotographic properties of the photoconductor deteriorate with increased exposure to light, which in turn causes a degradation in print-quality. In some cases the degradation is so severe that the photoconductor does not discharge at all. The degradation in the photoconductor performance and print-quality may be overcome by suitably selecting charge generation and/or charge transport materials that are unaffected by room light, or additives that can increase the resistance to the effects of the room light. This invention pertains to the use of additive blends of acetosol yellow 5GLS (AY) and an electron acceptor such as tetraphenylcyclopentadienone (TPCPDEO) or 9-fluorenone in the charge transport layer. The mixture of additives helps increase the resistance of the photoconductor drum to room light exposure, and also in the recovery of the drums that have been affected.
[0017] In order to evaluate the effects of the additives on the effect of room light several charge transport molecules were evaluated. The CTM's were either arylamines such as N,N′diphenyl-N,N′-ditolyl-4,4′-biphenyldiamine (TPD) or tri(p-tolylamine) (TTA) or hydrazones such as N,N-diethylaminobenzaldehyde-1,1-diphenylhydrazone (DEH).
[0000] Materials Used:
[0000]
TPD:N,N′diphenyl-N,N′-ditolyl-4,4′-biphenyldiamine
DEH: N,N-diethylaminobenzaldehyde-1,1-diphenylhydrazone
Tetraphenylcyclopentadienone (TPCPDEO):
9-Fluorenone:
Test Method
[0022] In a typical case, two photoconductor drums containing the same formulation were used for analysis. Initial photo induced decay (PID) was measured by charging the drum using a charge roll, and measuring the discharge voltage as a function of laser energy, using a 780 nm laser. The PID was obtained as a plot of negative photoconductor voltage (−V) against laser energy (μJ/cm 2 ). A duplicate drum was exposed to fluorescent light for about 20 minutes to about 60 minutes, and the PID measured immediately.
[0023] In some cases, the drums were electrically cycled by repeated charge/discharge, for 1000 cycles (1 k), and the PID measured, followed by the measurement of the dark decay. Dark decay corresponds to the charge lost as a function of time, and is represented as V/sec. In order to evaluate the extent of recovery from the room light exposure, the drums were stored in a black plastic bag, and a PID curve was obtained after the required recovery time frame. The recovery of the photoconductor drum was then compared to the initial charge/discharge voltages, and the difference corresponds to the fatigue induced in the photoconductor drum due to room light.
[0024] Positive fatigue corresponds to photoconductor drums that discharge at lower voltages either on exposure to room light or on cycling (repeated charge/discharge cycles) the drums, i.e. if a drum discharges to −200V, and discharges to −150V either on cycling or on exposure to room light, the drum is exhibiting positive fatigue of +50V. In this case, if the drum were to be used in printing a page, the prints corresponding to the lower discharging system would be darker than the initial prints. Similarly, negative fatigue corresponds to a drum exhibiting a discharge voltage that is higher than the initial. For example, if a drum on exposure to room light discharges at −200V instead of its −150V initial discharge, the drum exhibits −50V (or a negative fatigue of 50V). Positive and negative fatigue terminology is applicable to the change in dark decay for the drum for cycling or exposure to room light.
Hydrazone Tranports
[0025] Hydrazone transports such as DEH are prone to exhibit negative fatigue (in the absence of room light fatigue mitigant) on exposure to room light. On exposing the photoconductor drums containing a hydrazone transport material to fluorescent light, the discharge voltage for the drum increases. If the drum was used in a laser printer, the prints would appear to be lighter owing to the higher discharge voltage. In some cases, on electrically cycling the drums following exposure to room light, the drum does not discharge, and hence cannot be used to print. Hence it is critical to suitably protect charge transport layers from the effects of fluorescent light.
[0026] As a first procedure, acetosol yellow 5GLS was used as an additive in the charge transport layer. The use of acetosol yellow 5GLS is known in prior art. It is a common ingredient in a DEH formulation, and it helps improve the room light fatigue resistance. In a similar manner, the use of tetraphenylcyclopentadienone (TPCPDEO) as an electron transport material is known. Formulations of these materials were prepared, either as pure materials or as additives, in a DEH/polycarbonate transport formulation (Table 1). The charge generation layer was based on a 45/55 mixture of type IV oxotitanium phthalocyanine (TiOpc) in a polyvinylbutyral matrix. The photo induced decay (PID) was measured at an expose-to-develop time of 76 ms. Results from this experiment are presented in Table 2.
TABLE 1 Formulations corresponding to acetosol yellow 5GLS (AY) and TPCPDEO Transport 2 Transport 4 Transport 1 (Acetosol Transport 3 (SY/ Materials (Control) Yellow) (TPCPDEO) TPCPDEO) MAKROLON- 12 g 12 g 12 g 12 g 5208 DEH 8 g 8 g 8 g 8 g Surfactant 3 drops 3 drops 3 drops 3 drops (DC-200) THF 75 g 75 g 75 g 75 g 1,4-Dioxane 25 g 25 g 25 g 25 g Acetosol 0 g 0.3 g 0 g 0.15 g Yellow 5GLS TPCPDEO 0 g 0 g 0.3 g 0.15 g
[0027]
TABLE 2
Electrical characteristics at 0k and 1k for DEH/MAKROLON-5208/drums
ct.
wt.
Transport
(mg/
0.0 μJ/cm 2
0.2 μJ/cm 2
0.4 μJ/cm 2
0.8 μJ/cm 2
(1.5% Additive)
in2)
V(0k/1k)
V(0k/1k)
V(0k/1k)
V(0k/1k)
Transport 1
10.7
−846/−841
−401/387
−169/−149
−100/−95
(Control)
Transport 2
11.94
−841/−858
−389/−394
−191/−182
−156/−151
(AY)
Transport 3
11.21
−849/−835
−291/−301
−159/−147
−129/−122
(TPCPDEO)
Transport 4
11.23
−842/−822
−382/−381
−186/−177
−143/−140
(AY:TPCPDEO
1/1)
[0028]
TABLE 3
Electrical characteristics before and following a 20 min. exposure to room light
Transport
ct. wt.
0.0 μJ/cm 2
0.2 μJ/cm 2
0.4 μJ/cm 2
0.8 μJ/cm 2
(1.5% Additive)
(mg/in2)
V(init/RLE)
V(init/RLE)
V(init/RLE)
V(init/RLE)
Transport 1
10.57
−846/−853
−401/−554
−169/−554
−100/−525
(Control)
Transport 2
11.46
−841/−852
−389/−386
−191/−168
−156/−129
(AY)
Transport 3
11.16
−849/−856
−291/−409
−159/−268
−129/−212
(TPCPDEO)
Transport 4
11.79
−842/−838
−382/−344
−186/−185
−143/−159
(AY:TPCPDEO 1/1)
(init: electrostatics prior to exposure;
RLE: electrostatics following exposure to room light)
[0029]
TABLE 4
Electrical characteristics at 0k and 1k, following
a 20 min. exposure to room light
ct.
wt.
Transport
(mg/
0.0 μJ/cm 2
0.2 μJ/cm 2
0.4 μJ/cm 2
0.8 μJ/cm 2
(1.5% Additive)
in2)
V(0k/1k)
V(0k/1k)
V(0k/1k)
V(0k/1k)
Transport 1
10.57
−853/−860
−554/−780
−554/−770
−525/−761
(Control)
Transport 2
11.46
−852/−846
−386/−391
−168/−182
−129/−154
(AY)
Transport 3
11.16
−849/−856
−409/−452
−214/−268
−156/−212
(TPCPDEO)
Transport 4
11.79
−847/−838
−344/−364
−153/−185
−124/−159
(AY:TPCPDEO
1/1)
[0030] The results from Table 2, indicate that the addition of the additives, acetosol yellow 5GLS and TPCPDEO tend to lower the dark decay and reduce the 1 k electrical cycling fatigue. The best results are obtained when the two materials are used together, rather than individually (Table 2).
[0031] On exposing the drums to room light for 20 minutes, the control drum (DEH with no additive) showed severe negative fatigue, to the extent that it exhibited no photoconducting property (Table 3). However, the additives were relatively more stable. TPCPDEO, caused the drum to fatigue negative. Acetosol yellow 5GLS results in slight positive fatigue.
[0032] In contrast, the mixture of additives caused the smallest change in the drum electrical characteristics with respect to room light exposure. Also, this system exhibited the lowest dark decay and its change when the drum was subjected to 1000 charge-discharge cycles (e.g. Table 4).
[0033] The effect of the additives on mitigating the room light fatigue occurring from a long-term exposure was explored further. Higher concentrations of the additives were used. The control drum was based on a 2% acetosol yellow 5GLS concentration, and compared to 2% AY/0.5% TPCPDEO or 9-fluorenone blend (Table 5). The charge generation layer comprised of 45% TiOpc (type IV/type I2/1 blend) and 55% (polyvinylbutyral/epoxy resin 1/1) binder blend. Electrostatic characteristics were measured with an expose-to-develop time of 174 ms (Table 6).
TABLE 5 Formulations corresponding to acetosol yellow 5GLS and TPCPDEO or 9-Fluorenone Transport 8 Transport 5 Transport 6 Transport 7 (SY:TPCPDEO Materials (AY) (9-Fluorenone) (SY:Fluorenone 3/1) 3/1) MAKROLON-5208 42 g 42 g 42 g 42 g DEH 28 g 28 g 28 g 28 g Surfactant (DC-200) 6 drops 6 drops 6 drops 6 drops THF 210 g 210 g 210 g 210 g 1,4-Dioxane 70 g 70 g 70 g 70 g Acetosol Yellow 1.40 g 0 g 1.40 g 1.40 g 5GLS 9-Fluorene 0 g 0.77 g 0.35 g 0 g TPCPDEO 0 g 0 g 0 g 0.35 g
[0034]
TABLE 6
Electrical characteristics before and following a 60 min. exposure to room light
ct. wt.
0.0 μJ/cm 2
0.2 μJ/cm 2
0.4 μJ/cm 2
1 μJ/cm 2
Dark decay
Additive
(mg/in2)
V(init/RLE)
V(init/RLE)
V(init/RLE)
V(init/RLE)
(init/RLE)
Transport 5
16.3-16.7
−746/−742
−382/−373
−211/−191
−159/−135
20/32
(Acetosol Yellow
5GLS)
Transport 6
14.5/14.2
−743/−741
−359/−491
−242/−433
−64/−380
31/19
(9-Fluorenone)
Transport 7
17.5/17.2
−739/−754
−377/−374
−208/−202
−158/−158
20/30
(AY:Fluorenone 3/1)
Transport 8
16.8-16.7
−734/−741
−376/−365
−207/−204
−157/−165
16/29
(AY:TPCPDEO 3/1)
ct. wt.
0.21 μJ/cm 2
0.33 μJ/cm 2
1 μJ/cm 2
Dark decay
Additive
(mg/in2)
V Fatigue
V Fatigue
V Fatigue
Fatigue
Transport 5
16.3/16.7
9
20
24
12
(Acetosol Yellow
5GLS)
Transport 6
14.5/14.2
−132
−191
−316
−12
(9-Fluorenone)
Transport 7
17.5/17.2
3
6
0
10
(AY:Fluorenone 3/1)
Transport 8
16.8/16.7
11
3
−8
13
(AY:TPCPDEO 3/1)
[0035] As can be seen from Table 6, the control drum (2% acetosol yellow 5GLS) exhibited positive fatigue (lower discharge, more sensitive), whereas in the presence of either 0.5% fluorenone or TPCPDEO, the room light fatigue was mitigated, without compromising on initial electrostatic characteristics. It may also be noted that the use of fluorenone alone (in the absence of acetosol yellow 5GLS) does not offer any protection towards room light.
Benzidine Transports
[0036] The use of acetosol yellow 5GLS as a room light fatigue mitigant was evaluated in benzidine transports. Formulations were based on either the use of pure acetosol yellow 5GLS or as a blend with other electron-acceptors such as 9-fluorenone or TPCPDEO. Results from various experiments are presented in Table 7 below.
TPD/TOSPEARL Silicone Microspheres/MAKROLON-5208 Polycarbonate
[0037] Anodized drums were coated with a charge generation layer corresponding to 45% TiOpc/BX-55Z and a charge transport layer comprising of, by weight, 30% TPD/MAKROLON-5208 polycarbonate/2.3% TOSPEARL silicone microspheres charge transport layer, in the presence of the additives (acetosol yellow 5GLS and TPCPDEO) were evaluated for resistance to light fatigue. Table 7 describes the various formulations and the corresponding electrostatics for these drums, prior, after exposure to room light and following a 2 h recovery time are presented in Table 8.
TABLE 7 Formulations for room light fatigue (RLF) additives in a TPD/PC_A and TOSPEARL silicone microspheres containing transports. Transport 10 Transport 12 Transport 9 (Acetosol Yellow Transport 11 (AY:TPCPDEO Materials (Control) 5GLS) (TPCPDEO) 1/1) MAKROLON-5208 15.75 g 15.75 g 15.75 g 15.75 g TPD 6.75 g 6.75 g 6.75 g 6.75 g TOSPEARL-120 0.52 g 0.52 g 0.52 g 0.52 g Surfactant (DC-200) 3 drops 3 drops 3 drops 3 drops THF 67.5 g 67.5 g 67.5 g 67.5 g 1,4-Dioxane 22.5 g 22.5 g 22.5 g 22.5 g Acetosol Yellow 0 g 0.38 g 0 g 0.19 g 5GLS TPCPDEO 0 g 0 g 0.38 g 0.19 g
[0038]
TABLE 8
Electrical characteristics before (initial) and following a 20 min. exposure to room
light and its recovery (Rec) following a 2 h rest. (exposure-of 76 ms to-develop)
Additive
Ct. wt.
0.0 μJ/cm 2
0.2 μJ/cm 2
0.4 μJ/cm 2
0.8 μJ/cm 2
Dark decay
(1.5%)
(mg/in2)
V(In/RLE/Rec)
V(In/RLE/Rec)
V(In/RLE/Rec)
V(In/RLE/Rec)
Fatigue
Transport 9
17
−856/−851/−850
−214/−150/−217
−138/−85/−94
−124/−79/−85
64/118/108
(Control)
Transport 10
17
−851/−854/−847
−255/−206/−243
−185/−131/−141
−165/−118/−127
55/97/90
(Acetosol Yellow
5GLS)
Transport 11
21
−849/−851/−850
−254/−226/−243
−197/−167/−172
−177/−153/−157
55/59/54
(TPCPDEO)
Transport 12
21
−847/−847/−839
−269/−231/−266
−215/−175/−197
−199/−162/−183
47/62/60
(AY/TPCPDEO 1/1)
[0039] The control drum exhibits about a 50V positive fatigue on exposure to room light. The increased sensitivity may also be due to the increase in dark decay, when the drums fatigue on exposure to room light. The fatigue is however mitigated on adding acetosol yellow 5GLS or TPCPDEO, or a mixture of the two. The presence of TPCPDEO appears to be a significant contributor to the RLF resistance, and the smallest change in electrical characteristics and dark decay is observed when the additives are used together. The drum also exhibits relatively stable dark decay, and a tendency to fully recover following a 2 h rest.
[0040] 9-fluorenone was also evaluated for its ability in controlling room light fatigue associated with benzidene, as either pure materials or as a blend with acetosol yellow 5GLS. Formulations and results are presented in Tables 9-12. All ratios are by weight.
TABLE 9 Formulations involving acetosol yellow 5GLS and fluorenone blends Transport 14 Transport 15 Transport 16 Transport 13 (Acetosol Yellow (AY:Fluorenone (AY:Fluorenone Materials (Control) 5GLS) 3/1) 1/1 MAKROLON-5208 45.5 g 45.5 g 45.5 g 45.5 g TPD 24.5 g 24.5 g 24.5 g 24.5 g Surfactant (DC-200) 6 drops 6 drops 6 drops 6 drops THF 210 g 210 g 210 g 210 g 1,4-dioxane 70 g 70 g 70 g 70 g TOSPEARL-120 0.70 g 0.70 g 0.70 g 0.70 g Acetosol Yellow 0 g 1.40 g 1.05 g 0.70 g 5GLS 9-Fluorenone 0 g 0 g 0.35 g 0.70 g
[0041]
TABLE 10
Electrostatic characteristics for acetosol yellow 5GLS/fluorenone blends with
TPD transport material (room light exposure: 1 h). charge generation layer: 45% TiOpc
(type IV/type I); BX55Z polyvinylbutyral/epoxy resin (1/1); expose-to-develop time: 135 ms
Ct. wt.
0.0 μJ/cm 2
0.2 μJ/cm 2
0.34 μJ/cm 2
1 μJ/cm 2
Dark Decay
Transport
(mg/in2)
V(In/RLE)
V(In/RLE)
V(In/RLE)
V(In/RLE)
(In/RLE)
Transport 13
18.1/18.3
−734/−732
−185/−82
−105/−44
−77/−42
23/72
(Control)
Transport 14
18.6/18.8
−744/−761
−188/−93
−105/−55
−105/−52
30/108
(Acetosol Yellow
5GLS)
Transport 15
19.5/19.6
−741/−762
−198/−153
−127/−97
−103/−90
28/59
(AY:Fluorene 3/1)
Transport 16
18.1/17.8
−745/−730
−199/−158
−114/−98
−89/−91
30/51
(AY:Fluorenone 1/1)
0.2 μJ/cm 2
0.34 μJ/cm 2
1 μJ/cm 2
Dark Decay
Transport
Ct. weight (mg/in2)
V Fatigue
V Fatigue
V Fatigue
Fatigue
Transport 13
18.1/18.3
103
61
35
49
(Control)
Transport 14
18.6/18.8
95
50
53
78
(Acetosol Yellow)
Transport 15
19.5/19.6
45
30
13
31
(AY:Fluorenone 3/1)
Transport 16
18.1/17.8
41
16
−2
21
(AY:Fluorenone 1/1)
[0042] Both the control drum (no room light fatigue mitigant additives) and 2% acetosol yellow 5GLS exhibit positive fatigue on exposure to room light (1 hour). However, as the acetosol yellow 5GLS concentration is lowered and on addition of 9-flourenone, the tendency to exhibit positive light fatigue is reduced. This is evident from the behavior of Transports 15 and 16. Transports 15 and 16 correspond to a 3/1 and 1/1 mixture of acetosol yellow 5GLS and 9-fluorenone, respectively. Increase in the fluorenone concentration in the blend mixture, reduces the room light fatigue, i.e. fatigue related to the discharge voltage and dark decay.
TTA Transport
[0043] Tri(p-tolyl)amine is known to exhibit fatigue, when exposed to white fluorescent light. The room light fatigue agents namely, a 1:1 mixture by weight of TPCPDEO and acetosol yellow 5GLS was used in the TTA based transport formulation, at a 1.5% by weight concentration. Effect of curing the drums with UV radiation was also studied. The formulations and electrostatics for a drum exposed to white fluorescent light are given below:
TABLE 11 RLF additives in a TTA transport. APEC 9201 is a commercially available resin of mixed polycarbonates. Transport 17 Transport 18 Materials (Control) (SY:TPCPDEO 1/1) APEC 9201 13.5 g 13.5 TTA 9 g 9 g Surfactant (DC-200) 3 drops 3 drops THF 67.5 g 67.5 g 1,4-dioxane 22.5 g 22.5 g Acetosol Yellow 0 g 0.19 g TPCPDEO 0 g 0.19 g
[0044]
TABLE 12
Effect of room light exposure on initial electrostatics for TTA transport
containing photoconductors
(CG: 45% TiOpc (type IV); BX55Z, expose-to develop time: 76 ms)
Ct. wt.
UV
0.0 μJ/cm 2
0.2 μJ/cm 2
0.4 μJ/cm 2
0.8 μJ/cm 2
Dark decay
Additive (1.5%)
(mg/in2)
Cure
V(In/RLE)
V(in/RLE)
V(In/RLE)
V(In/RLE)
(In/RLE)
Transport 17
18.5
No
−852/−852
−234/−353
−184/−336
−170/−355
62/75
No Additive
Transport 17
19.2
Yes
−850/−853
−848/−856
−854/−860
−862/−872
15/15
No Additive
Transport 18
19.5
No
−844/−852
−276/−264
−235/−232
−226/−224
49/56
SY:TPCPDEO
(1/1)
Transport 18
19.2
Yes
−852/−849
−345/−307
−315/−279
−312/−279
50/66
SY:TPCPDEO
(1/1)
Ct. wt.
UV
0.2 μJ/cm 2
0.4 μJ/cm 2
0.8 μJ/cm 2
Dark decay
Additive (1.5%)
(mg/in2)
Cure
V Fatigue
V Fatigue
V Fatigue
Fatigue
Transport 17
18.5
No
−119
−152
−185
13
No Additive
Transport 17
19.2
Yes
—
—
—
—
No Additive
Transport 18
19.5
No
8
3
2
7
SY:TPCPDEO
(1/1)
Transport 18
19.2
Yes
38
31
33
16
SY:TPCPDEO
(1/1)
[0045] On exposing the TTA drum to white fluorescent light, the discharge voltage is increased significantly (−150V). Also, on subjecting the drum to a UV radiation, the photoconducting properties are dramatically affected, and the net result is an insulator. However, the addition of the TPCPDEO/acetosol yellow 5GLS mixture in the transport matrix eliminates any fatigue from the white fluorescent light. The increase in the discharge voltage is also reduced significantly, when the additive containing drums are UV cured.
[0046] Hence it is apparent from the above, that the use of the tetraphenylcyclopentadienone or fluorenone with acetosol yellow 5GLS as additive blends in an arylamine or hydrazone transport system helps mitigate the effect of room light (white fluorescent light) on the performance of the photoconductor drum. These additives may also be used in the charge generation layer to lower the fatigue induced by exposing drums to room light.
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A photoconductor having a charge generation layer and a charge transport layer, the charge transport layer having hydrazone or aryl amine charge transport molecules and also having as room light protective additives acetosol yellow 5GLS and tetraphenylcyclopentadienone or 9-fluorenone. Preferably the amount of the acetosol yellow is 2 to 4 percent by weight of the weight of the charge transfer layer and the ratio of weight between the acetosol yellow and the dienone or fluorenone is in the range of 1:1 to 1:3.
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BACKGROUND
[0001] The invention relates to an open refrigerated display case and a flow stabilizing device for an open refrigerated display case.
[0002] The display of chilled or frozen items is commonplace in many retail environments, most notably in supermarkets. Conventionally, such items have been displayed in refrigerated display cases having glass doors to allow customers to browse items before opening the doors to access the items. However, the presence of such doors has been seen as problematic in that they make it difficult for several customers to access the contents of the case, as well as providing an obstruction when open, narrowing the usable aisle space.
[0003] It is therefore common for supermarkets to use open-fronted display cases (Open Refrigerated Display Cases; herein “ORDCs”). ORDCs utilize an air curtain which is cooled to below ambient temperature and propelled downward, across the open front of the display case. The air curtain separates the refrigerated interior of the display case from the ambient air surrounding the display case. The air curtain thus keeps the cool air inside the display case from spilling out due to buoyancy effects, and also provides a barrier from other external motions of air around the display case. ORDCs therefore do not need any physical barrier separating customers from the contents of the display case. Accordingly, ORDCs provide a desirable method of displaying food and other perishable goods as they allow both easy access and clear visibility of merchandise.
[0004] However, as a direct consequence of their open design, ORDCs do have significantly higher energy consumption compared to the closed-fronted alternative. The main energy losses occur within the air curtain, and are caused by the entrainment of warm ambient air into the air curtain and the turbulent mixing which occurs within the air curtain itself. The entrainment of warm ambient air causes an increase in temperature within the air curtain, and this warmer air must be cooled as it re-circulates through the system. It has been estimated that 70% to 80% of the cooling load of an ORDC is due to such effects.
[0005] In recent years, multi-decked designs have become commonplace to maximize the display space per unit of floor space. Consequently, the air curtains of such ORDCs must seal a larger display area. This has exacerbated entrainment issues and the resulting energy losses, as well as making the design of air curtains more challenging, particularly in respect of ensuring product integrity and temperature homogeneity while attempting to minimize their energy consumption.
[0006] The invention thus seeks to improve the efficiency of ORDCs by reducing entrainment within the air curtain.
BRIEF SUMMARY
[0007] According to an aspect of the invention there is therefore provided an open refrigerated display case comprising: a refrigerated display area comprising one or more shelves; an air outlet and an air inlet opening into the display area and spaced from one another; a duct fluidically coupling the air inlet to the air outlet, the duct being configured to direct air flow out of the air outlet across the display area and toward the air inlet to form an air curtain across the display area; wherein each of the one or more shelves are provided with an associated flow stabilizing device; wherein the one or more flow stabilizing devices each comprise a cellular structure which extends transversely across the display area perpendicular to the direction of the air flow within the air curtain, the cellular structure forming a matrix of stabilizing channels; wherein the one or more flow stabilizing devices are each positioned so that the stabilizing channels receive the entire air curtain and stabilize the air flow within the air curtain; wherein an upper surface of the or each flow stabilizing device is arranged so as to be substantially level with or below an upper surface of the associated shelf.
[0008] The cellular structure is a honeycomb structure.
[0009] The flow stabilizing devices may be spaced from the air outlet and/or one another by a distance which corresponds to approximately 4 to 6 times a width of the air outlet.
[0010] The flow stabilizing devices may be spaced by a distance which corresponds to approximately 5 times a width of the air outlet.
[0011] Each flow stabilizing device may be connected to the one or more shelves.
[0012] Each flow stabilizing device may be pivotably connected to the one or more shelves.
[0013] Each flow stabilizing device may be configured so as to allow a position of the matrix of stabilizing channels relative to the shelf to be varied.
[0014] Each flow stabilizing device may be integrally forming in one of the shelves.
[0015] The stabilizing channels may each have a uniform cross-section along their length (i.e. they are parallel-sided).
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] For a better understanding of the invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
[0017] FIG. 1 is a side cross-sectional view of a conventional open refrigerated display case (ORDC);
[0018] FIG. 2 is a perspective view of a shelf having a flow stabilizing device according to an embodiment of the invention;
[0019] FIG. 3 is a side cross-sectional view of an ORDC according to an embodiment of the invention having a plurality of shelves with flow stabilizing devices as shown in FIG. 2 ;
[0020] FIG. 4 schematically shows air flow from the conventional ORDC of FIG. 1 ;
[0021] FIG. 5 schematically shows air flow from the ORDC of FIG. 3 ;
[0022] FIG. 6 is a plan view of a shelf having a flow stabilizing device according to another embodiment of the invention; and
[0023] FIG. 7 is a side cross-sectional view of an ORDC according to another embodiment of the invention having a plurality of shelves with flow stabilizing devices as shown in FIG. 6 .
DETAILED DESCRIPTION
[0024] FIG. 1 shows a conventional ORDC 2 . The ORDC 2 comprises a cabinet portion formed by a lower wall 4 , a back wall 6 , an upper wall 8 , and left and right side walls (not shown). A lower panel 10 , a back panel 12 and an upper panel 14 are disposed within the cabinet portion.
[0025] The lower, back and upper panels 10 , 12 , 14 form a display area 15 which is provided with a plurality of shelves 17 (six are shown) on which items may be displayed. The shelves 17 are affixed to the back panel 12 .
[0026] As shown, the lower, back and upper panels 10 , 12 , 14 are spaced from the respective lower, back and upper walls 4 , 6 , 8 to form a duct 16 . An intake grille 18 is provided at the lower panel 10 to form an inlet to the duct 16 . Similarly, a discharge grille 20 is provided at the upper panel 14 to form an outlet from the duct 16 . The intake grille 18 and the discharge grille 20 are thus fluidically coupled to one another by the duct 16 . The intake grille 18 and the discharge grille 20 are spaced from the back panel 12 toward the front of the cabinet portion and ahead of the shelves 17 .
[0027] A fan 22 and a heat exchanger 24 are located within the duct 16 adjacent to the intake grille 18 and thus are disposed between the lower wall 4 and the lower panel 10 . The fan 22 draws air into the duct 16 via the intake grille 18 which then passes through the heat exchanger 24 where it is cooled to well below the ambient temperature.
[0028] After passing through the heat exchanger 24 , the air continues through the duct 16 between the back wall 6 and the back panel 12 . The back panel 12 is perforated allowing air to pass from the duct 16 into the display area 15 where it cools items located on the shelves 17 and on the lower panel 10 .
[0029] The remaining air flows through the duct 16 to the discharge grille 20 . The air is ejected from the discharge grille 20 and descends over the open front of the display area 15 to form an air curtain 26 . The air curtain 26 passes from the discharge grille 20 to the intake grille 18 , where it is drawn in by the fan 22 and re-circulated through the duct 16 . The air curtain 26 thus forms a non-physical barrier which separates the display area 15 from the ambient air surrounding the ORDC 2 .
[0030] As shown in FIG. 1 , the air curtain 26 may be angled away from vertical by around 5-10°. This may be achieved by angling the discharge grille 20 . In particular, the discharge grille 20 may be provided with a honeycomb panel (not shown) which rectifies the air flow as it exits the discharge grille 20 to provide laminar flow. The air curtain 26 may also deviate away from the back panel 12 as a result of the air passing through the perforations in the back panel 12 . The intake grille 18 is therefore offset from the discharge grille 20 to allow for this.
[0031] FIG. 2 shows a flow stabilizing device 28 according to an embodiment of the invention which is fitted to one of the shelves 17 of the ORDC 2 .
[0032] As shown in FIG. 2 , each shelf 17 comprises a shelf portion 30 and a pair of brackets 32 which support the shelf portion 30 and are configured to be received within slots in the back panel 12 of the ORDC 2 . A product information strip 34 extends across a front surface of the shelf portion 30 and has a channel for receiving tickets displaying information regarding the products on the shelf portion 30 , such as the product's price.
[0033] The flow stabilizing device 28 comprises a pair of arms 36 a, 36 b. The arms 36 a, 36 b are affixed to either lateral side of the shelf 17 such that they are spaced from one another across the width of the shelf 17 . Each of the arms 36 a, 36 b is connected at one end to the shelf 17 and extends away from the shelf 17 in a cantilevered manner to a free end. The arms 36 a, 36 b thus lie in the same plane as the shelf 17 . The arms 36 a, 36 b may be connected to the shelf 17 in any suitable manner, such as via attachment to the shelf portion 30 , the brackets 32 or the product information strip 34 .
[0034] A pair of stabilizing beams 38 a, 38 b extend between the arms 36 a, 36 b. The stabilizing beams 38 a, 38 b are spaced from one another and run parallel to one another across the full width of the shelf 17 (and the display area 15 ). The stabilizing beams 38 a, 38 b are arranged so that their widths extend in a vertical direction, substantially perpendicular to the shelf 17 . The stabilizing beams 38 a, 38 b are, however, angled relative to one another so that the gap between the stabilizing beams 38 a, 38 b tapers toward the lower end of the stabilizing beams 38 a, 38 b. The stabilizing beams 38 a, 38 b thus define a first slot 39 a having a vertical extent (length). The first slot 39 a comprises an inlet at an upper end and an outlet at a lower end. The inlet has a greater width than the outlet and a convergent throat is disposed between the inlet and the outlet. The stabilizing beams 38 a, 38 b may taper at an angle of greater than 0° and less than 20° to the vertical. The angle may, however, differ between the two stabilizing beams 38 a, 38 b within a single flow stabilizing device 28 . In particular, as shown, the outermost stabilizing beam 38 a may be arranged vertically and the innermost stabilizing beam 38 b angled relative to the outermost stabilizing beam 38 a.
[0035] The outermost stabilizing beam 38 a may be provided with a product information strip which can be used to display information regarding the products on the shelf portion 30 if the product information strip 34 of the shelf 17 itself is obscured by the stabilizing beams 38 a, 38 b . Alternatively, the stabilizing beams 38 a, 38 b may be transparent to allow the product information strip 34 of the shelf 17 to be viewed. This may also prevent the stabilizing beams 38 a, 38 b from blocking light from a light source within the ORDC 2 and thus ensure proper illumination of the products within the ORDC.
[0036] As shown in FIG. 3 , each of the shelves 17 is provided with a flow stabilizing device 28 . The stabilizing beams 38 a, 38 b of each shelf 17 are spaced from the shelf 17 so as to form a second slot 39 b between the innermost stabilizing beam 38 b and the shelf 17 . The stabilizing beams 38 a, 38 b are positioned such that the majority of the air curtain 26 passes between the stabilizing beams 38 a, 38 b, through the first slot 39 a. A portion of the air curtain 26 may pass between the innermost stabilizing beam 38 b and the shelf 17 , through the second slot 39 b, or beyond the exterior surface of the outermost stabilizing beam 38 a. As described previously, the back panel 12 is perforated to allow air to pass from the duct 16 into the display area 15 where it cools items located on the shelves 17 and on the lower panel 10 . The direction of air flow from the back panel 12 is thus predominantly perpendicular to that of the air curtain 26 . The air from the back panel 12 is entrained with the portion of the air curtain 26 passing through the second slot 39 a which turns the air flow towards the direction of the air curtain 26 . This reduces the effect the air flow from the back panel 12 has on the air curtain 26 .
[0037] As described previously, the air curtain 26 may be angled away from vertical and the stabilizing beams 38 a, 38 b may be spaced progressively further from the shelf 17 (or, where the shelves are of different lengths, from the back panel 12 ) from the uppermost shelf 17 to the lowermost shelf 17 so as to be aligned with the air curtain 26 . The spacing between the stabilizing beams 38 a, 38 b may increase from the uppermost flow stabilizing device 28 to the lowermost flow stabilizing device 28 to account for the air curtain 26 becoming thicker as it passes down the front of the ORDC 2 .
[0038] As described previously, the intake grille 18 is not directly aligned with the discharge grille 20 . To counteract this, the stabilizing beams 38 a, 38 b of the uppermost flow stabilizing device 28 are curved so that the air curtain 26 is turned slightly as it passes through this flow stabilizing device 28 . As shown, the stabilizing beams 38 a, 38 b of the uppermost flow stabilizing device 28 may also run parallel to one another such that they do not converge.
[0039] FIGS. 4 and 5 provide a comparison of the flow characteristics of the air curtain 26 without the flow stabilizing devices 28 of the invention ( FIG. 4 ) and with the flow stabilizing devices 28 ( FIG. 5 ).
[0040] As shown in FIG. 4 , the air leaves the discharge grille 20 as a coherent jet 40 . However, without the flow stabilizing devices 28 , the jet 40 soon becomes unstable in region 42 , and begins to separate. This causes a high level of turbulent mixing in region 44 which warms the air curtain 26 considerably, thus warming the ORDC 2 .
[0041] As shown in FIG. 5 , with the flow stabilizing devices 28 attached to the shelves 17 , the air again exits the discharge grille 20 , but before the air curtain 26 can become unstable the flow stabilizing device 28 acts to re-stabilize the flow. As described previously, the stabilizing beams 38 a, 38 b converge such that, as a result of the Venturi effect, the air is accelerated as it passes through the first slot 39 a of the flow stabilizing device 28 . The acceleration acts to further stabilize the air curtain 26 . The width of the air curtain 26 is also reduced which helps maintain a thin shear layer throughout the length of the air curtain 26 . The second slot 39 b formed between the innermost stabilizing beam 38 b and the shelf 17 further promotes stabilization of the air curtain 26 by drawing air from the back panel 12 into the air curtain 26 .
[0042] The shelves 17 may be configured so as to allow the shelf portion 30 to be positioned at different angles. This may be beneficial for displaying different types of products. To allow for this, each flow stabilizing device 28 may be pivotably connected to the shelf 17 so that the flow stabilizing device 28 remains horizontal (or at some other predetermined orientation). For example, the arms 36 a, 36 b may be pivotably connected to the shelf 17 . Alternatively, the arms 36 a, 36 b may each comprise first and second members connected to one another at an articulated joint. The arms 36 a, 36 b may also allow the distance of the stabilizing beams 38 a, 38 b from the shelf 17 to be varied. In particular, as the shelf 17 is angled away from horizontal, its horizontal extent will reduce so that the stabilizing beams 38 a, 38 b are located closer to the back panel 12 . The arms 36 a, 36 b may therefore allow for this to be counteracted so that the stabilizing beams 38 a, 38 b remain in the correct position for the air curtain 26 . For example, the arms 36 a, 36 b may allow the stabilizing beams 38 a, 38 b to be located in a plurality of positions (e.g. defined by discrete mounting holes or a continuous slot) or the arms 36 a, 36 b themselves may be connected to the shelf 17 in a plurality of positions. Alternatively, the arms 38 a, 38 b may comprise a telescoping arrangement to alter their length.
[0043] An initial study using Computational Fluid Dynamics has shown that the flow stabilizing device 28 of the invention could provide a reduction of around 40% in convective heat losses.
[0044] Although not shown, the flow stabilizing device 28 may comprise an injector port which receives additional air. For example, the injector port may be connected to the duct 16 via a conduit or the injector port may receive air which passes through the perforated back panel 12 . The injector port may be located adjacent the inlet of the flow stabilizing device 28 . The Venturi effect creates an area of low pressure within the flow stabilizing device 28 as the air curtain 26 is accelerated. This acts to draw in the additional air from the injector port which further increases the velocity of the air curtain, thus helping it to remain stable and intact in extreme ambient conditions.
[0045] The flow stabilizing devices 28 can be connected to a standard shelf 17 and thus allow the flow stabilizing devices 28 to be retrofit to existing ORDCs. The flow stabilizing devices 28 may, however, be integrally formed with the shelves 17 or the ORDC 2 . In this respect, “integral” is intended to convey that the flow stabilizing devices 28 are located within the perimeter of the shelves 17 , rather than being affixed thereto. Nevertheless, the flow stabilizing devices 28 may still be removable from the remainder of the shelf 17 to aid manufacturing and cleaning, for example.
[0046] Although each shelf 17 of the ORDC 2 has been described as having a flow stabilizing device 28 , this need not be the case and only some of the shelves 17 may be provided with flow stabilizing devices 28 . It is, however, desirable that the flow stabilizing devices 28 are provided at regular spacings of between 120 mm and 190 mm, which corresponds to approximately 4 to 6 times the width of the discharge grille 20 , and preferably at spacings of around 160 mm (5 times the width of the discharge grille 20 ).
[0047] Although the flow stabilizing devices 28 have been described as being connected directly to the shelves 17 , they may instead be connected to other parts of the ORDC 2 . For example, the arms 36 a, 36 b of the flow stabilizing devices 28 may connect to the back panel 12 such that the flow stabilizing devices 28 are positioned between adjacent shelves 17 (or between the lowermost shelf 17 and the lower panel 10 ). In particular, the flow stabilizing devices 28 may be positioned just below each of the shelves 17 . Alternatively, the flow stabilizing devices 28 may be connected to the left and right side walls of the ORDC 2 . In this case, the arms 36 a, 36 b can be omitted and the stabilizing beams 38 a, 38 b connected directly to the ORDC 2 .
[0048] The stabilizing beams 38 a, 38 b also need not lie in the plane of the shelf 17 . For example, the stabilizing beams 38 a, 38 b may be offset from the shelf 17 such that they are not aligned with the product information strip 34 , thus allowing the product information strip 34 to be viewed. This may be achieved by using arms which are stepped or otherwise configured so that the connection to the shelf 17 and the connection to the stabilizing beams 38 a, 38 b are offset from one another.
[0049] In certain embodiments, the stabilizing beams 38 a, 38 b may not converge and are instead arranged parallel to one another. Such parallel stabilizing beams 38 a, 38 b may guide the air flow and prevent expansion of the air curtain, thus still re-stabilizing the flow.
[0050] FIG. 6 shows a shelf 117 having a flow stabilizing device 128 according to another embodiment of the invention. As shown, the shelf 117 comprises a shelf portion 130 on which products may be displayed. The flow stabilizing device 128 is integrated into the shelf 117 to form a single component. The flow stabilizing device 128 forms a zone of the shelf 117 at or toward an outermost edge of the shelf 117 (i.e. furthest from the back panel 12 of the ORDC 2 ). The flow stabilizing device 128 comprises a honeycomb panel which is embedded within the shelf 117 . The honeycomb panel forms a matrix of open hexagonal cells extending in the direction of the air curtain 26 . Each cell forms a stabilizing channel through which air from the air curtain 26 (and optionally from the back panel 12 ) can pass. The honeycomb panel is positioned to receive the entire air curtain 26 . The stabilizing channels have a uniform cross-section along their length such that the longitudinal axes of the sides extend parallel to one another. However, the stabilizing channels of adjacent flow stabilizing devices 128 may be angled relative to one another to redirect the air curtain.
[0051] As shown in FIG. 7 , the flow stabilizing device 128 is substantially coplanar with the shelf 117 . Specifically, an upper surface of the flow stabilizing device 128 (i.e. of the hexagonal cells) is substantially coplanar with an upper surface of the shelf portion 130 . A lower surface of the flow stabilizing device 128 (i.e. of the hexagonal cells) may also be substantially coplanar with a lower surface of the shelf portion 130 such that the flow stabilizing device lies within the vertical bounds of the upper and lower surfaces of the shelf portion 130 . The flow stabilizing device 128 thus forms an integral part of the shelf portion 130 which does not obstruct the view of and access to products located on the shelf portion 130 , or on adjacent shelves 117 .
[0052] As shown in FIG. 7 , in use, the flow stabilizing device 128 acts to re-stabilize the flow of the air curtain 26 after it exits the discharge grille 20 before it can become unstable. Specifically, the stabilizing channels guide the air flow and prevent expansion of the air curtain 26 as it passes down the front of the ORDC 2 . They may also redirect air from the back panel 12 toward the direction of the air curtain 26 .
[0053] In other embodiments, the flow stabilizing device 128 may be a separate component which is attached to an existing shelf. This may allow the flow stabilizing device 128 to be angled relative to the shelf portion 130 , particularly when the shelf 117 itself is inclined. In this manner, the flow stabilizing device 128 may also be offset from the shelf 117 . However, even where the flow stabilizing device 128 is provided within the body of the shelf (as shown in FIG. 6 ), it may still be possible to angle the flow stabilizing device relative to the shelf portion 130 . For example, the flow stabilizing device 128 may be pivotably mounted via a gimbal joint. With this arrangement, it may be desirable for the upper surface of the flow stabilizing device 128 to remain at or below the level of the upper surface of the shelf 117 at each angular position. It may also be possible to adjust the fore and aft position of the flow stabilizing device 128 within the body of the shelf. For example, the flow stabilizing device 128 may be mounted on rails to allow it to be moved. The flow stabilizing device 128 may be moved along the rails so as to receive the entire curtain. Cover plates may be provided to between the flow stabilizing device and the shelf 117 to maximize the usable area of the shelf portion 130 .
[0054] Although the flow stabilizing device 128 has been described as being formed by a honeycomb panel, it will be appreciated that other cellular structures may be used with form a matrix of flow stabilizing channels.
[0055] Although the upper surface of the flow stabilizing device 128 has been described as being substantially coplanar with the upper surface of the shelf portion 130 , it may also lie below the level of the upper surface of the shelf portion 130 . It is, however, useful for the upper surfaces to be substantially coplanar so as to form a continuous surface. This may aid removing items from the shelf, particularly where they are heavy and the customer wishes to slide the item across the surface of the shelf. On the other hand, the lower surface of the flow stabilizing device 128 may terminate above or project below the lower surface of the shelf portion 130 . However, it is desirable, particularly where the shelves are close together relative to the height of goods on the shelf portions 130 , that the lower surface of the flow stabilizing device 128 terminates at or above the level of the shelf portion 130 so as not to obstruct the view of and access to the shelf 117 below.
[0056] The invention is not limited to the embodiments described herein, and may be modified or adapted without departing from the scope of the present invention.
[0057] To avoid unnecessary duplication of effort and repetition of text in the specification, certain features are described in relation to only one or several aspects or embodiments of the invention. However, it is to be understood that, where it is technically possible, features described in relation to any aspect or embodiment of the invention may also be used with any other aspect or embodiment of the invention.
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An open refrigerated display case including: a refrigerated display area having one or more shelves; an air outlet and an air inlet opening into the display area and spaced from one another; a duct fluidically coupling the air inlet to the air outlet, the duct being configured to direct air flow out of the air outlet across the display area and toward the air inlet to form an air curtain across the display area; wherein each of the one or more shelves are provided with an associated flow stabilizing device; wherein the one or more flow stabilizing devices each include a cellular structure which extends transversely across the display area perpendicular to the direction of the air flow within the air curtain, the cellular structure forming a matrix of stabilizing channels; wherein the one or more flow stabilizing devices are each positioned so that the stabilizing channels receive the entire air curtain and stabilize the air flow within the air curtain; wherein an upper surface of the or each flow stabilizing device is arranged so as to be substantially level with or below an upper surface of the associated shelf.
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BACKGROUND
[0001] Network performance tests are useful for evaluating the performance of various nodes in a network. Such performance tests typically have involved sending test packets through the network for evaluating network performance. Existing performance tests, however, have determined the status of a given node in the network by inferring from errors in the network performance tests, or from measures of the central processing unit (CPU), memory or other vital signs of the node. Such existing approaches to network performance measurement lead to confusion since the errors in the network performance tests may have been caused by many other network problems, and not necessarily by the status of a given network node.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is an exemplary diagram of a network in which systems and methods described herein may be implemented;
[0003] FIG. 2 is an exemplary diagram of a sending node or receiving node of FIG. 1 ;
[0004] FIG. 3 is a functional block diagram of the sending node of FIG. 1 ;
[0005] FIG, 4 is a functional block diagram of the receiving node of FIG. 1 ;
[0006] FIG. 5 is a flowchart of an exemplary process for sending a test data unit from a sending node to a receiving node and evaluating a status of the receiving node based on a response data unit returned to the sending node from the receiving node;
[0007] FIG. 6A illustrates an exemplary test data unit sent by a sending node of FIG. 1 ;
[0008] FIG. 6B illustrates an exemplary response data unit sent by a receiving node of FIG. 1 ;
[0009] FIG. 7 is an exemplary messaging diagram illustrating the sending of a test data unit from a sending node to a receiving node, and the return of a response data unit from the receiving node to the sending node; and
[0010] FIG. 8 is a flowchart of an exemplary process for sending a response data unit from a receiving node in response to the receipt of a test data unit from a sending node.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] The following detailed description refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements. The following detailed description does not limit the invention.
[0012] As described herein, an exemplary technique for testing network nodes is provided that evaluates a given network node's status based on a processing time associated with a test data unit sent to that node. When a test data unit is sent from a sending node and received at a receiving node, the receiving node identifies a time at which the test data unit is received. The receiving node further identifies a time at which a response data unit will be returned to the sending node. A time value associated with the difference between the time at which the response data unit will be returned to the sending node and the time at which the test data unit is received may be inserted into the response data unit that is sent from the receiving node to the sending node. This time value may be related to the processing time associated with the test data unit. The time value may be extracted from the response data unit at the sending node and a magnitude of the time value may be used to evaluate the status of the receiving node.
[0013] FIG. 1 is an exemplary diagram of a network 100 in which systems and methods described herein may be implemented. Network 100 may include a sending node 105 and a receiving node 110 interconnected via a network 115 . A single sending node 105 and a single receiving node 110 have been illustrated as connected to network 115 for simplicity. In practice, there may be more or fewer sending and/or receiving nodes.
[0014] Sending node 105 and receiving node 110 may include any type of device that can send, receive and process data. For example, sending node 105 and/or receiving node 110 may include a personal computer, a wireless telephone, a personal digital assistant (PDA), a lap top, a router, a switch, a network interface card (NIC), a hub, a bridge, or another type of computation or communication device, a thread or process running on one of these devices, and/or an object executable by one of these devices.
[0015] Network 115 may include one or more networks of any type, including a local area network (LAN), a wide area network (WAN), a metropolitan area network (MAN), a telephone network, such as the Public Switched Telephone Network (PSTN) or a Public Land Mobile Network (PLMN), an intranet, the Internet, or a combination of networks. The PLMN(s) may further include a packet-switched sub-network, such as, for example, General Packet Radio Service (GPRS), Cellular Digital Packet Data (CDPD), or Mobile IP sub-network. Sending node 105 and receiving node 110 may connect to network 115 via wired, wireless, and/or optical connections.
[0016] FIG. 2 is a diagram of an exemplary configuration of sending node 105 . Receiving node 110 may be similarly configured. Sending node 105 may include a bus 210 , a processing unit 220 , a main memory 230 , a read only memory (ROM) 240 , a storage device 250 , an input device 260 , an output device 270 , and a communication interface 280 . Bus 210 may include a path that permits communication among the elements of sending node 105 .
[0017] Processing unit 220 may include a processor, microprocessor, or processing logic that may interpret and execute instructions. Main memory 230 may include a random access memory (RAM) or another type of dynamic storage device that may store information and instructions for execution by processing unit 220 . ROM 240 may include a ROM device or another type of static storage device that may store static information and instructions for use by processing unit 220 . Storage device 250 may include a magnetic and/or optical recording medium and its corresponding drive.
[0018] Input device 260 may include a mechanism that permits an operator to input information to sending node 105 , such as a keyboard, a mouse, a pen, voice recognition and/or biometric mechanisms, etc. Output device 270 may include a mechanism that outputs information to the operator, including a display, a printer, a speaker, etc. Communication interface 280 may include any transceiver-like mechanism that enables sending node 105 to communicate with other devices and/or systems. For example, communication interface 280 may include mechanisms for communicating with another device or system via a network, such as network 115 .
[0019] Sending node 105 and/or receiving node 110 may perform certain operations or processes, as will be described in detail below. Sending node 105 and/or receiving node 110 may perform these operations in response to processing unit 220 executing software instructions contained in a computer-readable medium, such as memory 230 . A computer-readable medium may be defined as a physical or logical memory device and/or carrier wave.
[0020] The software instructions may be read into memory 230 from another computer-readable medium, such as data storage device 250 , or from another device via communication interface 280 . The software instructions contained in memory 230 may cause processing unit 220 to perform operations or processes that will be described later. Alternatively, hardwired circuitry may be used in place of or in combination with software instructions to implement processes described herein. Thus, implementations described herein are not limited to any specific combination of hardware circuitry and software.
[0021] FIG, 3 is a functional block diagram illustrating various functions performed by sending node 105 consistent with exemplary embodiments. As shown in FIG. 3 , sending node 105 may include a test data unit constructor 300 , a delta time extractor 310 and a node evaluator 320 . Test data unit constructor 300 may construct a test data unit 330 and may send the test data unit 330 to receiving node 110 via an output interface (not shown). Delta time extractor 310 may extract a delta time (Δt res ) from a response data unit 340 received from receiving node 110 at an input interface (not shown) of sending node 105 . As described further below, delta time Δt res may include a difference between a time at which test data unit 330 is received at receiving node 110 and a time at which receiving node 110 sends response data unit 340 to sending node 105 . Node evaluator 320 may evaluate the status of receiving node 110 based on a magnitude of the delta time (Δt res ) extracted from response data unit 340 . The magnitude of the delta time may provide some indication of a data unit processing time at receiving node 110 . A larger magnitude for the delta time may indicate that receiving node 110 is busy processing other data units and, therefore, may be too busy to conduct a test session with sending node 105 .
[0022] FIG. 4 is a functional block diagram illustrating various functions performed by receiving node 110 consistent with exemplary embodiments. As shown in FIG. 4 , receiving node 110 may include a clock 400 , a responder function 410 , a response data unit constructor 420 and a delta time determiner 430 . Clock 400 may timestamp a test data unit 330 received at receiving node 110 from sending node 105 with a time t 2 at which test data unit 330 is received. Based on receipt of test data unit 330 , responder function 410 may be executed. Responder function 410 may include a specific set of operations to be performed by receiving node 10 upon receipt of test data unit 330 . The responder function may include, for example, a CPU testing function, a memory access testing function, or the like. The responder function may include, though, any type of testing function, or other type of function that may be executed at receiving node 110 . Subsequent to, or during, execution of responder function 410 , response data unit constructor 420 may construct response data unit 340 for returning to sending node 105 . Delta time determiner 430 may determine a delta time (Δt res ) that includes a difference between the time t 2 at which test data unit 330 was received and a time t 3 at which response data unit 340 may be sent back to sending node 105 . Delta time determiner 430 may further insert the determined delta time into the outgoing response data unit 340 for transmission to sending node 105 .
[0023] FIG. 5 is a flowchart of an exemplary process for sending a test data unit from sending node 105 to receiving node 110 and for evaluating the status of receiving node 110 . The process exemplified by FIG. 5 may be performed by sending node 105 .
[0024] The exemplary process may begin with the construction of a test data unit by test data unit constructor 300 (block 500 ). FIG. 6A illustrates an exemplary test data unit 330 according to one implementation. Test data unit 330 may include a header 610 and a payload 620 . In this implementation, test data unit 330 may be designated as a test data unit by leaving payload 620 empty. An empty payload 620 minimizes test data unit 330 's affect on network bandwidth and on processing resources at receiving node 110 . In other implementations (not shown), test data unit 330 may include, instead of an empty payload 620 , an identifier field in header 610 that identifies data unit 330 as a test data unit. Header 610 may include data unit overhead information, such as, for example, a network address associated with the sending node and the destination node (e.g., network addresses of sending node 105 and receiving node 110 ). The structure of test data unit 330 shown in FIG. 6A is for illustrative purposes only. Other data unit structures may be used, based on the type of protocol used for testing.
[0025] Test data unit 330 may be sent by sending node 105 at various times For example, in one implementation, test data unit 330 may be sent by sending node 105 before the start of a network performance test to verify whether receiving node 110 is ready for the test session. In another implementation, test data unit 330 may be sent by sending node 105 after a test session to verify whether receiving node 110 is in a proper status to validate or invalidate the results of a previous test session. In still another implementation, test data unit 330 may also be sent by sending node 105 in between data units of a test session that performs other testing, and the results can be collected by sending node 105 . The results may be used by sending node 105 to evaluate the status of receiving node 110 during the test session, and to validate or invalidate the results of the test session. Receiving node 110 may distinguish test data unit 330 from other test session data units by test data unit 330 's empty payload 620 . Any combination of the above may be used for evaluating a status of receiving node 110 before, during and/or after a test session.
[0026] Returning to FIG. 5 , sending node 105 may send the constructed test data unit to responding node 110 at a time t 1 (block 510 ). As depicted in the messaging diagram of FIG. 7 , sending node 105 sends test data unit 330 to receiving node 110 at time t 1 710 .
[0027] Sending node 105 may receive a response data unit from responding node 110 at a time t 4 (block 520 ). FIG. 6B illustrates an exemplary response data unit 340 according to one implementation. Response data unit 340 may include a header 640 and a payload 650 . A delta time value (Δt res ) 660 may be inserted within payload 650 by receiving node 110 . The delta time value (Δt res ) is described further below in connection with FIG. 8 . Header 640 may include data unit overhead information, such as, for example, a network addresses associated with the sending node and the destination node (e.g., network addresses of sending node 105 and receiving node 110 , respectively). As shown in the messaging diagram of FIG. 7 , receiving node 110 sends response data unit 340 at a time t 3 730 . Sending node 105 receives response data unit 340 at time t 4 740 .
[0028] As further shown in FIG. 5 , delta time extractor 310 of sending node 105 may extract the delta time (Δt res ) 660 from payload 650 of the received response data unit 340 (block 530 ). Node evaluator 320 of sending node 105 may then evaluate the status of receiving node 110 based on a magnitude of the delta time (Δt res ) (optional block 540 ). As described below with respect to FIG. 8 , the magnitude of the delta time may provide some indication of a data unit processing time at receiving node 110 . A larger magnitude for the delta time may indicate that receiving node 110 is busy processing other data units and, therefore, may be too busy to conduct a test session with sending node 105 . Based on an evaluation of the status of receiving node 110 , sending node 105 may take appropriate actions, such as, for example, terminating the testing session, sending an alarm, or sending another test data unit to receiving node 110 .
[0029] FIG. 8 is a flowchart of an exemplary process for receiving a test data unit at receiving node 110 and, in response, returning a response data unit to sending node 105 . Sending node 105 may, in some implementations, then use the response data unit for evaluating the status of receiving node 110 (see exemplary process of FIG. 5 above). The process exemplified by FIG. 8 may be performed by receiving node 110 .
[0030] The exemplary process may begin with the receipt of test data unit 330 at receiving node 110 from sending node 105 , and determining a time t 2 at which test data unit 330 is received (block 800 ). Receiving node 10 may receive test data unit 330 from sending node 105 via network 115 and may time stamp, e.g., using clock 400 , the received test data unit 330 . As graphically shown in the messaging diagram of FIG. 7 , receiving node 110 receives test data unit 330 from sending node 105 at time t 2 720 . Test data unit 330 may be identified as a test data unit via a specific type of field in header 610 of test data unit 330 indicating that test data unit 330 is a test data unit, or by a determination that payload 620 of test data unit 330 is empty, providing an implicit indication that test data unit 330 is a test data unit.
[0031] Receiving node 110 may the process the received test data unit 330 using an appropriate responder function 410 (block 810 ). The responder function 410 may include a specific set of operations to be performed by receiving node 110 upon receipt of test data unit 330 . The responder function may include, for example, a CPU testing function, a memory access testing function, or the like. The responder function may include, though, any type of testing function, or other type of function that may be executed at receiving node 110 . In one implementation, test data unit 330 may indicate the appropriate responder function to be executed at receiving node 110 . In another implementation, test data unit 330 may automatically cause the execution of a given responder function when test data unit 330 is received. Execution of the responder function may include a time period t x and receiving node 110 may not send response data unit 340 until completion of the time period t x .
[0032] Response data unit constructor 420 of receiving node 110 may construct response data unit 340 (block 820 ). As shown in FIG. 6B , and described above, response data unit 340 may include header 640 and payload 650 . Receiving node 110 may insert the appropriate information (e.g., network addresses of sending node 105 and receiving node 110 ) in header 640 for sending response data unit 340 to sending node 105 .
[0033] Receiving node 110 may determine time t 3 at which response data unit 340 will be sent (block 830 ). The determined time t 3 may be based on the responder function execution time t x and, possibly, other factors (e.g., output queuing capacity). Delta time determiner 430 of receiving node 110 may determine delta time 660 : Δt res =t 3 -t 2 (block 840 ). The delta time Δt res , therefore, may include the difference between time t 2 at which test data unit 330 was received at receiving node 110 and time t 3 at which receiving node 110 will send response data unit 340 to sending node 105 . A component of delta time (Δt res ) 660 may, thus, include the responder function execution time t x . Receiving node 110 may insert delta time (Δt res ) 660 in payload 650 of the constructed response data unit 340 (block 850 ). Alternatively, the time t 2 720 that receiving node 110 received test data unit 330 from sending node 105 , and the time t 3 730 at which response data unit 340 will be sent from receiving node 110 may both be inserted in payload 650 of response data unit 340 , instead of the delta time Δt res .
[0034] Receiving node 110 may send response data unit 340 to sending node 105 at time t 3 (block 860 ). As shown in the messaging diagram of FIG. 7 , receiving node 110 sends response data unit 340 at time t 3 730 for receipt by sending node 105 at time t 4 740 . As described above with respect to FIG. 5 , sending node 105 may use delta time value (Δt res ) 660 inserted in response data unit 340 for evaluating a status of receiving node 110 .
[0035] In the preceding specification, various preferred embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense. Modifications and variations are possible in light of the specification, or may be acquired from practice of the invention. For example, while a series of acts has been described with regard to FIGS. 3 and 6 , the order of the acts may be modified in other implementations consistent with the principles of the invention. Further, non-dependent acts may be performed in parallel.
[0036] It will be apparent that embodiments, as described above, may be implemented in many different forms of software, firmware, and hardware in the implementations illustrated in the figures. The actual software code or specialized control hardware used to implement embodiments is not limiting of the invention. Thus, the operation and behavior of the embodiments have been described without reference to the specific software code, it being understood that software and control hardware may be designed based on the description herein.
[0037] No element, act, or instruction used in the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one” or similar language is used. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.
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A system receives a data unit from a sending node and identifies if the data unit indicates that it is a test data unit. The system determines a delta time that includes a difference between a time at which a response data unit is going to be sent to the sending node and a time at which the data unit was received. The system inserts the delta time, if the identification indicates that the data unit is a test data unit, in the response data unit and sends the response data unit to the sending node.
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FIELD OF THE INVENTION
The field of the invention is equipment for servicing oil and gas wells.
BACKGROUND OF THE INVENTION
Oil or gas wells are typically drilled to depths of hundreds or thousands of feet. Sections of well pipe are linked together and are lowered into the well. For various reasons, it occasionally becomes necessary to pull the well pipe from the well. This can require large lifting forces since the well pipe can weigh several pounds per foot and hundreds or thousands of feet of pipe must be lifted from the well.
Specialized well servicing rigs have been used for pulling is well pipe. These rigs are generally driven to the well where a derrick on the rig is erected over the well. A winch on the rig is used to pull the well pipe from the well. Workers on an elevated platform on the derrick unhook well pipe from the winch cable and temporarily store the extracted well pipe along side the derrick. Workers on the ground around the well uncouple or separate well pipe sections as they are extracted from the well. Accordingly, the well servicing rig can extract well pipe much more quickly and easily than e.g., a general purpose crane.
The winch or draw works on the well servicing rig is typically powered by the rig's internal combustion engine. Winching accordingly generates substantial exhaust emissions and noise. When working on "town lot" wells, i.e., wells located in or near residential areas, it is especially desireable to reduce noise and emissions from operations at the well site, including pipe extraction operations. In the Southern California area, emissions from oil refineries and oil fields are limited by government regulations. Any increase in emissions generated by expanded operations, etc., must be compensated for by reduced emissions in other areas. Accordingly, there is a need to reduce all emissions associated with oil well operations in Southern California oil fields.
SUMMARY OF THE INVENTION
The present invention is directed to mobile well servicing equipment which can perform oil well servicing operations, and especially pipe extraction, with little or no exhaust emissions and substantially reduced noise levels. To this end, a well servicing rig has a winch adapted to receive an external drive shaft. An auxiliary truck has an electric motor driving a transmission or torque convertor. A drive shaft connects the transmission to the winch on the well servicing rig. The internal combustion engine on the rig ordinarily used for the winch is disengaged and the winch is driven by the electric motor on the auxiliary truck.
Accordingly, it is an object of the present invention to provide well servicing equipment which can extract well pipe with minimized emissions and noise. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 is a perspective view of the present well servicing equipment operating at a well site;
FIG. 2 is a perspective view of the drive shaft linking the auxiliary truck and well servicing rig of the present invention; and
FIG. 3 is a perspective view of an adaptor for connecting the drive shaft to the winch of the well servicing rig.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to the drawings, as shown in FIG. 1, a well servicing rig 16 is set up over a well 12 at a well site 10. The well servicing rig can be a Franks 300 Mobilrig available from Ingersoll-Rand Oil Field Products Company, Pampa, Tex. or other similar well servicing rig. The well servicing rig 16 has an internal combustion engine 18 (typically Diesel) linked to a transmission 20. The transmission 20 can be shifted to drive the road wheels of the rig, to move the rig 16 from site to site. The transmission 20 can also be shifted so that the engine 18 drives a winch or draw works 22. The transmission 20 also has a neutral position.
A winch cable 24 extends from the winch over the top of a derrick 26 and then down to a hook 32 mounted on sheaves. An elevator cylinder 28 is provided on the rig 16 to erect the derrick 26 over the well 12. A platform 30 is provided on the derrick 26 sufficiently above the ground to allow well pipe segments 14 to be pulled out of the well 12 and positioned along side the derrick 26. An operator's control panel 34 is provided at the back of the rig 16 adjacent to the derrick 26 to control winching operations.
In Southern California and in other areas, certain oil wells have electric power available to them or nearby, whereas other remote wells have no readily feasible source of electric power available. Where, as shown in FIG. 1, electric power is available near by to the well 12, for example, through power lines 76, the present invention finds application. Specifically, the well servicing rig 16 is driven to the well 12 powered by the engine 18, in the usual way. The derrick 26 is also erected using standard practices. However, since electric power is available at the well site 10, it has now been realized that well servicing operations can be performed with electric power, thereby dramatically reducing noise and emissions in contrast to diesel or gasoline engine power.
An auxiliary truck 60 has an electric motor 62 attached to a torque converter or transmission 64. The auxiliary truck 60 is maneuvered into position along side the winch 22 on the well servicing rig 16, as shown in FIG. 1. The electric motor 62 is connected to the source of electric power at the well site 10, for example, by a power cable 72 leading to a junction box 74 on a fence, field office or other structure linked to a power line 76.
Turning to FIGS. 2 and 3, the standard well servicing rigs 16 generally have a winch 22 with a winch drive housing 36 at one side. A cover plate 38 covers the winch drive housing 36. Within the winch drive housing 36 are drive sprockets 40 and driven sprockets 42 linked by roller chains 44. The drive sprockets 40 are ordinarily mechanically linked to the rig transmission 20. The driven sprockets 42 are linked to the winch drum for pulling in or letting out the winch cable 24. A hub 46 typically extends from the driven sprockets 42.
To mechanically connect the output shaft 58 driven by the electric motor 62 on the auxiliary truck 60, preferably a spacer 48 and coupler 52 are attached to the hub 46 by a nut 50. A drive shaft 54 having quick disconnect U-joints 56 at each end attaches to the coupler 52 on the well servicing rig 16 and to the output shaft 58 on the auxiliary truck 60. Suitable quick disconnect U-joints 56 are available from Twin Disk, Inc., Racine, Wis. and connect and disconnect via a single bolt. The U-joints allow for substantial misalignment between the driven sprockets 42 on the well servicing rig 16 and the output shaft 58 on the auxiliary truck 60. Of course, other mechanical linkage designs are available.
Referring once again to FIG. 1, with the electric motor 62 on the auxiliary truck 60 connected to the driven sprockets 42 by the drive shaft 54, the internal combustion engine 18 on the rig 16 need not be operated for well servicing operations. The mechanical linkage between the rig engine 18 and winch 22 is disconnected e.g., by shifting the rig transmission 20 into neutral, so that all mechanical power to the rig 16 is provided by the auxiliary truck 60. Electric hook up cables 68 and hydraulic lines 70 are also connected between the auxiliary truck 60 and the rig 16 to provide both hydraulic and electric power to the rig 16, via the electric motor 62 (as well as auxiliary hydraulic pumps) on the auxiliary truck 60, since the well servicing rig 16 itself has no operating power source. A control cable 66 is connected from the control panel 34 to the auxiliary truck 60 so that the electric motor 62 can be controlled during servicing operations in place of the rig engine 18. The control cable 66 may also be linked from the auxiliary truck 60 to an alternate control junction point on the rig 16.
When well servicing operations have been completed (using electric power) the power cable 72, hydraulic line 70, electric hook up cable 68, control cable 66 and drive shaft 54 including the U-joints 56 are disconnected and stored on the auxiliary truck 60. The auxiliary truck 60 can then move to link up with another rig at another well site having electric power. The well servicing rig 16 can be used with conventional diesel power when electric power is not available. The interconnections between the auxiliary truck 60, the well servicing rig 16 and the electric power source, such as the junction box 74 can be quickly connected and disconnected with a minimum of labor. The motor 62 preferably runs on 480 volt three phase power, to reduce current requirements. A compressed air starter may be provided for electric motor starting operations. Of course, various electric motor designs can be used. In addition, the electric motor 62 can also be on a trailer, a sled, etc., and need not be on a vehicle.
Thus, while a single embodiment has been shown and described, it will be apparent to those skilled in the art that many modifications may be made thereunto without departing from the spirit and the scope of the present invention.
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An electrically powered oil well pipe extractor includes a standard well servicing rig having a winch driven by a combustion engine. An auxiliary vehicle has an electric motor connected through a transmission or torque convertor, through a drive shaft, to the winch on the well servicing rig. The combustion engine is disengaged from the winch and the winch is driven by the electric motor on the auxiliary vehicle during pipe extraction operations at a well site having electric power available. Exhaust emissions and noise are significantly reduced.
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[0001] This application claims priority to Provisional U.S. Patent Application Ser. No. 61/735,414, filed Dec. 10, 2012.
FIELD OF THE INVENTION
[0002] The present invention provides a system for allowing an individual to actively manage, oversee, direct and interact regarding their healthcare. At present, the principal participants managing, overseeing and directing patient healthcare are healthcare providers and insurance companies, thus leaving out the individual with the greatest interest and the only participant whose only motive is to avoid the need for healthcare and/or to get better as expeditiously as possible. In particular, the present invention provides a personal communication device (a “PCD”) and system whereby individuals can actively manage, oversee and direct their healthcare by way of the continuous input and exchange of updated information from the individual, healthcare providers and other stakeholders. The device and system of the present invention provides access to the patient's health history and personal electronic health record (“PHR”), patient symptoms and other relevant facts such as personal history and tendencies, other information and services, and analysis of same, all with the ability for real time analysis to provide both non-critical preventative recommendations and resources and critical recommendations and resources when necessary or recommendable. The device and system of the present invention compiles a database of PHR information to enable caregivers across a continuum of the healthcare process, from pre-admission, during admission, and post-admission, to provide more effective and comprehensive care with full patient and/or patient representative monitoring. The present invention also provides a device and system whereby the individual's PHR is selectively and securely inputted and shared with others, such as, for example, healthcare providers, laboratories, insurance companies, public health officials and compared with databases of stored information, and the information returned is used by the individual, together with others, to maximize management of the individual's healthcare and provide for efficient management of public health emergencies. The clinical integration associated with the device and system of the present invention helps prevent errors that would otherwise occur from the absence of such integration.
BACKGROUND
[0003] The expansion and availability of computing power, particularly in connection with PCD's and the internet, the advent of user interfaces and social media and the ease of access to reliable information via the internet, have resulted in individuals being capable of and demanding a more active role in their healthcare in connection with healthcare decisions heretofore reserved for health care professionals and insurance company stakeholders. Recent studies have concluded that involving patients as qualified partners in co-producing health care is a positive development that health care provider services need to embrace.
[0004] To date, the principal stakeholders with decision-making authority and power over a patient's healthcare are the physician, the hospital and the insurance company. While those stakeholders have patient wellness as a material goal, those stakeholders also necessarily subject to business, market and regulatory forces. The only participant whose single-minded motivation is to get well as expeditiously as possible is the patient and until now, patients have only had a limited and indirect ability to manage, oversee and direct their own health care decisions. The present invention provides the means and “artificial intelligence” necessary to raise the individual's “medical IQ” such that they are capable of more material input and oversight into their care at levels that were heretofore impossible unless the patient was also a physician in the particular area of the illness.
[0005] While advances in electronic healthcare records have brought marked improvements to the efficient transfer of medical information amongst multiple healthcare providers, simply granting the patient access to those records does not inherently empower the patient to take an active role in their own healthcare or even improve healthcare. Rather it is vital to build a database of electronic healthcare records over time in order to supply caregivers across a continuum of healthcare provision of services with information sufficient for providing more effective care. Caregivers and medical experts need to be able to understand the information regardless of its language or formatting or coding. The information needs to be easily transportable across geographic boundaries in an effort to clinically integrate different care providers while maintaining full regulatory compliance.
[0006] Recent technological advances such as greater access to computing power, reliable information and knowledge (in part because of increasing use and availability of technology, social media and social changes), experience with self-management programs and new legal requirements for patient involvement have all contributed to creating a new dynamic through which patients and citizens are redefining their roles as informed consumers in relation to health and social care. For example, rendering the individual capable of determining the relative merit, advisability and implications of proposed tests and procedures.
[0007] For example, individuals, particularly those living with a health condition, or those who desire to prevent health conditions and to take an active role in maintaining their own health, track data including for example, data relating to allergies and adverse drug reactions, chronic diseases, family and personal medical history, illnesses and hospitalizations, imaging reports (such as, for example, X-rays, CT scans, MRI and the like), laboratory test results, medications and dosing, prescription records, surgeries and other procedures, vaccinations, observations of daily living (ODLs), and the like. Such a wealth of information is important in the management of the individual's healthcare and can be useful to others who may not be familiar with the individual, or their past health history, such as, for example, the individual's attending physician at a hospital. However, such information frequently does not get shared with others, may be overlooked, or may be stored in a manner that is not easily accessible, either by the individual or others, leading to incorrect diagnosis and treatment. Preventing this incorrect diagnosis and treatment therefore remains a vital goal, one that can be accomplished through increased clinical integration. Sharing patient information through virtual transportation of information with a patient can serve to satisfy the clinical integration aim while allowing the patient to monitor the completeness and security of such information.
[0008] Individuals are able to utilize the internet to consult with healthcare professionals (such as, for example, via the service disclosed in the website www.mdlivecare.com, offered under the trademark MDLIVE™, or via the service disclosed in the website www.hellohealth.com, offered under the trademark HELLOHEALTH®). Individuals are also able merge their health records (either manually or by logging into their accounts at partnered health services providers) into a centralized health profile, by using, for example, the service formally offered at and disclosed by GOOGLEHEALTH™.
[0009] However, the principal participants with decision-making power over a patient's healthcare are and have been the health care providers, hospitals and insurance companies. While all such participants ostensibly have patient wellness as a material goal, all participants are also necessarily subject to business, market and regulatory forces. For example, both the hospital and insurance company can only continue to provide their valuable services if they maintain profitability and stay in business. Physicians have malpractice considerations as well as being personally remunerated based on the number of procedures performed. The only participant whose single pure motivation is to get well as expeditiously as possible is the patient and until now, only had the ability to manage, oversee and direct their own health care decisions with limited ability. Even new technologies tend to leave out this all important participant.
[0010] For example, U.S. Pat. No. 7,953,699 titled, SYSTEM FOR THE PROCESSING OF INFORMATION BETWEEN REMOTELY LOCATED HEALTHCARE ENTITIES which issued May 31, 2011 discloses “systems and methods for reconciling healthcare data between multiple distributed computing nodes that enable an individual node, a topic object, or an intelligent agent to determine synchronization with other nodes, comprising sending source node data to a payload generator, the source node data including difference data, an encapsulated topic object, or intelligent agent communications, generating a payload including the source node data and destination attributes, and sending the payload to a destination node, topic object, or destination intelligent agent, and using the source node data to update destination node data according to destination node, topic object, or destination intelligent agent requirements.
[0011] In another example, U.S. Pat. No. 7,885,822 titled, SYSTEM AND METHOD FOR ELECTRONIC MEDICAL FILE MANAGEMENT which issued Feb. 8, 2011 discloses, “a system for transferring electronic medical files is provided, such as for providing for patient file integrity and continuity in a telemedicine system. The system includes a record server that has a medical record data file for each patient, wherein each patient's medical record data file holds medical record data for that patient. A record client coupled to the record server receives the medical record data file. The medical record data is encapsulated to prevent modification of the medical record data, thus providing for integrity and continuity of the patient's medical record.”
[0012] In another example, U.S. Application No. 2012/0101849 titled VIRTUAL CARE TEAM RECORD FOR TRACKING PATIENT DATA, which published Apr. 26, 2012 discloses, “a system and method for managing healthcare information is disclosed. The data servers each include a data manager that comprises a controller, applications, an application manager, a virtual care team module, and a user interface engine. The controller manages the core functions and the transmission of data between data manager components. The applications are applications that are created by the user or downloaded as third-party applications. The application manager manages the creation and communication between applications. The virtual care team module manages the transmission of patient data between data servers. The user interface engine generates user interfaces for displaying the applications and collecting clinical trial data.”
[0013] There are also patents that assist healthcare providers in making more efficient diagnoses and decisions. For example, U.S. Pat. No. 8,548,827 titled COMPUTER-IMPLEMENTED METHOD FOR MEDICAL DIAGNOSIS SUPPORT, issued Oct. 1, 2013 discloses, “a computer-implemented method for medical diagnosis support for patient data of a patient through a data processing system, Wherein the data processing system comprises a graphical user interface and a database contain ing rules for calculating diagnosis risks.”
[0014] In another example, a disclosure at ISABELHEALTHCARE.COM discloses, “Accessed directly or fully integrated with an EMR system, the web-based Isabel tool uses the patient's demographics and clinical features to produce a list of possible diagnoses, including time-sensitive ‘Don't Miss Diagnoses.’ The tool integrates knowledge resources from leading publishers, together with local resources, to form a unique and practical knowledge organizer”
[0015] In another example, U.S. Pat. No. 7,379,885, titled SYSTEM AND METHOD FOR OBTAINING, PROCESSING AND EVALUATING PATIENT INFORMATION FOR DIAGNOSING DISEASE AND SELECTING TREATMENT, issued May 27, 2009 discloses, “A computer-based system and method which constructs medical histories by direct interactions between the patient and system that acquires pertinent and relevant medical information covering the complete life of a given patient. The system and method insure that a complete life long medical history is acquired from every patient interacting with the health care system. Once acquired, the facts of the patient's life long and family medical history are analyzed automatically by databases to generate a set of the most reasonable diagnostic possibilities (the differential diagnosis) for each medical problem identified and for each risk factor for disease that is uncovered in the historical database. Further, the automatically analyzed database of historical medical information is used as the search tool for bringing to bear, on the diagnosis and treatment of each medical problem identified in each patient, the entirety of medical knowledge that relates to and can be useful for the correct and efficient diagnosis and treatment of each of every patient's medical problems. This collection of information is analyzed to generate a final diagnosis and treatment regimen.”
[0016] There remains, therefore an unmet need for a device and system that allows an individual to actively manage, oversee and direct their healthcare, and that allows an individual to selectively and securely share and discuss their personal health records with others, such as, for example, healthcare providers, in a manner that educates and empowers the individual to manage their healthcare and enhances prevention, diagnosis, treatment and prognosis, all increasing overall health. The present invention also allows an individual to access and share all information relevant to their healthcare and consequently provide better information to health care providers and make a more informed decision, based on all facts and patient desires. The present invention also provides public health officials an efficient mechanism to learn of and manage public health concerns and emergencies.
SUMMARY
[0017] The present invention provides a solution to the unmet need, by providing a system that allows an individual to manage, oversee and direct their healthcare comprising a patient interface and an at least one node selected from the group consisting of:
a) an at least one patient healthcare record database; b) an at least one healthcare facility database; c) an at least one patient individual complaint database; d) an at least one billing database; e) an at least one other user interface; f) access to healthcare facility services; and g) access to the internet;
wherein the patient interface provides: (i) access to the at least one selected node; and (ii) continuous analysis based on the individual's input to all of the foregoing to provide output of likely critical and non-critical information to consider in formulating a diagnosis, plan of treatment, or other healthcare or personal decisions.
[0026] In one embodiment, the patient interface is an application on a personal communication device.
[0027] Each of the elements of the system of the present invention can be thought of as nodes. For example, the patient interface is the central node connecting with and interacting with each other node. Other nodes include hospital services, including for example, dining options, television options, nurse's station and the like; the healthcare facility database, including for example, the hospitals records such as billing, patient history within that hospital, complete patient history, patient family history, medical library database and the like; the patient complaint database including for example the patient's specific itemized illness, where it hurts, pain score, and the like; the patient healthcare record database including for example, the patient's electronic health records history, family medical history, personal tendencies and the like; and the internet.
[0028] In one embodiment, the patient healthcare record database contains files and an engine such that the files may be translated into different languages, formatting and health codes.
[0029] In one embodiment, the individual utilizes the patient interface to access information stored in any node.
[0030] In one embodiment, the individual has read only access to one, or more than one of the databases accessed via the system of the present invention.
[0031] In one embodiment, the individual has read and write access to one, or more than one of the databases accessed via the system of the present invention. In one embodiment, the individual has read and write access to the at least one individual complaint database only. In one embodiment, read-write access to the at least one healthcare records database requires a verification step, prior to any change to the information stored therein. In one embodiment, only the individual's healthcare provider may make changes to the information stored in the at least one healthcare records database.
[0032] In one embodiment, the individual utilizes the patient interface to communicate with and to access communications with the individual's healthcare providers.
[0033] In one embodiment, the individual utilizes the patient interface to access information stored in any of the connected databases and/or the internet, including databases in geographic locations different from that of the individual and databases with information stored years in advance of the present year.
[0034] In one embodiment, the individual utilizes the patient interface to access and request hospital services, for example to call the nurse or order dinner.
[0035] In one embodiment, the patient interface is able to access all available features, such as, for example, entertainment services (for example, TV, radio and the like), communications (telephone, email, for example), a call button, order food, update their social media allowing selected others to view their current condition, or receive messages or gifts from others.
[0036] In one embodiment, the individual utilizes the patient interface to access and evaluate different forms of medication utilized over varying periods of time, medication interactions, expected efficacy and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 depicts a representation of the home screen of a PCD capable of allowing access to one embodiment of the present invention. Specifically, and not by way of limitation, an APPLE® IPHONE® screen is depicted with an icon for accessing the downloaded application.
[0038] FIG. 2 depicts a representation of a next screen of the PCD prompting the user to either register or login.
[0039] FIG. 3 depicts a representation of a next screen of the PCD prompting the user to login under the assumption that they have already registered, with an option for the application to remember the user on this PCD.
[0040] FIG. 4 depicts a representation of a screen of the PCD that represents a patient interface portal screen allowing access to the various patient specific databases and action entry screens.
[0041] FIG. 5 depicts a representation of one of many next screens of the PCD depending on menu navigation, specifically in this instance, and again not by way of limitation, a “my history” screen, allowing the patient to access his historical conditions, his medical charts, his pain score, his entry of a new complaint, his bio and his family history with access to immediate request for help.
[0042] FIG. 6 depicts a representation of another of one of many next screens of the PCD depending on menu navigation, specifically in this instance, and again not by way of limitation, a “my schedule screen”, allowing the patient to access his schedule for the day, the week, the month, the year, his schedule of medications and scheduled doctor visits again with access to immediate request for help.
[0043] FIG. 7 shows another graphical representation of one embodiment of the system of the present invention. The individual components of the system are shown in black boxes detailing the availability of certain databases to certain access point users.
[0044] FIG. 8 shows a graphical representation of one embodiment of the system of the present invention. The individual components of the system are shown in black boxes. Examples of the features and/or information that are stored or available in the individual components are shown in grey.
[0045] FIG. 9 shows a graphical representation of one process by which an individual gains access to the system of the present invention and populates the system of the present information with information.
[0046] FIG. 10 shows a graphical representation of one possible mechanism by with the system of the present invention may be utilized.
[0047] FIG. 11 shows a graphical representation of one process by which an individual and his/her healthcare providers receive new information relating to the individual's pre-existing condition, based on the information the individual enters into the system of the present invention.
[0048] FIG. 12 shows a graphical representation of one process by which the system of the present invention may be utilized following an adverse reaction to the treatment an individual is receiving.
[0049] FIG. 13 shows another graphical representation of how the system of the present invention may be utilized.
DETAILED DESCRIPTION
[0050] For clarity of disclosure, and not by way of limitation, the detailed description of the invention is divided into the following subsections that describe or illustrate certain features, embodiments or applications of the present invention.
Definitions
[0051] “Electronic medical record”, or “EMR”, or “electronic health record”, or “EHR” as used herein refers to a computerized record, or any portion thereof, of the documentation of a patient's medical record.
[0052] “Healthcare provider” or “healthcare facility” as used herein means an organization, entity, or individual, such as, for example, a hospital, clinical laboratory, physician, physical therapist, outpatient service provider, home health care provider, insurance company, and the like, that provides any treatment or services related to the treatment of an individual.
[0053] The term “healthcare record” or “medical record” as used herein refers to the documentation of the body of information, or any portion thereof, that comprises a patient's individual medical history and care, including, but not limited to information sufficient to identify the patient, information on medical encounters, orders and prescriptions, history of the present illness/complaint, previous illnesses, diagnoses, prognoses, physical examinations, x-rays, lab test results, digital images of the patient, informed consent forms, insurance information, billing records, patient tendencies and the like.
[0054] “PHR” as used herein refers to an individual's personal health record.
[0055] “PHR records database” as used herein refers to an organized collection of personal health records.
The System of the Present Invention
[0056] In one embodiment the present invention provides a system that allows an individual to manage, oversee and direct their healthcare comprising a patient interface and at least one node selected from the group consisting of:
a) an at least one patient healthcare record database; b) an at least one healthcare facility database; c) an at least one patient individual complaint database; d) an at least one billing database; e) an at least one other user interface; f) access to hospital services; and g) access to the internet;
wherein the patient interface provides: (i) access to the at least one selected node; and (ii) continuous analysis based on the individual's input to all of the foregoing to provide output of likely critical and non-critical information to consider in formulating a diagnosis, plan of treatment, or other healthcare or personal decisions.
[0065] In one embodiment, the system of the present invention is used to generate a Continuity of Care Record (CCR). A CCR is a flexible document that contains the most relevant and timely core health information about an individual. The system of the present invention may send the CCR from one caregiver to another. The CCR may contain various sections such as patient demographics, insurance information, diagnoses and problem list, medications, allergies and care plan. These represent a “snapshot” of a patient's historical and current health data that can be useful or possibly lifesaving, if available at the time of clinical encounter.
[0066] In one embodiment, the system of the present invention enables individuals and their families or other third parties, where authorized, to become engaged in the individual's healthcare. Authorized third parties may be necessary in instances where the individual does not, or cannot accurately or adequately communicate or describe their problems and needs. Such instances may include, for examples, an inability to communicate due to illness, disability, an inability to speak the language, and the like.
[0067] In one embodiment, the system of the present invention improves the quality, safety and efficiency of an individual's healthcare and reduces disparities. The system of the present invention improves the coordination of an individual's care amongst their numerous healthcare providers. The system of the present invention allows for information about an individual and care of the individual to be seamlessly communicated amongst healthcare providers in different geographic locations. The system of the present invention improves the overall public health. The system of the present invention allows for evaluation of medication provided in the present, near past and distant past. The system of the present invention makes information capable of understanding from an elementary level of comprehension through a medical expert. The system of the present invention can translate the information into any language and decipher all recognized health records formatting and coding. The system of the present invention maintains the privacy and security of health information. Only certain authorized users can grant access to various levels of information contained within the various nodes.
[0068] In one embodiment, the system of the present invention allows the individual to access and modify information across multiple visits or treatments. The system of the present invention allows the comparison and merging of data with proper analysis and information output (such as, for example, insurance eligibility, claims, drug-drug interactions and the like). The system of the present invention enables the individual, or others to analyze the data for decision support (such as, for example, the treatment's effectiveness, risks, side effects, likely time to heal, likely prognosis, pain, etc., by condition and severity of condition, and the like).
[0069] In one embodiment, the individual is able to select their preferred language. The individual may also summon medical assistance. In one embodiment, the individual is able to select the urgency by which the individual desires assistance.
[0070] In one embodiment, the individual may communicate with others, such as, for example, healthcare professionals, family members, and the like. In one embodiment, the communication is electronic, by any suitable medium, such as, for example, email, telephone, video, and the like.
[0071] In one embodiment, the individual may enter and/or review at least one category of information selected from the group consisting of: Pain score, room temperature, mood, food/dietary need, schedules, checklists, the individual's care team, healthcare records, medications, tests, test results, emails, educational materials, care plan(s), discharge plan(s), and community care plan(s).
[0072] In one embodiment, the structure of the present invention is based on a client-server model, with the patient-side device operating as a client, and a computer or a series of computers elsewhere in the medical facility operating as the server.
[0073] Alternatively, the server, or any one or more node(s) of the server, could be located in the cloud.
[0074] In one embodiment, the patient interface is on a personal communication device “PCD”. In one embodiment, the PCD may take the form of a laptop, a tablet computer, a smart phone, or any other technology suitable as a function of its size to be located next to a hospital bed. There may be many PCD's capable of operating as a client. For example, one PCD may be operated by a physician. One PCD may be operated by a lab technician. One PCD may be operated by a friend or family member.
[0075] On the server side, multiple redundancies and administrative safeguards will ensure data storage integrity.
[0076] In one embodiment, the PCD will connect to the server via the Internet and to a health care provider's internal network (“LAN”) via a wireless connection protected by WPA2-Enterprise (802.11x) with strong 256-bit AES encryption or other suitable data secure technology. This level of network security ensures health record privacy and conforms to CFR Title 45, Part 164.312. The network will employ multiple redundant wireless access points to prevent network failure and protect the patient's (or other PCD user's) login session. This type of connection has an “always up” capability by ensuring that even if access to the public internet is down in case of an outage or an emergency, the patient can locate and review his or her locally-stored medical records, and access other functions of the present invention, such as the applications and the complaint database or other locally accessible databases.
[0077] In one embodiment, after the user is authenticated and logged in, the session is protected by automatic logoff, which is required by HIPAA (see CFR Title 45, Part 164.312). Either the client-side software or the wireless LAN or both will initiate automatic logoff to disconnect a user after a pre-configured period of time of inactivity.
[0078] In one embodiment, the PCD will contain the “front end” of each application—i.e. its graphical user interface portion which allows for display and for input from the patient or other PCD user, with the data stored and accessed on the server by the PCD user at that particular PCD user's level of accessibility. This will ensure data integrity in case of destruction or disablement of the PCD, or the need to simply borrow access from someone else's PCD. In that eventuality, a brand new PCD can simply be swapped in for the destroyed or disabled PCD, with no data loss, i.e., the proper login credentials will allow access to the corresponding level of database access. For example, the patient PCD login credentials will allow full access to all patient databases except those requiring professional license such as entering prescriptions and lab orders. An allowed physician PCD login credentials will allow access to all pertinent patient complaint and diagnosis and test result databases applicable to the complaint that that physician is responsible for treating. An allowed friend PCD login credentials may only allow access to certain “current patient status” databases. The patient determines the level of accessibility of all other PCD users with respect to his applicable databases. Further, since an individual PCD never stores any health records of a patient, these records cannot be compromised as a result of unauthorized access to the PCD by a third party.
[0079] FIG. 8 shows a graphical representation of one embodiment of the system of the present invention. The individual components of the system are shown in black boxes. Examples of the features and/or information that are stored or available in the individual components are shown in grey. Central to the embodiment shown, is the patient interface, where an individual may receive and/or transmit information to or from the other components of the system. What is not shown, but can be readily appreciated by one of ordinary skill in the art, is the ability of information to be transmitted and/or received to or from any individual component of the system to any other. Such information exchange may be via the patient interface. Alternatively, the information exchange may not be via the patient interface.
[0080] The system of the present invention may be applied to any setting (such as, for example, a hospital, a long term care facility, a doctor's office, an individual's home or work place, and the like) and once information is entered, the system will always be updated to include in past history during the next setting visit. The choice of settings can be readily selected by one of ordinary skill in the art. Furthermore, the features and/or information that are stored or available in the individual components may be tailored specifically for any given setting, and the selection of features and/or information can be readily determined by one of ordinary skill in the art.
[0081] For example, in one embodiment, an individual may utilize the system of the present invention outside of a healthcare setting, and update information stored within the system, either regularly, or upon completion of a step, such as, for example, a vaccination, routine physical, enrollment in a support group, and the like. In one embodiment, the system of the present invention generates a CCR, containing the information entered by the individual, and sends the CCR to the individual's healthcare professionals. The CCR may be sent to one, or more than one of the individual's healthcare professionals.
[0082] In another example, an individual may utilize the system of the present invention in a public health emergency. Public health emergencies may include, for example, incidents of flooding, severe weather, disease outbreaks, anomalous pockets of health related activity, and the like.
[0083] In one embodiment, system of the present invention may alert the individual to a potential public health emergency, and provide relevant information to the individual and/or the individual's healthcare professionals, based in information pertaining to the individual that is stored and/or accessed on or by the system of the present invention. In an alternate embodiment, the individual may utilize the system of the present invention to search for information manually.
[0084] In an alternate embodiment, the present invention collects and assembles the health information from more than one individual and performs analysis on all the health information stored on the system. In one embodiment, the system of the present invention collects one individual's health information in real-time and compares the information with the health information of other individuals. In one embodiment, the comparison of the one individual's health information with the health information of other individuals provides real-time preventative and/or predictive analysis of public health emergencies. In one embodiment, the system of the present provides alerts, based on the comparison of the one individual's health information with the health information of other individuals. Depending on the nature of the public health emergency, the alert may be sent to the one individual, the other individuals, the local healthcare authorities, national healthcare authorities, or any combination thereof.
[0085] In one embodiment, in addition to the comparison of the one individual's health information with the health information of other individuals, the system of the present invention analyses the health information of the individual and the health information of other individuals statistically. In one embodiment, the statistical analysis provides additional accuracy to predicting public health emergencies.
[0086] In one embodiment, pharmaceutical companies may utilize the system of the present invention to predict supplies of drugs, vaccines, medical supplies, and the like.
[0087] It can be readily appreciated that the system of the present invention accesses information from multiple disparate sources, wherein the disparate sources may utilize different database architecture and/or languages. Issues with combining heterogeneous data sources under a single query interface have existed for some time. The rapid adoption of databases has led to the need to share or to merge existing repositories. This merging can take place at several levels in the database architecture.
[0088] For example, one solution involves data warehousing. In data warehousing, a warehouse system extracts, transforms, and loads data from heterogeneous sources into a single common queriable schema so data becomes compatible with each other. This approach offers a tightly coupled architecture because the data is already physically reconciled in a single repository at query-time. However, problems arise with the “freshness” of data, which means information in the warehouse is not always up-to-date. Combining heterogeneous data sources efficiently and accurately is essential, for example, to prevent loss of data, and to minimize cost.
[0089] In one embodiment, the system of the present invention provides continuity of information amongst the various sources of information by utilizing a service or software that facilitates the ubiquitous transfer of information, such as, for example, the service and software available under the tradename ION®.
[0090] While one of ordinary skill in the art can appreciate the many embodiments of the system of the present invention; for clarity, operation of the system of the present invention is described in detail below using the example of an individual managing, overseeing and directing their healthcare in a hospital setting.
The Patient Interface
[0091] In one embodiment, the patient interface is a graphical user interface “GUI” by which the individual is able to utilize the system of the present invention. One of ordinary skill in the art can readily appreciate and construct a suitable GUI by which the individual may utilize the system of the present invention. The patient interface can access one, or more than one, or all of the other components of the present invention. The access may be unidirectional, either to or from the other component(s), or bidirectional, or any combination of the foregoing, with varying levels of security levels and protocols.
[0092] In one embodiment, the GUI is a touchscreen with multiple levels of menu choices whereby the patient chooses to access certain databases and/or services and/or the internet and within the same screen is provided the output requested by touching the requested menu choice.
[0093] In one embodiment, the GUI is activated with voice commands.
[0094] In one embodiment, the GUI may require input at certain intervals or, failing such input, report a possible emergency condition for response by emergency response team.
[0095] In one embodiment, the patient interface controls access to the system of the present invention. In one embodiment, the individual may only access the system of the present invention after the individual's identity has been verified. Verification may be via any suitable mechanism, such as, for example, entry of the individual's social security number, entry of a unique code, fingerprint verification and the like.
[0096] In one embodiment, the individual access and edits information stored on the system of the present invention via the patient interface. The individual may be the individual receiving treatment, a family member of the individual receiving treatment, a person designated by the individual, or any combination thereof.
[0097] In one embodiment, once the individual has been granted access to the system of the present invention, the individual has access to all the information and/or features of the system of the present invention.
[0098] In an alternate embodiment, the degree of access the individual has to the system of the present invention may be restricted. For example, the individual may only be granted access to a subset of the information and/or features of the system of the present invention. In one embodiment, the individual requires a subscription to access to all, or subsets of the information and/or features of the system of the present invention. In an alternate embodiment, the individual may select the features and/or information to which they desire access.
[0099] In certain embodiments, the ability of the individual to edit information contained within one, or more than one databases of the present information may be restricted. Such restriction may be necessary to maintain the integrity and/or security of the particular database(s) in question. For example, in one embodiment, the individual may access and search the health records that are maintained by the individual's healthcare provider(s) and healthcare facility in the at least one healthcare records database of the present invention. However, the ability of the individual to edit their healthcare records is prohibited.
[0100] In one embodiment, the individual may only enter, store and/or edit information in the at least one individual complaint database of the present invention, via the patient interface. The information entered, stored or edited in the at least one individual complaint database may be used to edit information stored in other components of the system of the present invention. In one embodiment, the information entered, stored or edited in the at least one individual complaint database may be used to edit information stored in other components of the system of the present invention only after being reviewed by a healthcare professional. In one embodiment, the healthcare professional manually edits the information stored in other components of the system of the present invention.
[0101] In one embodiment, the individual can access other features, such as, for example, communication services (email, telephone and the like), entertainment (for example, TV, radio, social media and the like). Access to other features may be unlimited, or, alternatively, restricted, requiring a subscription, for example.
[0102] In one embodiment, the patient interface further includes a call button, or other suitable mechanisms by which the individual may summon assistance, such as, for example, from a healthcare provider.
[0103] In one embodiment, the patient interface allows the individual to interact with a family member or other third party. In the case where a family member or other third party is able to interact with the system of the present invention, a separate login may be required.
[0104] In one embodiment, a healthcare professional is able to enter, store and/or edit information via the patient interface. In the case where a healthcare professional is able to enter, store and/or edit information via the patient interface, a separate login may be required.
[0105] In one embodiment, the patient interface may be in the patient's bed, such as for example, included as part of the hospital bed with nurse call system interface disclosed in U.S. patent application Ser. No. 13/356,906.
[0106] In an alternate embodiment, the patient interface may be a web-based application. Alternatively, the patient interface may be on a hand-held device, such as, for example, a smart phone or tablet.
[0107] FIG. 9 depicts one possible mechanism by with the system of the present invention may be utilized. The individual logs into the system of the present invention by entering the requested verification information via the patient interface. The system of the present invention creates an at least one individual complaint database that is specific to the individual and is linked to the individual's patient interface. The system of the present invention then populates the at least one individual complaint database with information. The population of the at least one individual complaint database may be automatic, or, require input from the individual, the individual's healthcare provider, or any combination thereof
[0108] In the example depicted in FIG. 9 , the system of the present invention prompts the individual to upload their personal health records via the patient interface. In one embodiment, the individual utilizes the patient interface to search for their personal health records. The individual may upload all or, alternatively a subset of their personal health records. The individual may also use the patient interface to highlight of flag portions of their personal health records. In instances where portions of the personal health records are flagged, the flags may serve to indicate items that the individual feels relevant to their complaint, or, alternatively, items which the individual may wish to discuss with others.
[0109] In the example depicted in FIG. 9 , the system of the present invention prompts the individual to enter information sufficient to identify others whom the individual desires to play a role in the individual's healthcare via the patient interface. Such information may include, for example, the individual's living will or advanced healthcare directive. Alternatively, the information may include the names and contact information of the individual's relatives, legal guardians, and the like. The individual may restrict or modify degree of access that any of the other persons that the individual designates to the system of the present invention using the patient interface.
[0110] In the example depicted in FIG. 9 , the system of the present invention populates the at least one individual complaint database with information from the individual's healthcare records. The system of the present invention preserves information from the individual's healthcare records for future access by caregivers or other individuals. The system of the present invention prompts the individual to verify and/or correct the information via the user interface. The system of the present invention may generate an alert if the individual verifies and/or corrects the information. Any or all nodes may be continuously updated with information, not just in connection with specific patient information, but also with general knowledge and advances in the field of medicine generally such that the most up to date clinical integration is possible of all nodes at any given point in time.
[0111] In the example depicted in FIG. 9 , the system of the present invention prompts the individual to answer questions via the patient interface. The questions may be, for example, questions relating to the individual's health, symptoms, appetite, lifestyle, hobbies, sports and the like. The answers to the questions are then stored in the at least one individual complaint database.
[0112] In one embodiment, at least one other user is able to utilize the system of the present invention. Such at least one other user may include, for example, the individual's health care provider. The at least one other user may utilize the system of the present invention via the patient interface. Alternatively, the at least one other user may utilize the system of the present invention via an at least one other user interface. In one embodiment, the at least one other user interface is on a PCD.
[0113] In one embodiment, the at least one other user interface is a graphical user interface “GUI” by which the at least one other user is able to utilize the system of the present invention. One of ordinary skill in the art can readily appreciate and construct a suitable GUI by which the at least one other user may utilize the system of the present invention. The at least one other user interface can access one, or more than one, or all of the other components of the present invention. The access may be unidirectional, either to or from the other component(s), or bidirectional, or any combination of the foregoing, with varying levels of security levels and protocols.
The Individual Complaint Database
[0114] In one embodiment, individual is able to enter information freely into the at least one individual complaint database. In alternate embodiment, the individual enters information in the form of answers to specific questions. The patient's attending physician may ask the questions. Alternatively, the questions may be pre-written questions.
[0115] In one embodiment, the information entered by the individual is stored on the at least one individual complaint database. In one embodiment, the information stored on the at least one individual complaint database is used by the system of the present invention to search for information. The system of the present invention may search one, or more than one, or all of the components of the present invention. Similarly, the at least one individual complaint database may be accessed by one, more than one, or all of the other components of the system of the present invention.
[0116] In one embodiment, the system of the present invention searches the patient's healthcare record for information. The parameters of the search may be based on the information stored on the at least one individual complaint database. Alternatively, the parameters of the search may be set by the individual, or, alternatively, the patient's medical advisers, such as for example, an individual's healthcare professional (such as, for example, the individual's attending physician) or any other appropriately trained person with access to the individual's information on the system of the present invention or alternatively or cumulatively, a family member or other loved one or independent consultant.
[0117] The information that is stored on the at least one individual complaint database may be the symptoms the individual is experiencing. Alternatively, the information may be the individual's prior or pre-existing medical conditions. Alternatively, the information may be questions that the individual has regarding their treatment or condition. Alternatively, the information may be all of the foregoing. In one embodiment, the information, combination of information or additional information generated by its analysis may generate an alert that is transmitted to a healthcare professional.
[0118] In one embodiment, the at least one individual complaint database may contain information that the individual's attending physician, or any other person with access to the individual's information on the system of the present invention has entered into the database. Such information may include, for example, articles or other reference material that the individual may wish to review, discharge instructions, test results, biometric data, prescriptions, information on the individual's complaint, support groups, common side effects, and the like.
[0119] In an alternative embodiment, the combination of at least one individual complaint database, the patient's PHR database, and other health care records databases include automated analysis means whereby articles or other reference material that the individual may wish to review, discharge instructions, test results, biometric data, prescriptions, information on the individual's complaint, support groups, common side effects, and the like are automatically generated.
[0120] In one embodiment, the individual may utilize the at least one individual complaint database to request information relating to the individuals responsible for conducting any or all tests that are being performed on the individual. The system of the present invention can search one, or more than one, or all of the components of the system of the present invention to locate the requested information and report it to the individual. The individual may then contact the individual responsible for a test directly and request further information, or, alternatively, discuss the test further.
[0121] In one embodiment, the at least one individual complaint database stores the individual's personal health records or PHR. PHR may comprise data including for example, data including for example, data relating to allergies and adverse drug reactions, chronic diseases, family history, illnesses and hospitalizations, imaging reports (such as, for example, X-rays, CT scans and the like), laboratory test results, medications and dosing, prescription records, surgeries and other procedures, vaccinations, observations of daily living (ODLs), and the like.
[0122] In one embodiment, the individual may collect PHR utilizing specialized applications. As used herein, specialized applications (“apps”) are websites, desktop applications, and mobile apps that perform at least one designated task. The individual may use one, or, alternatively more than one app.
[0123] In one embodiment, the at least one designated task is selected from the group consisting of: connecting with a healthcare provider, organization, improving fitness, community interaction, management of lab tests, management of medical records, management of medications, activities, emergency preparation, tracking health conditions, apps related to a specific condition (such as, for example, aging, diabetes, allergies, asthma, cancer, coronary disease, or mental health), and apps related to a medical device (such as, for example, blood glucose monitors, blood pressure monitors, EEG devices, or heart rate monitors).
[0124] In one embodiment, the information contained within the individual's PHR is stored electronically in a database, and is accessible by the system of the present invention. The individual may grant the system of the present invention access to all, or a subset of the information stored in the PHR database.
[0125] In one embodiment, the database of PHR's and/or the apps used are commercially available, such as, for example, the database and services offered by Microsoft Corporation, offered under the tradename HEALTHVAULT®.
[0126] In one embodiment, the individual is able to ask questions of their treating physician or other healthcare professional, including without limitation the persons responsible for performing any tests, the individual's attending physician, the individual's primary care physician, the individual's specialist physician, or any other person the individual may chose to designate. In one embodiment, the system of the present invention generates an alert once the individual asks a question.
[0127] In one embodiment, the various healthcare professionals that the individual employs are able to exchange information amongst each other using the system of the present invention. In one embodiment, the exchange of information is made in response to and/or based on the information stored in the individual complaint database. In one embodiment, the exchange of information improves the coordination of care between the various healthcare professionals that the individual employs.
[0128] In one embodiment, the individual is able to monitor the exchange of information. Such information exchange may be at the request of the individual, and may be to enhance the level of care the individual is receiving.
[0129] In one embodiment, the exchange of information is initiated by the individual's attending physician. In an alternate embodiment, the exchange of information is initiated by the individual's primary care physician. In an alternate embodiment, the exchange of information is initiated by the individual's specialist.
[0130] In one embodiment, the individual is able to access their at least one individual complaint database after the individual has been discharged from hospital, or after the individual has stopped receiving medical care for their complaint.
[0131] In one embodiment, the healthcare professionals employed by the individual are able to access the at least one individual complaint database after the individual has been discharged from hospital, or after the individual has stopped receiving medical care for their complaint. In one embodiment, the individual complaint database will continue to maintain a record of all complaints in order to allow post-admission caregivers and/or future pre-admission and during admission caregivers to view the record(s) and provide more effective, up to date, care recommendations and decisions.
[0132] In one embodiment, the information stored in the at least one individual complaint database is used to query one, or more than one of the other databases in the system of the present invention. In one embodiment, the query searches for information relevant to the individual's complaint. In one embodiment, the information relevant to the individual's complaint changes the patient's treatment. In one embodiment, the individual initiates the query.
[0133] FIG. 10 depicts one possible mechanism by with the system of the present invention may be utilized. After the individual has logged onto the system of the present invention the system of the present invention creates an at least one individual complaint database that is specific to the individual and is linked to the individual's patient interface. The system of the present invention then populates the at least one individual complaint database with information. The population of the at least one individual complaint database may be automatic, or, require input from the individual, the individual's healthcare provider, or any combination thereof.
[0134] In the example depicted in FIG. 10 , the system of the present invention prompts the individual to upload their personal health records onto the at least one individual complaint database via the patient interface. In one embodiment, the individual utilizes the patient interface to search for their personal health records. Such search may be via the internet, either to a website, or link to the individual's home computer of mobile device. Such a search is facilitated by the system of the present invention, via a dedicated internet access.
[0135] In the example depicted in FIG. 10 , the system of the present invention prompts the individual to enter information sufficient to identify others whom the individual desires to play a role in the individual's healthcare, to be stored on the individual complaint database via the patient interface. Such information may include, for example, the individual's living will or advanced healthcare directive. Alternatively, the information may include the names and contact information of the individual's relatives, legal guardians, and the like. The individual may restrict or modify degree of access that any of the other persons that the individual designates to the system of the present invention using the patient interface.
[0136] In the example depicted in FIG. 10 , the system of the present invention populates the at least one individual complaint database with information from the individual's healthcare records. The system of the present invention prompts the individual to verify and/or correct the information via the user interface. The system of the present invention may generate an alert if the individual verifies and/or corrects the information. The individual is able to review the information using the system of the present invention, and ask questions, or discuss the information, either in person, or via the system of the present invention.
[0137] In the example depicted in FIG. 10 , the system of the present invention prompts the individual to answer questions via the patient interface. The questions may be, for example, questions relating to the individual's health, symptoms, appetite, lifestyle, hobbies, sports and the like. The answers to the questions are then stored in the individual's complaint database.
[0138] In the example depicted in FIG. 10 , the individual is able to ask questions of the healthcare professionals employed by the individual. The system of the present invention is able to direct those questions to the relevant professional, based on the instructions of the individual.
[0139] In the example depicted in FIG. 10 , the at least one individual complaint database is able to access and report information stored in the at least one healthcare facility database. Such information may include, for example, the team of persons employed in the individual's healthcare, biometric data (heart rate, blood pressure and the like), medications prescribed to the individual, test results and the like. Such information may also be stored on the at least one individual complaint database. The individual is able to review the information using the system of the present invention, and ask questions, or discuss the information, either in person, or via the system of the present invention.
[0140] In the example in FIG. 10 , the information stored in the at least one individual complaint database is used to update the individual's healthcare records and/or PHR once the individual is discharged from hospital, or care for the individual complaint terminates. Such update may occur automatically, or may occur manually, via the individual's attending physician, for example. The system of the present invention generates an alert if the individual's healthcare records are updated.
[0141] The patient's healthcare records can be maintained by one or more than one of the patient's primary care physician, a specialist who is treating, or has treated the patient, a hospital, or diagnostic testing facility. In one embodiment, the healthcare records are electronic. The electronic healthcare records may be stored and managed on any system.
The Healthcare Records Database
[0142] In one embodiment, the system of the present invention provides an at least one database of the patient's healthcare records. The database may be located on one, or more than one server.
[0143] For example, in one embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20050187794A1.
[0144] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20010049610A1.
[0145] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110119481A1.
[0146] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110119729A1.
[0147] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110153364A1.
[0148] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110119089A1.
[0149] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110106564A1.
[0150] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110004491A1.
[0151] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110004071A1.
[0152] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110153359A1.
[0153] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20110099024A1.
[0154] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20100030580A1.
[0155] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. WO2009117655A2.
[0156] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20100063845A1.
[0157] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. WO2004051415A2.
[0158] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20040078229A1.
[0159] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in U.S. Pat. No. 7,275,220.
[0160] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20020145634A1.
[0161] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in US Patent Application No. US20020145634A1.
[0162] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in U.S. Pat. No. 6,453,297.
[0163] In an alternate embodiment, the electronic healthcare records are stored and managed on the system disclosed in U.S. Pat. No. 5,644,778.
[0164] In one embodiment, the individual's healthcare records are freely exchanged amongst the individual's healthcare providers, and the system of the present invention provides the individual access to the records. In one embodiment, the individual's healthcare records are transportable across the care continuum, where any applications using said healthcare records will correspond to updated care and general knowledge. In one embodiment, the individual's healthcare records may be exchanged and integrated between healthcare providers and/or between nodes of the healthcare continuum so that care provided by one healthcare provider can be known and understood by another healthcare provider and/or by the patient.
[0165] In one embodiment, the individual's healthcare records are maintained on a central server. The central server may be located remote to the healthcare facility, or, alternatively, within the healthcare facility. In one embodiment, the individual's healthcare records are only accessible via the system of the present invention.
[0166] In one embodiment, the system of the present invention creates an at least one healthcare record database for the individual, and populates the database with all, or subsets of the individual's healthcare records. In one embodiment, at least one healthcare record database preserves an individual's healthcare records to allow caregivers across the health care continuum to understand the actions and decisions made during an individual's hospital stay and correspondingly provide more effective aftercare and/or future care.
[0167] In one embodiment, the patient has been admitted to a healthcare facility, such as, for example, a hospital, and the healthcare facility is able to update the patient's medical records, which the patient is able to monitor in real time.
[0168] Updates to the individual's healthcare records may be via direct input into the at least one healthcare record database, or via one, or more than one component of the system of the present invention. In one embodiment, the system of the present invention may only update the individual's healthcare records via the information stored within the at least one individual complaint database. In an alternate embodiment, the system of the present invention may only update the individual's healthcare records via the information stored within the at least one healthcare facility database. In an alternate embodiment, the system of the present invention may only update the individual's healthcare records via the information stored within either the information stored within the at least one healthcare facility database or the at least one individual complaint database.
[0169] In one embodiment, any change to the individual's healthcare records requires verification, to maintain the integrity, privacy and/or security of the individual's healthcare records.
[0170] In one embodiment, the system of the present invention is able to search the individual's healthcare records for information. The parameters of the search may be dictated by the individual, or via the information stored in the at least one individual complaint database. The information located may be used to modify the individual's treatment, or, alternatively, the individual may discuss the implications of the search with others. The system of the present invention is able to make the information capable of being understood by elementary level comprehension through a medical expert. The system of the present invention enables the information to be translated to and understood in at least one other language and/or the language understood at any one node of the system such that persons and/or other applications may understand all relevant information within all other nodes of the system pertinent to the use of that one node.
[0171] For example, using FIG. 11 for guidance, an individual is admitted to hospital for a torn rotator cuff. In the at least one individual complaint database, the individual indicates that he/she is diabetic. The system of the present invention searches the internet, the individual's PHR and the individual's healthcare records for information related to the individual's diabetes. Such information may include, for example, the individual's endocrinologist, the individual's blood glucose results for the past three months, or any possible adverse reactions observed in diabetic patients undergoing any proposed therapeutic intervention for a torn rotator cuff (such as impaired glycemic control following steroid injections, for example). The system of the present invention generates alerts, so that the individual, or others may review the located information.
The Healthcare Facility Database
[0172] In one embodiment, the individual is in the care of a healthcare facility. The system of the present invention provides an at least one database wherein information pertaining to the healthcare facility is stored. Such information may include, for example, the persons tasked with the care of the individual, the schedules of such individuals, the individual's care plan, the individual's dietary choices, the individual's medical prescriptions, the individual's test and results. In one embodiment, the individual may access, but not edit the information stored within the at least one healthcare facility database.
[0173] In one embodiment, the at least one healthcare facility database may search one, or more than one, or all of the components of the present invention and store information located from the search. Such information may include, but not be limited to, for example, the individual's test results, information relating to the individual's complaint, information relating to the individual's other healthcare providers, information relating to the individual's other medical condition, information from the individual's complaint database corresponding to information flagged or located by the individual, or any combination thereof
[0174] The information relating to the individual's complaint may be the symptoms. Alternatively, the information may be the individual's medications, either the medications necessary to treat the complaint, or the medications that the individual is taking for a previous condition, or both. Alternatively, the information may be the individual's blood pressure, pulse, and the like. Alternatively, the information could be the individual's medical test results. Alternatively, the information could be the individual's treatment plan. Alternatively, the information could be the individual's discharge orders.
[0175] In one embodiment, the system of the present invention may update the individual's healthcare records via the information stored within the at least one healthcare facility database. In an alternate embodiment, the system of the present invention may only update the individual's healthcare records via the information stored within the at least one healthcare facility database. In one embodiment, any change to the individual's healthcare records requires verification, to maintain the integrity and/or security of the individual's healthcare records.
[0176] In one embodiment, the system of the present invention is able to search the at least one healthcare facility database for information. The parameters of the search may be dictated by the individual, or via the information stored in the at least one individual complaint database. The information located may be used to modify the individual's treatment, or, alternatively, the individual may discuss the implications of the search with others.
[0177] For example, using FIG. 12 for guidance, the same individual discussed in FIG. 11 above that was admitted to hospital for a torn rotator cuff experiences an adverse reaction to the treatment he/she is receiving. In the individual complaint database, the individual indicates that he/she is diabetic. The system of the present invention searches the internet, the individual's PHR, the individual's healthcare records, and the at least one healthcare facility database for information related to the individual's diabetes. Such information may include, for example, the individual's endocrinologist, the individual's blood glucose results for the past three months, the individual's current therapy and any biometric data taken whilst the individual has been undergoing treatment. The information located may be used to modify the individual's treatment, or, alternatively, the individual may discuss the implications of the search with others.
[0178] In one embodiment of the present invention, all of the foregoing component parts and resources are connected and automatically analyzed and programmed to generate prevention, diagnosis, treatment and prognosis recommendations; including, but not limited to, for example: (a) an analysis of the patient EHR and current symptoms to recommend articles related to those symptoms, preventative measures to be taken and treatment to be sought, if necessary or desirable; (b) alerts and recommendations generated in response symptom progression and changes in conditions; (c) diagnosis, treatment and prescription recommendations generated in response to and concurrent with treatment regimens; and (d) recommendations generated by virtue of patient's reaction to treatment regimen; (e) recommendations for post treatment conduct and monitoring for relapse and subsequent necessary treatment; and (f) continued and ongoing analysis of patient EHR and current symptoms and conditions to recommend articles related to those symptoms, preventative measures to be taken and treatment to be sought, if necessary or desirable.
Hospital Services and the Internet
[0179] In one embodiment, the individual may access certain hospital services through the patient interface. For example, the individual may summon the nurse on call to the patient's room. For example, the individual may order available menu choices based on their individual dietary restrictions. For example, the individual may access a movie on television.
[0180] In one embodiment, the individual may access certain social media accounts such as a service known as FACEBOOK® wherein the individual can allow selected others to be updated as to the individual's current condition.
[0181] In one embodiment, others may reciprocate by offering get-well wishes and/or ordering gifts from the hospital gift shop or other service providers.
[0182] In one embodiment, there is provided a direct video link through, for example through existing service providers such as SKYPE® or FACETIME®, whereby the individual may share a video chat with a healthcare provider, family member or other selected third party.
[0183] In one embodiment, the individual may simply “surf the net” or access personal data repositories, such as email, and the like.
[0184] In one embodiment, queries in one node, for example, within the healthcare facility database, may automatically query databases within another node, for example, the internet.
[0185] In one embodiment, certain patient healthcare database entries may trigger alerts to public authorities where certain outbreaks may be occurring based on multiple similar entries across disparate patient databases.
[0186] The present invention is further illustrated, but not limited by, the following examples.
Examples
[0187] Referring to FIG. 13 , the present invention provides a graphical user interface (“GUI”) suitable for an interactive doctor-patient relationship, wherein the patient can both learn additional information about his or her diagnosis, prognosis, and treatment, and inform the treating professionals of his or her concerns and questions. In one embodiment, the GUI is presented to the user via a bedside terminal in an inpatient setting, and can be activated by either standard keyboard-and-mouse controls, or an alternate voice control interface.
[0188] Upon launch of the GUI, the patient is presented with messages from the clinical staff and reminders, both staff-inputted and machine-generated. These messages can instruct the patient to take his medicine at a certain time, for instance, or to remember his or feet elevated. It can also remind the patient to expect a visitor at a certain time, or to call home.
[0189] At that time, the patient will have a choice to browse his electronic personal medical records (“PHR”) or to proceed to insert his information into the “complaint queue” for later review by medical professionals. The “complain queue” is used to store patient-provided information about symptoms, side effects, drug interactivity, and other treatment concerns.
[0190] The patient can browse the PHR to ensure its completeness, and ensure that all relevant information, such as allergies to medication and disease history is complete and correct. In case the patient needs to update his PHR record, he may not do so directly, but must enter a request into the complaint queue. From the PHR records, the patient may also access outside sources, such as WEBMD®, to learn more about his condition and the treatment currently prescribed by the medical professional.
[0191] The patient can also learn more about upcoming treatment modalities, such as testing and the introduction of new medication by accessing a personalized treatment calendar, and then likewise access outside sources to get more information on these issues. Any questions or comments are once again directed into the complaint queue.
[0192] At the end of the session, either a machine or a staff member reviews comments submitted by the patient and decides whether or not to alter the course of treatment based on the patient's input submitted into the complaint queue, and whether or not to provide more information to either the patient or the treating physician.
[0193] Publications cited throughout this document are hereby incorporated by reference in their entirety. Although the various aspects of the invention have been illustrated above by reference to examples and preferred embodiments, it will be appreciated that the scope of the invention is defined not by the foregoing description but by the following claims properly construed under principles of patent law.
[0194] Each and every feature described herein, and each and every combination of two or more of such features, is included within the scope of the present invention provided that the features included in such a combination are not mutually exclusive.
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The present invention provides a system allowing an individual to actively manage, oversee, direct, and interact with their healthcare. Specifically, the present invention provides a system that allows for the continuous input of updated information from the team of healthcare providers and the patient with full access to the patient history all with real time continuous analysis to provide feedback of likely critical data to consider in the decision of next best steps to provide the only participant whose only motive is to get better as expeditiously as possible with the knowledge necessary to actively manage, oversee and direct their own healthcare. In particular, the present invention provides a system whereby the individual's personal health records are selectively inputted and shared with others and compared with databases of stored information, and the information returned is used by the individual, or others to provide efficient healthcare and manage public health emergencies.
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This application is a continuation of application Ser. No. 10/695,610, entitled “Mobile Gas Separator System and Method for Treating Dirty Gas at the Well Site of a Stimulated Gas Well,” filed Oct. 28, 2003, now U.S. Pat. No. 6,955,704 B1, issued Oct. 18, 2005 and the contents of that application are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to methods and devices for cleaning “dirty” gas from a recently stimulated gas well.
BACKGROUND OF THE INVENTION
When a gas well is stimulated, the initial raw gas emitted at the wellhead is a mixture of natural gas, other hydrocarbons and contaminates, such as hydrogen sulfide (H2S), water (H2O) and carbon dioxide (CO2). This so-called “dirty” gas may also contain particulate matter, such as sand and particles of drilling fluids.
Each pipeline company has its own set of natural gas quality specifications that delivered gas must meet. For example, pipelines typically limit CO2 content due to its corrosive properties. A common maximum for CO2 content in delivered is gas is one to three percent (1-3%) by volume, while raw gas from a recently stimulated well may exceed 30 percent. Similarly, hydrogen sulfide is corrosive and is hazardous to humans if inhaled, so it is also subject to restrictions (typically ≦4 ppm) by pipeline companies. In addition, delivered gas specifications typically limit water vapor content.
Because of these common contaminants, raw gas produced immediately after stimulation rarely meets typical delivered gas specifications. However, in most wells, the gas stream will soon become pipeline quality if the well is flared or vented for a brief period. For example, most gas wells begin producing marketable gas after 3-5 days of flaring. The dirty gas usually is vented to the atmosphere until sensors show reduced and acceptable levels of contaminants.
Flaring has a detrimental effect on the environment because it releases the contaminants into the air. In addition, flaring wastes a significant amount of natural gas and other hydrocarbons. For example, when raw gas containing five percent (5%) contaminants is flared, ninety-five percent (95%) of the flared product is good natural gas that is wasted. Treatment and sale of the dirty gas would significantly increase profits to operators, tax revenues to the states, and payments to the royalty owners.
Permanent and semi-permanent treatment systems have been used at well sites where the deep gas is not pipeline quality and permanent treatment of the produced gas is required. Alternately, produced gas from such wells has been shipped to processing facilities remote from the well. Neither of these options is economically feasible for cleaning the gas produced after a stimulation procedure in a well where only the initial post-stimulation gas is unmarketable.
The present invention provides a mobile gas separation system suitable for temporary use at the well site of a recently stimulated gas well. The system is adequate to serve wells with a range of different requirements. The method of this invention permits the sequential use of the gas separation system for short periods of time at a number of wells, each having different capacities and requirements. Accordingly, the method and system of this invention provide a temporary, on-site cleaning of dirty gas, preserving this valuable natural resource, protecting the environment, and maximizing revenues to the state, the operators and the royalty owners.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the method and system of the present invention constructed in accordance with one preferred embodiment of the present invention.
FIG. 2 is a detailed schematic illustration of a preferred mobile gas separator system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings in general and to FIG. 1 in particular, there is shown therein a mobile gas separator system constructed in accordance with one preferred embodiment of the present invention and designated generally by the reference numeral 10 . The system is designed for temporary, short-term use at a gas well immediately after stimulation, when the initial raw gas is dirty or heavily contaminated. In particular, the system 10 is designed to be moved from well to well. In this way, a small mobile system is available to operators to treat and sell the initial post-stimulation gas instead of flaring or venting it to the atmosphere.
As used herein, “immediately after stimulation” and similar expressions refer to the period following completion of a stimulation procedure during which the well is producing gas that is not marketable. As used herein, “marketable gas” refers to natural gas that meets pipeline company delivered gas standards.
Turning now to FIG. 2 , the system 10 comprises a mobile support adapted to be moved from well site to well site and to be parked temporarily at each site preferably near the well head 14 ( FIG. 1 ). As used herein, “at the well site” means in the general vicinity of the well head or in a nearby location associated with the well. In the case of adjacent wells, “at the well site” may include a single location near to all the adjacent wells.
This mobile support preferably takes the form of one or more trailers 16 and 18 that can be removably connected to trucks or other vehicles (not shown). In this way, the system 10 can be transported easily from well to well. In one preferred embodiment, the entire system is supported on two equally-sized trailers 16 and 18 that can be parked side by side adjacent the wellhead 14 .
A gas separator is mounted on the mobile support. The gas separator is adapted to remove selected contaminants from the dirty gas to produce marketable gas. The contaminants to be removed may vary depending on the characteristics of the gas produced. Accordingly, the type of gas separator may vary as well. As explained herein, typical major contaminants of raw gas produced immediately after stimulation include carbon dioxide, hydrogen sulfide and water. Accordingly, an ideal gas separator for this application is a membrane separator 20 . More preferably, the membrane separator 20 is adapted to selectively reduce the content of carbon dioxide, hydrogen sulfide and water in the gas being treated. Most preferably, the membrane separator 20 comprises cellulose acetate polymer membrane modules. Suitable membrane separators are available from Natco Group, Inc. (Houston, Tex.), UOP L.L.C. (Des Plaines, Ill.), and Kvaerner Process Systems US, Inc. (Houston, Tex.).
Optimal function and durability of the preferred membrane separator 20 depends on the condition of the raw gas introduced into the separator. For example, permeation characteristics of the cellulose acetate membranes can be adversely affected by liquid water, glycol, amine, lubricating oil, and other heavy hydrocarbon liquids in the gas. In addition, permeability of a given molecule is affected by feed gas pressure, feed gas temperature and concentration of the molecule in the feed gas. Thus, the dirty gas should be heated and pressurized to a prescribed range. For these purposes, the system 10 preferably will include a pretreatment assembly 24 mounted on the trailers 16 and 18 .
The pretreatment assembly 24 is adapted to receive the dirty gas from the wellhead 14 of gas well (not shown). Usually, the operator will provide a sand separator 26 , a production unit 28 and a frac tank 30 at the well site, and the system will simply receive dirty gas from the production unit in a known manner through a conduit 32 . The conduit 32 to the pretreatment assembly 24 typically will be equipped with an isolation (ball) valve 34 and a throttle valve 36 . This throttle valve 36 allows the dirty gas feed to the system 10 to be maintained at a constant flow and pressure. The isolation valve 34 is a shutdown and safeguard. Conduits 38 and 40 are provided to the frac tank 30 for oil and water, respectively.
The pretreatment assembly 24 is adapted to prepare the dirty gas for the membrane separator 20 . To that end, the pretreatment assembly 24 preferably includes a first separator 44 adapted to remove selected contaminants from the dirty gas. More preferably, the first separator 44 is a sand separator adapted to remove sand and other particulate matter from the dirty gas passing through it.
The pretreatment assembly 24 preferably includes a second separator 46 connected to the first separator 44 by a conduit 48 . The second separator 46 is adapted to remove small oil and water aerosols from the dirty gas. Most preferably, the second separator 46 is a two-chamber coalescing filter separator designed to agglomerate and capture about ninety-nine percent (99%) of small oil and water aerosols greater than 0.3 microns. This filter may be equipped with two independent level controls, two level gauges, and two automatic liquid level control valves.
The pretreatment assembly 24 preferably also includes a heater, such as a water bath heater 50 , adapted to adjust the temperature of the dirty gas to a temperature suitable for the membrane separator 20 . In most instances, this temperature range will be from about 125 degrees to 120 degrees Fahrenheit. A conduit 52 connects the separator 46 to the heater 50 . A conduit 54 connects the production unit 28 to circulate dirty pretreatment gas to fuel the heater 50 . An isolation valve 56 may be included in this conduit. Thus, the heater 50 initially can be fueled by the dirty gas until sweetened gas from the system 10 is available, as explained hereafter.
The pretreatment assembly 24 preferably also includes a guard vessel 60 adapted to remove oil and glycol vapors from the dirty gas. Preferably, the guard vessel comprises an activated carbon adsorbent. The guard vessel 60 receives warm dirty gas from the heater 50 through the conduit 62 . The conduit 62 and other conduits downstream of the heater 50 should be insulated to minimize heat loss.
To ensure that the gas entering the guard vessel 60 is warmed to the desired temperature, the system 10 may be provided with a recirculating assembly. The recirculating assembly preferably takes the form of a recirculating valve 64 and temperature sensor 66 connected in series in the conduit 62 between the heater and guard vessel 60 . The fluid leaving the heater through the conduit 62 will be diverted through the three-way valve 64 to the conduit 52 through a crossover conduit 68 until the sensor 66 senses that the fluid has acquired the desired temperature. When the gas leaving the heater 50 has reached the desired temperature, it will redirected to the guard vessel 60 .
Still further, the preferred pretreatment assembly 24 includes a polishing filter 70 connected to the guard vessel 60 by a conduit 72 . The polishing filter 70 is designed to remove additional aerosols and fine particulate matter from the dirty gas. Pre-treated gas from the polishing filter is fed to the membrane separator 20 through the conduit 74 . A gas analyzer 76 , preferably providing a BTU reading, may be included in the conduit 74 to verify the condition of the pretreated dirty gas before it enters the membrane separator 20 .
Conduits, indicated collectively at 78 , allow carbon dioxide and methane removed from the gas by the membrane separator 20 to be flared to the atmosphere, vented to the frac tank 30 by a conduit (not shown), or collected and treated further. For example, the carbon dioxide can be liquefied and recycled.
Sweetened gas produced by the membrane separator 20 exits the separator through a conduit 80 and is conducted to a heat exchanger 82 . The heat exchanger 82 , or chiller, cools the treated gas to a pipeline-acceptable or marketable temperature range, usually about 65-70 degrees Fahrenheit. The chilled gas is directed to the sales connection through the conduit 84 , which connects to the conduit 80 by means of a four-way valve 86 . An adjustable choke valve 88 may be included in the sales conduit 84 to maintain the pressure of the treated gas directed to the sales pipeline at a marketable level. A gas analyzer 90 of any suitable type may be included in the sales line. Preferably, the gas analyzer will provide BTU reading.
The preferred heat exchanger 82 is electrically operated. To provide power to the heat exchanger 82 , the system 10 preferably includes its own generator 92 , which may be mounted on the trailer 18 . The generator is electrically connected to the heat exchanger 82 by a suitable connector (not shown). The generator, then, preferably is powered by natural gas. Initially, dirty gas from the production unit 28 is used to fuel the generator 92 through the conduit 94 . Once the system begins producing clean or “sweetened: (post-treatment) gas from the membrane separator 20 , the sweetened gas is used to fuel the generator 92 through the conduit 96 . Sweetened gas may also be circulated through the conduit 96 to fuel the heater 50 . An isolation valve 98 may be included in the conduit 96 .
In the preferred design of the system 10 , the valves are operated hydraulically. Thus, the system 10 preferably includes its own hydraulic plant mounted on the trailer 18 to supply hydraulic power to the system. The hydraulic plant 100 is electrically connected to the generator 92 by conductors not shown, and is fluidly connected to the various valves and other components by conduits, not shown.
Controls for the various components in the system conveniently may be enclosed in a control room 102 . Preferably, the control room 102 is enclosed. If space permits, a storage area 104 may also be provided on the trailer 18 .
Returning to FIG. 1 , where a pipeline is not available, the treated or “clean” gas can be liquefied and placed in containers. To that end, the system 10 may further include a liquification unit 106 . This unit will remove any remaining water in the clean gas and convert it to a liquid phase. The liquid gas can then be placed in containers 108 that can be stored on site until a pipeline becomes available, at which time the liquefied natural gas can be restored to a gaseous state and sold. Alternately, the storage containers 108 can be transported for sale or use elsewhere.
In accordance with the method of the present invention, a first gas well is selected. The selected gas well preferably will have recently undergone a stimulation treatment and will be producing dirty gas. Following the stimulation procedure, the dirty natural gas from the first gas well is conducted to a mobile gas separation system at the well site. Preferably, the mobile gas separation system is similar to the system described above. Next, the dirty gas is processed in the gas separation system to produce marketable gas for subsequent sale to a pipeline company.
In the preferred practice of this method, the pre-processed dirty gas coming from the well is intermittently tested to determine its marketability. This testing is carried out with conventional equipment according to known procedures and is not described in detail herein. Once the pre-processed gas is determined to be marketable, then the processing of the gas is terminated. The mobile system now can be removed from the first well site and transported to a second gas well in need of temporary gas processing in accordance with the method of this invention.
Various additional features will suggest themselves to those skilled in this field. For example, a low pressure alarm would be advantageous as it would alert the operator of the system to a leak or other problems that require operator intervention.
Changes can be made in the combination and arrangement of the various parts and elements described herein without departing from the spirit and scope of the invention as defined in the following claims.
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A method and mobile system for cleaning dirty gas from a newly stimulated gas well. The entire system is supported on a trailer or other mobile support so that it can be driven from well site to well site for short-term, post-stimulation use only. The system comprises a gas separator, such as a membrane separator. The system also includes a pretreatment assembly for preparing the gas for the gas separator. The pretreatment assembly may include separators, a heater, a guard vessel and a polishing filter. A chiller or heat exchanger cools the treated gas to a marketable temperature. A generator and a hydraulics plant provide power to the system. Each mobile system will be designed to treat gases with widely different operating conditions varying from well to well.
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FIELD OF THE INVENTION
The present invention relates to a gas turbine control device that controls a gas turbine so that the gas turbine can maintain stable combustion without combustion vibrations even in a case where the ambient temperature, the fuel content, or the fuel calorific, value changes in the gas turbine plant in which the gas turbine is operated.
BACKGROUND OF THE INVENTION
There are several types of combustion nozzles provided in a combustor of a gas turbine; for instance, there are a main nozzle that is used for premix combustion and a pilot nozzle that is used for diffusion combustion; further, a certain combustor is provided with a top-hat nozzle that is used for NOx reduction during high load operation as well as combustion stability during low load operation. An example of the configuration as to such a combustor is disclosed, for instance, in the patent reference 1 (JP2008-25910); the disclosed configuration as to the combustor in the patent reference 1 is hereby explained in consultation with FIGS. 6 and 7 .
Within the outer casing 102 of the combustor 100 , the inner tube 104 of the combustor is anchored to the outer casing so that the inner tube is supported by the outer casing and a predetermined space is kept between the outer casing and the inner tube; the tail pipe 106 of the combustor is connected to the tip end side of the inner tube 104 so that a casing of the combustor is formed. In the middle center area of the inner casing 104 , the pilot nozzle 108 is arranged; on the other hand, along the hoop direction of the inner surface of the inner tube 104 , a plurality of main nozzles 110 is arranged so as to surround the pilot nozzle 108 . The pilot cone 112 is fitted to the tip part of the pilot nozzle 108 . Further, a plurality of top-hat nozzles 114 is arranged along the hoop direction of the inner surface of the outer casing 102 .
As shown in FIG. 7 , an end part of the outer casing lid part 118 is fastened to the base end part of the outer casing body 116 , with a plurality of fastening bolts 120 ; at another end part of the outer casing lid part 118 , the base end part of the inner tube 104 is fitted so that the air passage 122 is formed between the outer casing lid part 118 and the inner tube 104 . Further, the tip end part of each main nozzle communicates with the main burner 124 .
The top-hat forming part 126 is fitted into the outer casing lid part 118 , being fastened to the outer casing lid part 118 with a plurality of the fastening bolts 128 . As shown in FIG. 7 , the top-hat nozzles 114 are configured in the top-hat forming part 126 ; namely, a plurality of fuel cavities 130 is formed along the hoop direction of the top-hat forming part 126 ; a plurality of first fuel passages 132 is formed from each cavity toward the outer casing lid part 118 . At the front end of each first fuel passage 132 , a second fuel passage 134 is formed toward the air passage 122 ; each second fuel passage 134 is connected to a peg 136 that is fitted to the inner surface of the top-hat forming part 126 .
A pilot fuel line (not shown) is connected to the fuel port 138 for the pilot nozzle 108 and supplies pilot fuel f p into the combustor; a main fuel line (not shown) is connected to the fuel port 140 for the main nozzles 110 and supplies main fuel f m into the combustor; a top-hat fuel line (not shown) is connected to the fuel port 142 for the top-hat nozzles 114 and supplies main fuel f t into the combustor.
In the configuration described above, when the compressed air of a high temperature and a high pressure is supplied from the airflow channel 144 toward the air passage 122 along the direction of the arrow a, the compressed air is premixed with the fuel f t that is injected through the top-hat nozzles 114 ; the premixed air-fuel mixture streams into the inner side of the inner tube 104 .
Inside of the inner tube 104 , the air-fuel mixture (being premixed as described above) is further premixed with the fuel f m that is injected through the main nozzle 110 , turning into revolution flow and streaming into the inner side of the tail pipe 106 of the combustor.
Further, the premixed air-fuel mixture is mixed with the fuel f p that is injected through the pilot nozzle 108 so that the finally premixed air-fuel mixture is ignited by a pilot flame (not shown), is burnt, turns into combustion gas and blows out into the inner side of the tail pipe 106 ; thereby, a part of the combustion gas blows out into the inner side of the tail pipe 106 , accompanying the flame propagation so that the combustion gas diffuses; the combustion gas that diffuses in this way ignites the air-gas mixture that streams from the main nozzles toward the tail pipe 106 ; thus, the combustion continues. In other words, since the lean air-fuel mixture produced by the fuel from the main nozzles 110 can stably burns thanks to the diffusion frame propagation produced by the pilot fuel that is injected through the pilot nozzle 108 , the flame propagation can be prevented from reducing inflammation. Further, the compressed air is firstly mixed with the fuel injected through the top-hat nozzles 114 ; this approach can bring the reduction of NOx produced in the gas turbine.
In the conventional gas turbine plants, the fuel flow rate and the airflow rate are predetermined on the basis of the generator output (demand power), the ambient temperature and so on; the fine adjustments of the operation conditions as to the gas turbine and the plant thereof are performed in the test operations or the commissioning operation; after commissioning, the gas turbine and the plant thereof are operated on the basis of the fine adjusted operation conditions. According to the conventional control device for the gas turbine plant, however, the operation state conditions cannot respond to, for example, the change of fuel contents during the operation. Accordingly, by the limitation of the ability of the conventional control device, the combustion stability is often hindered or the combustion vibrations are often caused.
In a case where combustion vibrations occur, the vibrations seriously hinder the operation of the gas turbine; hence, it is strongly required to restrain the combustion vibrations of the gas turbine as far as possible, in view of the protection of the plant facility and the enhancement of the plant availability.
The patent reference 2 (JP1993-187271) discloses a control device by which the airflow rate or the fuel flow rate as to the gas turbine combustor is controlled on the basis of the changes regarding the ambient temperature, the ambient humidity, the fuel calorific value and so on. According to the technology of the patent reference 2, in response to the technological requirement as described above, the bias control regarding the airflow rate or the fuel flow rate is made use of in order to improve the robustness for the combustion stability.
In the control means disclosed in the patent reference 2, the airflow rate or the fuel flow rate is uniformly controlled when the bias control is applied; thus, the degree of freedom as to the control is limited; therefore, it is difficult to adjust the airflow rate or the fuel flow rate so that either of the flow rates converges to an optimally controlled value.
SUMMARY OF THE INVENTION
In view of the difficulties in the conventional technologies as described above, the present invention aims at improving the stability of the combustion as well as preventing the combustion vibrations from happening, by enhancing the degree of freedom regarding the control settings in a case where the airflow rate or the fuel flow rate is optimally adjusted in response to the target power output corresponding to the load demanded on the generator in the gas turbine plant.
In order to overcome the difficulties described above, the present invention discloses a gas turbine control device for controlling a fuel flow rate or an airflow rate in response to a target power output of the gas turbine, the fuel and the air being supplied to a plurality of combustors, the device comprising:
a first function generator for establishing the fuel flow rate or the airflow rate, in response to the target power output, the fuel and the air being supplied to each combustor;
a second function generator for establishing a correction value to correct the established fuel flow rate or the established airflow rate on the basis of the suction air temperature detected by a suction air temperature sensor that is provided so as to detect the suction air temperature at an air inlet of the compressor;
a third function generator for establishing an amendment value to amend the established correction value as to the fuel flow rate or the airflow rate, in taking the target power output into consideration;
a first computing element for computing a correction-amendment value by use of the correction value established by the second function generator and the amendment value established by the third function generator;
a second computing element for computing an order fuel flow rate or an order airflow rate by adding the correction-amendment value to the fuel flow rate or the airflow rate either of which is established in the first function generator, the order fuel flow rate or the order airflow rate being used to determine the flow rate as to the fuel or the air to be supplied to the combustor.
In the present invention, the fuel flow rate or the airflow rate is established in response to the target power output; a correction value to correct the established fuel flow rate or the established airflow rate is set by the second function generator, on the basis of the detected value as to the suction air temperature at the air inlet of the compressor. In other words, the present invention pays attention to the suction air temperature as a control variable (parameter) to be used for controlling the fuel flow rate or the airflow rate in order to maintain the stable combustion of the gas turbine.
In the patent reference 2, the ambient air temperature is selected as a control variable; however, the ambient air temperature does not necessarily uniquely correspond to the suction air temperature. Both the ambient air temperature and the suction air temperature are correlated to some extent; the suction air temperature changes in response to the flow speed thereof; the greater the flow speed, the higher the temperature drop of the suction air temperature after being inhaled.
By detecting the suction air temperature that is the temperature of the air inhaled into the gas turbine, rather than by detecting the ambient air temperature, the mass balance (the mass flow balance) and the heat balance as to the gas turbine can be known more correctly. Thus, in order to maintain the combustion stability without being influenced by the changes of weather condition, it is advantageous to use the suction air temperature rather than the ambient air temperature as a state variable (parameter) in relation to the gas turbine control.
Further, in the third function generator, the amendment value to amend the correction value established in the second function generator as to the fuel flow rate or the airflow rate is set in taking the target power output into consideration; thus, the fuel flow rate or the airflow rate can be optimally adjusted in response to the target power output. Accordingly, in comparison with the approach of the patent reference 2, the present invention provides an approach of greater freedom of control thereby combustion vibrations are prevented and stable combustions are maintained.
Further, another preferable embodiment of the present invention is the gas turbine control device, further comprising:
a fourth function generator for establishing a second correction value to correct the fuel flow rate or the airflow rate established in the first function generator, in response to the contents or the calorific value of the fuel;
a fifth function generator for establishing a second amendment value to amend the established second correction value, in taking the target power output into consideration;
a third computing element for computing a second correction-amendment value by use of the second correction value established by the fourth function generator and the second amendment value established by the fifth function generator;
a fourth computing element for computing an order fuel flow rate or an order airflow rate by adding the correction-amendment value and the second correction-amendment value to the fuel flow rate or the airflow rate, the order fuel flow rate or the order airflow rate being used to determine the flow rate as to the fuel or the air to be supplied to the combustor.
As described above, the contents of the fuel or the calorific value of the fuel is also taken into consideration, as a parameter to be used for the control of the gas turbine; based on the parameter, a second correction value to correct the fuel flow rate or the airflow rate is established; further, a second correction-amendment value to amend the established second correction value is set, in taking the target power output into consideration; thus, the second correction-amendment value is computed; based on the second correction-amendment value, an order fuel flow rate or an order airflow rate is determined. Thus, the stable combustion of the gas turbine is maintained without producing combustion vibrations, even in a case where the contents of the fuel, the calorific value of the fuel, or the percentage content of the inert gas included in the fuel fluctuates.
Further, another preferable embodiment of the present invention is the gas turbine control device, wherein a detecting means for detecting the contents or the calorific value of the fuel is provided on the fuel supply main-pipe at the upstream side of the combustor; and, the second correction value is established on the basis of the detected values detected by the detecting means. The contents of the fuel or the calorific value of the fuel can be specified in advance, or can be inputted every time the contents or the calorific value of the fuel changes. However, as described in this embodiment, the contents or the calorific value of the fuel is preferably detected by a detecting means provided on the fuel supply main-pipe. In addition, preferably, there may be an approach in which the calorific value is estimated through the arithmetic calculations by use of the values as to the generator output and the fuel flow rate.
Hence, it becomes not necessary to specify the contents or the calorific value of the fuel in advance; further, the detecting means can detect the contents or the calorific value, even when the value thereof changes during the gas turbine operation; the contents or the calorific value can be detected without stopping the gas turbine operation; thus, the second correction value can be established in response to the changing value as to the contents or the calorific value of the fuel, while the gas turbine is placed under operation.
Further, another preferable embodiment of the present invention is the gas turbine control device, wherein the target power output is a load index with respect to the load demanded on the generator connected to the gas turbine or the temperature of the combustion gas flowing into the combustor; and, to be controlled variable is one of:
the opening of a plurality of fuel flow rate control valves provided on the fuel supply pipes connecting the fuel supply main-pipe with, each combustor;
the attack angle of a plurality of inlet guide vanes provided in the compressor of the gas turbine; or,
the opening of the bypass valves provided on each air bypass pipe passing the air compressed by the compressor so that the compressed air bypasses the combustion gas area in each combustor.
As described above, by controlling the fuel flow rate control valves, the inlet guide vanes, or the bypass valves, it becomes easy to adjust the fuel flow rate or the airflow rate; the flow rate of the fuel or the air supplied to each combustor can be properly set in relation to the suction air temperature the contents of the fuel, or the calorific value of the fuel; accordingly, the combustion control can be realized thereby the gas turbine operation is hard to be influenced by the fluctuations regarding the suction air temperature, the contents of the fuel, or the calorific value of the fuel.
Further, another, preferable embodiment of the present invention is the gas turbine control device, wherein the target power output is a load index with respect to the load demanded on the generator connected to the gas turbine or the temperature of the combustion gas flowing into the turbine; and, to be controlled variable is one of:
the pilot fuel ratio that is the percentage ratio of the pilot fuel flow rate to the total fuel flow rate; or,
the top-hat fuel ratio that is the percentage ratio of the top-hat fuel flow rate to the total fuel flow rate.
As described above, by controlling the ratio of the pilot fuel flow rate or the top-hat fuel flow rate to the total fuel flow rate, the flow rate of the fuel supplied to each combustor can be properly set without fluctuating the total fuel flow rate, even in a case where the suction air temperature, the contents of the fuel, or the calorific value of the fuel fluctuates; accordingly, the combustion control can be realized thereby the gas turbine operation is hard to be influenced by the change in the load demanded on the generator or the combustion temperature, even in a case where the suction air temperature, the contents of the fuel, or the calorific value of the fuel fluctuates.
As described above, the present invention provides a gas turbine control device for controlling the fuel flow rate or the airflow rate in response to the target power output of the gas turbine, the fuel and the air being supplied to a plurality of combustors, the device comprising:
a first function generator for establishing the fuel flow rate or the airflow rate, in response to the target power output, the fuel and the air being supplied to each combustor;
a second function generator for establishing a correction value to correct the established fuel flow rate or the established airflow rate on the basis of the suction air temperature detected by a suction air temperature sensor that is provided so as to detect the suction air temperature at the air inlet of the compressor;
a third function generator for establishing an amendment value to amend the established correction value as to the fuel flow rate or the airflow rate, in taking the target power output into consideration;
a first computing element for computing a correction-amendment value by use of the correction value established by the second function generator and the amendment value established by the third function generator;
a second computing element for computing an order fuel flow rate or an order airflow rate by adding the correction-amendment value to the fuel flow rate or the airflow rate either of which is established in the first function generator, the order fuel flow rate or the order airflow rate being used to determine the flow rate as to the fuel or the air to be supplied to the combustor.
In this way, the degree of freedom regarding the gas turbine control can be enhanced; further, in response to the target power output, the optimum control regarding the fuel flow rate or the airflow rate can be performed by use of the suction air temperature, as a parameter for the control; thus, even when the weather condition fluctuates, the combustion of the gas turbine can be stably maintained, and combustion vibrations can be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in greater detail with reference to the preferred embodiments of the invention and the accompanying drawings, wherein:
FIG. 1 shows the configuration of the gas turbine plant according to a first embodiment of the present invention;
FIG. 2 shows a block diagram regarding a gas turbine control unit according to a first embodiment;
FIG. 3 shows a block diagram regarding a gas turbine control unit according to a second embodiment of the present invention;
FIG. 4 shows a block diagram regarding a gas turbine control unit according to a third embodiment of the present invention;
FIG. 5 shows a block diagram regarding the control mechanism of the fuel flow rate control valves according to the third embodiment;
FIG. 6 shows a longitudinal cross-section of the combustor of the gas turbine;
FIG. 7 shows an enlargement of a part of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereafter, the present invention will be described in detail with reference to the embodiments shown in the figures. However, the dimensions, materials, shape, the relative placement and so on of a component described in these embodiments shall not be construed as limiting the scope of the invention thereto, unless especially specific mention is made.
First Embodiment
The device as a first embodiment according to the present invention is now explained with reference to FIGS. 1 and 2 . FIG. 1 shows the configuration of the gas turbine plant according to a first embodiment of the present invention. In FIG. 1 , a gas turbine 1 is provided with a gas-turbine body 10 and a combustor assembly 30 . The gas-turbine body (assembly) 10 is provided with a compressor 12 having a plurality of inlet guide vanes 14 , a rotating shaft 16 , and a turbine 18 ; a generator is connected to the turbine 18 . A suction air temperature sensor 22 for detecting the temperature of the suction air s passing through the space among the inlet guide vanes 14 is provided; the detected value (signal) detected by the suction air temperature sensor 22 is inputted into a gas turbine control unit 60 for controlling the gas turbine plant according to the present embodiment; incidentally, the explanation about the gas turbine control unit 60 will be given later.
The turbine 18 is connected to a combustion gas guide pipe 26 and an exhaust gas pipe 28 that discharges combustion exhaust gas e outward; Further, the turbine 18 is connected to the compressor 12 and the generator 20 via the rotating shaft 16 . The produced combustion gas is supplied to the turbine 18 through the combustion gas guide pipe 26 ; the exhaust gas rotates the turbine 18 ; the rotation movement is transmitted to the generator 20 and the compressor 12 . The combustion gas that is used for the power generation is discharged outward as the exhaust gas e through the exhaust gas pipe 28 . At the combustion gas inlet of the turbine 18 , the temperature sensor 19 for detecting the temperature of the combustion gas guided through the combustion gas guide pipe 26 is fitted. The detected value (signal) detected by the temperature sensor 19 is inputted into the gas turbine control unit 60 as described later.
The compressor 12 is connected to an ambient air guide pipe 13 and a compressed air guide duct 24 ; the compressor 12 is coupled with the turbine 18 and the generator 20 via the rotating shaft 16 ; the rotation movement of the turbine 18 is transmitted to the compressor 12 and the compressor 12 rotates; by the rotation movement of the compressor 12 , the ambient air is inhaled through the ambient air guide pipe 13 ; the suction air s thus inhaled is compressed and delivered to the combustors.
The inlet guide vanes of the compressor are provided at the passage of the suction air s; the flow rate of the suction air s can be adjusted by adjusting the attack angles of the inlet guide vanes on the condition that the rotation speed of the compressor is constant. The gas turbine control unit 60 controls the attack angle, as described later.
In the next place, the combustor assembly 30 is now explained. The combustor 32 is connected to the compressed air guide duct 24 and the combustion gas guide pipe 26 . The configuration of the combustor 32 is the same as that of a combustor assembly 100 shown in FIGS. 6 and 7 . The suction air s is guided to the combustor 32 through the compressed air guide duct 24 . A bypass pipe 34 is connected to the compressed air guide duct 24 and the combustion gas guide pipe 26 ; on a part way of the bypass pipe 34 , a bypass valve is installed. The bypass valve 36 controls the flow rate of the suction air guided to the combustor 32 . The gas turbine control unit 60 controls the opening of the bypass valve, as described later.
The fuel f is supplied to the combustor 32 from a fuel supply main-pipe 38 through three branch pipes 40 , 42 and 44 ; on the fuel supply main-pipe 38 , a calorimeter 46 for detecting the calorific value of the fuel f is fitted; at the branch pipe 40 , namely, a main fuel supply pipe 40 , a main fuel flow rate control valve 48 is installed; between the control valve 48 and the combustor 32 , a main fuel supply valve 50 is installed; at the branch pipe 42 , namely, a top-hat fuel supply pipe 42 , a top-hat fuel flow rate control valve 52 is installed; between the control valve 52 and the combustor 32 , a top-hat fuel supply valve 54 is installed; at the branch pipe 44 , namely, a pilot fuel supply pipe 44 , a pilot fuel flow rate control valve 56 is installed; between the control valve 56 and the combustor 32 , a pilot fuel supply valve 58 is installed.
In the configuration described thus far, as shown in FIG. 7 , the fuel f m delivered from the main fuel supply pipe 40 is supplied to a fuel port 140 communicating with a plurality of main (fuel) nozzles 110 ; the fuel f t delivered from the top-hat fuel supply pipe 42 is supplied to a fuel port 142 communicating with a plurality of top-hat (fuel) nozzles 114 ; the fuel f p delivered from pilot fuel supply pipe 44 is supplied to a fuel port 138 communicating with a pilot (fuel) nozzle 108 . Thus, the fuel f is burned in the combustor 32 according to the combustion method described above.
FIG. 2 shows a gas turbine control unit 60 according to the first embodiment; in FIG. 2 , the target power output of the gas turbine is specified. The target power output may be a target value corresponding to the load requirement (MW) on the generator or a target value that is specified on the basis of the temperature of the combustion gas guided into the turbine 18 . For instance, in a case where the target value corresponding to the load requirement (MW) is used, the target value as the target power output is specified as a non-dimensional value in an interval such as 50% to 100% ([0.5, 1.0]); thereby, the 100% corresponds to full load.
On the basis of the specified target power output, the fuel flow rate as to the fuel flow delivered through the fuel supply main-pipe 38 is specified (established) in a first function, generator 62 ; the specified value (as to the fuel flow rate) is inputted into a first adder-subtractor 64 .
In the next place, the suction air temperature detected by the suction air temperature sensor 22 is inputted into a second function generator 69 in which a correction value (a first correction value) is established in response to the suction air temperature; the correction value established in the second function generator 69 is inputted into a first multiplier 68 . In addition, since the combustion state fluctuates according to the target power output, the setting value as to the fuel flow rate needs to be amended under the condition that the combustion state fluctuations are taken into consideration; thus, another target power output (a second target power output) is inputted into a third function generator 66 in which an amendment value (a first amendment value) is established; the amendment value established in the third function generator 66 is inputted into the first multiplier 68 .
In the first multiplier 68 , a correction-amendment value (an overall correction value for the fuel flow rate setting value) is computed on the basis of the a first correction value established in the second function generator 69 in response to the suction air temperature and the first amendment value established in the third function generator 66 in response to the second target power output; and, the correction-amendment value (the overall correction value for the fuel flow rate setting value) is inputted into the first adder-subtractor 64 ; in the first adder-subtractor 64 , the correction-amendment value is added to (or subtracted from) the fuel flow rate setting value specified in a first function generator 62 . Thus, the fuel flow rate in response to the first target power output and the second target power output is determined.
On the basis of the determined fuel flow rate, the opening of each of the fuel valves 48 , 52 , and 56 is determined according to a function expressed with the parameters as to the valve opening characteristics of each valve as well as the parameters such as fuel temperature and fuel pressure; the order signals for controlling the opening of each of the fuel valves 48 , 52 , and 56 are issued from the gas turbine control unit 60 toward each of the fuel valves 48 , 52 and 56 .
As described above, the fuel flow rates through each of the fuel valves 48 , 52 , and 56 are determined; the opening of each of the fuel valves 48 , 52 , and 56 can respond to the detected suction air temperature at the air inlet of the compressor 12 ; further, since the opening of each of the fuel valves is controlled so that the valve opening reflects the combustion characteristics regarding the target power output, the each fuel flow rate can be optimal in response to the target power output. Hence, the operation of the gas turbine can be continued in a stable combustion condition, without combustion vibrations. Moreover, the degree of freedom regarding the control settings can be enhanced, in comparison with the bias control (regarding the airflow rate or the fuel flow rate) disclosed in the patent reference 2.
In addition, in this first embodiment, the fuel flow rate as to the fuel flow delivered through the fuel supply main-pipe 38 is specified by the first function generator 62 ; the summation of the first correction value and the first amendment value is calculated by the first adder-subtractor 64 , and, the fuel flow rate in response to the target power output is determined. However, preferably, there may be an approach in which each of the fuel flow rates through the main fuel supply pipe 40 , the top-hat fuel supply pipe, and the pilot fuel supply pipe 42 is specified by the first function generator 62 ; and, the correction-amendment value (for the summation of the fuel flow rates) is calculated by the first adder-subtractor 64 so that the main fuel flow rate, the top-hat fuel flow rate, and the pilot fuel flow rate are determined in response to the target power output.
Further, in this first embodiment, an approach in which the fuel flow rate is controlled is adopted; instead, preferably, there may be an approach in which the flow rate of the compressed air guided from the compressed air guide duct 24 into the combustor 32 is controlled. In this case, the attack angle of each inlet guide vane 14 is adjusted so as to control the compressed airflow rate; or, the opening of the bypass valve 36 is adjusted so as to control the compressed airflow rate. Further, preferably, there may be an approach in which both the fuel flow rate and the compressed airflow rate are controlled at the same time.
Further, in this first embodiment, at the inlet of the turbine 18 , the temperature sensor 19 for detecting the temperature of the combustion gas is provided. However, preferably, there may be an approach in which the temperature of the combustion gas is estimated through arithmetic calculations as to the detected-values detected by other temperature sensors and flow rate meters, with respect to heat balance and mass balance.
Second Embodiment
In the next place, a second embodiment according to the present invention is now explained with reference to FIG. 3 . In FIG. 3 , the components (such as the function generators, the adder-subtractors or the multipliers) that are marked with the same numeral or symbol, as the components in FIG. 2 in relation to the first embodiment are common components over FIGS. 2 and 3 ; naturally, the common components have the same function. In this second embodiment, in addition to the control approach shown in FIG. 2 , a calorimeter 46 is provided on the fuel supply main-pipe so as to detect the specific heat value of the fuel f; and, in response to the detected-value detected by the calorimeter 46 , a second correction value is established in a fourth function generator 78 , the second correction value being a correction value for the setting of the fuel flow rate. Further, in a fifth function generator 74 , a second amendment value for amending the second correction value in consideration of the target power output (the first target power output) is established.
In the next place, the second correction value established in the fourth function generator 78 and the second amendment value established in the fifth function generator 74 are inputted into a second multiplier 76 , in which a second correction-amendment value is calculated. The second correction-amendment value is inputted into a second adder-subtractor 72 . Further, as is the case with the first embodiment, in the first adder-subtractor 64 , the first correction-amendment value is added to (or subtracted from) the fuel flow rate setting value specified in the first function generator 62 in response to the target power output; subsequently, in a second adder-subtractor 72 , the second correction-amendment value is added to (or subtracted from) the first correction-amendment value. Thus, the flow rate of the fuel supplied to the combustor 32 is determined; based on the determined fuel flow rate, the opening of each of the fuel valves 48 , 52 , and 56 is to be determined according to a function expressed with the parameters as to the valve opening characteristics of each valve as well as the parameters such as fuel temperature and fuel pressure.
According to this second embodiment, the detected calorific value of the fuel f is taken into consideration as a parameter of an additional kind. On the basis of the detected suction-air temperature at the inlet of the compressor and this detected calorific value of the fuel, the fuel flow rate setting value is corrected; further, the corrected value is amended in response to the target power output; thus, in addition to the effect brought by the first embodiment, the second embodiment can realize the effectiveness of maintaining the stable combustion without producing combustion vibrations, even in a case where the contents of the fuel, the calorific value of the fuel, or the percentage content of the inert gas included in the fuel fluctuates.
Further, in this first embodiment, an approach in which the fuel flow rate is controlled is adopted; instead, preferably, there may be an approach in which the flow rate of the compressed air guided from the compressed air guide duct 24 into the combustor 32 is controlled. In this case, the attack angle of each inlet guide vane 14 is adjusted so as to control the compressed airflow rate; or, the opening of the bypass valve 36 is adjusted so as to control the compressed airflow rate. Further, preferably, there may be an approach in which both the fuel flow rate and the compressed airflow rate are controlled at the same time. Moreover, in this first embodiment, the calorimeter 46 is provided on the part way of the fuel supply main-pipe. However, preferably, there may be an approach in which the calorific value is estimated through the arithmetic calculations by use of the values as to the generator output and the fuel flow rate.
Third Embodiment
In the next place, a third embodiment according to the present invention is now explained with reference to FIGS. 4 and 5 . In FIG. 4 according to the present embodiment, the temperature of the combustion gas at the gas inlet of the turbine 18 is adopted as a variable (parameter) to be established corresponding to the target power output. The temperature sensor 19 detects the temperature of the combustion gas. The gas inlet temperature as an index of the target power output is, for instance, directed to a value between 1480 to 1500° C. In FIG. 4 , the configuration components (such as the function generators, the adder-subtractors or the multipliers) of a gas turbine control unit 80 are the same as those in FIG. 3 ; the common components over FIGS. 3 and 4 are marked with the same numerals or symbols.
In the gas turbine control unit 80 , the combustion temperature is used as a variable (parameter) that corresponds to the target power output; as is the case with the second embodiment, the control parameters comprise the suction air temperature detected by the suction air temperature sensor 22 and the calorific value of the fuel f detected by the calorimeter 46 ; In the present embodiment, the first function generator 62 establishes the fuel ratios that are, for instance, the percentage ratios of the main fuel flow rate, the top-hat fuel flow rate and the pilot fuel flow rate in the total fuel flow rate. In the first adder-subtractor 64 , the first correction-amendment value is added to (or subtracted from) each fuel ratio; subsequently, in the second adder-subtractor 72 , the second correction-amendment value is added to (or subtracted from) the each result by the first correction-amendment. Incidentally, the ratio of the top-hat fuel flow rate to the total fuel flow rate, the ratio of the pilot fuel flow rate to the total fuel flow rate, and the ratio of the main fuel flow rate to the total fuel flow rate are called the top-hat fuel flow ratio, the pilot fuel flow ratio, and the main fuel flow ratio, respectively.
In this way, on the basis of the determined fuel flow rate ratios, the order signal as to the opening of each of the fuel valves 48 , 52 , and 56 is issued.
The steps of determining the opening of each of the fuel valves 48 , 52 , and 56 are on the basis of the determined fuel flow rate ratios are now explained with reference to FIG. 5 ; thereby, the pilot fuel flow rate is calculated by use of the pilot fuel flow ratio and the total flow rate; the top-hat fuel flow rate is calculated by use of the top-hat fuel flow ratio and the total flow rate; further, at the comparator 84 , the main fuel flow rate is calculated by subtracting the pilot fuel flow rate and the top-hat fuel flow rate from the total fuel flow rate.
Subsequently, according to a relation expressed with the parameters as to the valve opening characteristic of each of the fuel flow rate control valves 48 , 52 and 56 , as well as, the parameters such as fuel temperature and fuel pressure, the order signal for controlling the opening of each of the fuel flow rate control valves 48 , 52 , and 56 is issued toward the corresponding fuel flow rate control valve; thereby, before being issued, each signal for each corresponding fuel flow rate control valve is corrected, at correctors 86 , 88 and 90 (in FIG. 5 ), so as to reflect the effect of the parameters such as fuel temperature and fuel pressure.
Further, in this third embodiment, at the inlet of the turbine 18 , the temperature sensor 19 for detecting the temperature of the combustion gas is provided. However, preferably, there may be an approach in which the temperature of the combustion gas is estimated through arithmetic calculations as to the detected-values detected by other temperature sensors and flow rate meters, with respect to heat balance and mass balance.
According to the this third embodiment, as is the case with the second embodiment, the control parameters comprise the suction air temperature detected by the suction air temperature sensor 22 and the calorific value of the fuel f detected by the calorimeter 46 ; further, the temperature of the combustion gas at the gas inlet of the turbine 18 is adopted as a variable (parameter) to be established corresponding to the target power output; thus, in addition to the effect brought by the second embodiment, the third embodiment can realize the effectiveness of restraining the influence of the seasonal change in the suction air temperature on the combustion stability inside the combustor, to a minimal level.
INDUSTRIAL APPLICABILITY
According to the present invention, a stable combustion operation of a gas turbine plant can be realized with a simple control mechanism, without producing combustion vibrations, in a case where the suction air temperature changes or the calorific value of the supplied fuel fluctuates, for instance, because of the increase of the inert gas components in the fuel.
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A gas turbine controller having a first generator for setting the flow rate of fuel or air being supplied to a combustor in correspondence with a target load, a sensor for detecting intake temperature of a compressor, a second generator for setting a correction amount of a set value of fuel flow rate or air flow rate based on the value detected by the sensor, a third generator for setting a modification amount of the correction amount while taking account of the target load, a first multiplier for operating a modified correction amount from a correction amount set by the second generator and a modification amount set by the third generator, and a second multiplier for calculating the flow rate of fuel or air being supplied to a combustor by adding the modified correction amount to the set value of fuel flow rate or air flow rate.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is related to and claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 60/464,357 filed 22 Apr. 2003, which is expressly incorporated fully herein by reference.
FIELD OF THE INVENTION
The present invention relates to the field of battery and capacitor charging. In particular, the present invention provides pulsed current charging using changes, regardless of polarity, in the local energy environment to obtain power. The present invention relates, for example, to ambient energy charging thin film batteries, other batteries, or capacitors, via, for example, polyvinyladine fluoride homopolymer (PVDF), PVDF bi-axially poled, or other piezoelectric materials. Ambient energy may be defined as any change in energy within the local environment. Charging can be accomplished with, and is not limited to, positive or negative changes of the following energy types: thermal; visible light, including infrared and ultraviolet; mechanical motion or impact; triboelectric, including airflow or physical contact; movement in relation to a gravitational plane (increase or decrease in gravitational potential energy); and radio frequency (RF) electromagnetic energy, regardless of specific frequency. Defined elements of this invention, potentially including, for example, size of piezoelectric material, mechanical mounting and coupling of piezoelectric material, energy translation into useful current at required voltage levels, regulation (voltage or current), and filtering (if necessary), may all be tuned to fit or combine with required outputs in any specific environment based on the relative abundance of one type of energy over others in a particular environment.
DESCRIPTION OF THE ART
Presently, there are certain devices available that use relatively high frequency and/or impact energy to charge batteries or capacitors. Energy pulses from these devices may be at significant voltage levels and may be converted into useable charge energy with simple rectification. Previous devices for the collection of mechanical energy other than impact energy generally require a significant amount of motion within the device to generate useable charge pulses. Relatively large voltage pulses from changes in temperature, 8 volts per 1° C. (open circuit) for bi-axially poled PVDF film are also available for charging a battery or capacitor.
Battery charging techniques for portable devices have been discussed in a number of patents such as U.S. Pat. Nos. 3,559,027; 4,320,477; 4,360,860; 4,701,835; 5,039,928; and 6,307,142. Additionally, certain patents such as U.S. Pat. Nos. 4,523,261; 4,943,752; and 5,065,067 have discussed the use of piezoelectric elements to provide energy to an electrical circuit. Moreover, some patents such as U.S. Pat. Nos. 4,185,621; 4,239,974; 4,504,761; 5,838,138; and 6,342,776 discuss the use of piezoelectric elements in combination with an electric circuit that includes a rechargeable battery. Additionally, IBM Systems Journal Vol. 35, No. 3&4, 1996—MIT Media Lab “Human-powered wearable computing” discusses the various energy expenditures of everyday human activity and discusses techniques and devices for harnessing human energy.
Certain charging systems for conventional batteries also require access to system power because of the high power requirements of the charging system and the rechargeable device. Additionally, charging systems typically require an external electrical (contact-type) connection between an external power source and the charger or charger/battery combination.
Because a piezoelectric event generally produces only small amounts of energy, attempts at producing and storing usable energy from piezoelectric materials have generally been limited to consuming the energy as soon as it is produced. Although applications such as switches and transducers made from piezoelectric material produce an output, this output has been largely classified as sensor-level, energy-only signals which may be recognized and processed by additional circuitry. Storing the energy from these events is considered expensive and therefore generally undesirable, in part because battery technologies exhibit leakage currents that consume energy at a level similar to that produced by piezoelectric material. Thus, conventional energy collection and storage systems are considered to be too expensive and/or inefficient to supply energy in usable quantities for present or future use.
SUMMARY OF THE INVENTION
The present invention relates, for example, to charging batteries or other storage elements using a piezoelectric element to supply energy. The present invention relates to a battery or capacitor charge device that allows the use of previously unusable changes in local energy, regardless of polarity, by the beneficial effect of stacking available charge energy.
There may be significant advantages of stacking low frequency energy. For example, stacking low frequency energy allows the use of local energy change events (positive or negative) that were previously not of sufficient charge value or voltage levels to be useable in even the lowest voltage circuitry.
Another advantage of the present invention is that, in contrast to previous devices, the present invention preferably operates when supplied with even small amounts of energy such as longitudinal stretch motion relative to the object on which it is mounted. Furthermore, this stretch may supply energy even if it is limited to approximately 1.5 μm. Moreover, in temperature-based charging applications, the present invention may output pulses based on a significantly smaller temperature change due to the beneficial effect of charge stacking. In a stacked element array, the temperature change may be the same for all elements. Thus, to obtain the same voltage as with a prior charger that does not employ stacking, a change of 1° C./the number of elements=the change in degrees Centigrade required to obtain an 8 volt output pulse. For example, in a five element stack, a 0.2° C. (one fifth degree Celsius) change may produce an approximate 8 volt open circuit output pulse.
An object of the present invention is to provide an ambient energy battery charging device that may be optimized for almost any environment. Another object of the present invention is to provide an ambient energy capacitor charging device that may be optimized for almost any environment.
One embodiment of the present invention may be an apparatus for use as a charger utilizing ambient energy including a plurality of stacked piezoelectric elements, a rectification block on an output of each of the elements, a plurality of capacitors arranged to accumulate charge from the rectification blocks, and a blocking diode provided at an output of the plurality of capacitors. Moreover, in certain embodiments, a charge storage device may be connected to an output of the blocking diode.
In a particular embodiment of the present invention, the rectification block may be a full-wave rectification block or a half-wave rectification block. The apparatus may include five or more stacked piezoelectric elements. Moreover, in a further embodiment of the present invention, the apparatus may further include a signal phase delay element (such as, for example, an inductor) provided between the rectification blocks and the capacitors. In another particular embodiment of the present invention, the charge storage device may comprise a battery or capacitor.
The apparatus may be optimized for changes in ambient power from gravitational effects on a structure rotating at an angle to the surface of a significant gravity source. A wheel may be an example of such a structure. An appropriate angle to the surface may be approximately perpendicular, or approximately 90 degrees. Such an angle may provide the maximum amount of useful energy. In general, if other angles are used, the useful component will be the component perpendicular to the surface. Significant gravity sources may include the earth, the moon, or an asteroid.
The apparatus may be optimized for changes in ambient power from a human or other heartbeat. The apparatus may alternatively be optimized for changes in ambient power available from local electrical fields, particularly those on the approximate range of 50 to 60 Hz. In another embodiment, the apparatus may be optimized for changes in ambient power available from low power sound or ultrasound energy. In yet another embodiment, the apparatus may be optimized for changes in ambient power available from RF spectrum energy fields. In another embodiment, the apparatus may be optimized for changes in magnetic fields. Additionally, the apparatus may be optimized to capture very low frequency energy of any frequency down to the limit of the piezoelectric material. This limit is believed to be about 0.001 Hz for DT-1 material from Measurement Specialties Incorporated (Fairfield, N.J.).
In certain embodiments of the present invention, the apparatus may incorporate circuit board technology. In such an embodiment, the device's capacitive, resistive (if any), or inductive elements may be part of the circuit board or traces upon the circuit board, rather than discrete components. Additionally, inductors may be incorporated in certain embodiments. These may be particularly useful in adjusting the phase of the energy from each element in the stack and may aid in preventing the output of one element from canceling a portion of the output from another element.
Another embodiment of the present invention may be a method of manufacturing a charger utilizing ambient energy including the steps of arranging a plurality of piezoelectric elements into a stack, connecting a rectification block on an output of each of the elements, arranging a plurality of capacitors to accumulate charge from said rectification blocks, and providing a blocking diode at an output of said plurality of capacitors. A further embodiment of the present invention may include the step of connecting a charge storage device to an output of said blocking diode. In a particular embodiment of the present invention, the step of arranging may include providing said plurality of piezoelectric elements arranged in a stack according to size.
It is understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The invention is described in terms of solid-state thin-film batteries; however, one skilled in the art will recognize other uses for the invention. The accompanying drawings illustrating an embodiment of the invention together with the description serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a five-element stack within an embodiment of the present invention.
FIGS. 2A–2C are mechanical drawings of a five-element stack, one type of physical PVDF layout.
FIG. 3 is a general layout depicting a charge device optimized for gravitational energy capture mounted on a wheel at 90° to the surface of the earth or other significant mass (planets, moons, asteroids, etc.).
FIG. 4 is a general layout depicting a charge device optimized for electromagnetic energy capture.
FIG. 5 is a diagram of sine wave type energy stacking.
FIG. 6 is a schematic diagram of a two film, single element, charge device for capture of 50 to 60 HZ RF energy.
FIG. 7 is a schematic diagram of a five-element stack, with an optional signal phase delay element, such as an inductor, for example, in a further embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that the present invention is not limited to the particular methodology, compounds, materials, manufacturing techniques, uses, and applications described herein, as these may vary. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. Similarly, for another example, a reference to “a step” or “a means” is a reference to one or more steps or means and may include sub-steps and subservient means. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.
Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Preferred methods, techniques, devices, and materials are described, although any methods, techniques, devices, or materials similar or equivalent to those described herein may be used in the practice or testing of the present invention. Structures described herein are to be understood also to refer to functional equivalents of such structures. All references cited herein are incorporated by reference herein in their entirety.
As described in this specification, applied force is shown as being in the same general direction and magnitude to each element. The type of force does not particularly matter and a generic force vector will be used. Cases involving a different force applied versus film area or changes in force direction may readily be inferred from the described case, by an ordinarily skilled artisan. Small variables due to discrete component characteristics are not shown as specific component values can vary; and further because, although this may optimize performance, it does not affect primary performance.
In general, force applied to a PVDF film may cause longitudinal motion of at least a portion of the film. This longitudinal displacement of a portion of the film can generate a voltage output. The magnitude of the voltage output depends, for example, on the force applied, the physical dimension of the PVDF film, and the capacitance of the film. The PVDF film may be coated with a conductive surface to remove Coulombs of charge. In another embodiment, the PVDF film may be in contact with a conductor to remove charge. This process may be reversible, thus, for example, voltage applied to a conductively coated PVDF film surface may cause physical motion in the film. In bi-axially poled PVDF, most of such voltage induced movement may be in the longitudinal direction. Typically only about 1/1000 of the movement will be in any other direction. PVDF film that may be used in accordance with the present invention may be such film as DT1 film from Measurement Specialties Incorporated (Fairfield, N.J.).
FIG. 1 is a circuit diagram of an embodiment of the present invention. The diagram illustrates one way in which five piezoelectric elements ( 111 , 112 , 113 , 114 , and 115 ) may be electrically connected in combination with five bridge networks ( 121 , 122 , 123 , 124 , and 125 ), five capacitors ( 131 , 132 , 133 , 134 , and 135 ), a blocking diode ( 140 ), and a battery ( 150 ). It may readily be seen that a diagram for a four element stack may be the same as for the five element stack except that capacitor 134 would be connected to ground and piezoelectric element 115 , bridge network 125 , and capacitor 135 would be omitted.
FIGS. 2A , 2 B, and 2 C are drawings of a five element stack. FIG. 2A corresponds to a top view of a five element stack. FIG. 2B corresponds to a bottom view of a five element stack. Finally, FIG. 2C shows the application of force though a force application center 220 in view that superimposes top and bottom views. This embodiment is adapted, for example, to convert ambient mechanical energy. A single PVDF film may be sectioned into five segments of increasing lengths as shown. These segments (or elements) 211 , 212 , 213 , 214 , and 215 (which may correspond to piezoelectric elements 111 , 112 , 113 , 114 , and 115 in FIG. 1 ) may be ordered from smallest to largest as depicted. Elements may be created in different sizes to provide specifically higher voltages as the film size increases for an evenly applied force across the PVDF film. This permits the stack to obtain a positive charge from top to bottom (for example, from the positive (+) terminal of capacitor 131 to the negative (−) terminal of capacitor 135 in circuit diagram, FIG. 1 ). Capacitors 131 through 135 may preferably be matched in size to the specific capacitance value of the PVDF element with which they are paired. They may be paired via rectification bridges—shown as 160 through 169 in the circuit diagram. These rectification bridges may preferably be full-wave rectification bridges, but may alternatively be half-wave bridges. One advantage of full-wave bridges may be the ability to capture energy of both polarities. Such a matched pairing may permit maximum charge transfer from the film. Essentially, the charge transfer may preferably allow the maximum voltage generated on the PVDF film, minus two diode forward voltage drops, to be collected on the associated capacitor.
A preferred rectification block, for use with the present invention, is a full wave rectifier as this allows voltages lower in the stack to appear on both surfaces of elements higher in the stack. This configuration may also help, for example, in preventing or diminishing the effect of individual elements that may convert applied voltage on one side to mechanical motion within the film in a direction contrary to applied force.
Force may be applied to the film roughly perpendicular to the top surface at the center of the film, along the force line in the drawing, via an attached mass. For any applied force, a voltage may be generated across each piezoelectric element inversely proportional to the size of the element.
FIG. 3 is a depiction of an embodiment of the present invention that employs a piezoelectric element in a rotational setting. As such an embodiment rotates, the gravitational force on the piezoelectric element changes through 360 degrees of rotation. In a situation in which gravitational attraction is 1 G, the force (in the longitudinal direction) on the element (due to gravity) will vary between 1 G (as seen in position 320 ) and −1 G (as seen in position 310 ) over the course of the rotation.
FIG. 4 is a depiction of two PVDF films ( 411 and 412 ) coupled mechanically together with, for example, a slight amount of stretch applied in the longitudinal axis. This embodiment of the present invention may be particularly useful in environments that include ambient RF energy. The mechanical interface between the films ( 411 and 412 ) may be enhanced by small rods ( 430 ) attached to the substrate as shown in FIG. 4 . Both films ( 411 and 412 ) may be attached firmly to the substrate at the substrate's ends. Both films ( 411 and 412 ) also may be coated with a conductive layer on, for example, both their top and bottom surfaces. In an embodiment that is not shown here, the film may be in contact with a conductor that may collect the charge from the surfaces of the film. A circuit diagram for this device is shown in FIG. 6 . The film conductive surfaces at the center of the device 420 may preferably be the same dimension or slightly smaller than the outer surfaces 422 and 424 (which may be the positive and negative terminals respectively) to aid in preventing RF energy from striking the center of the device.
RF energy, particularly low frequency RF, may tend to strike the outer layers of one or the other film ( 411 or 412 ) from a given direction. Energy that strikes both films ( 411 and 412 ) at the same magnitude, frequency, and phase angle may essentially cancel itself out. However, when RF energy asymmetrically strikes an outer film 411 surface, that film surface may gather charge, acting essentially as a capacitive antenna. As charge builds on the outer surface, the film 411 may change length. When the first film 411 changes length, the second film 412 may also change length, in the same direction, because it is mechanically coupled to the first film 411 . This paired expansion may then allow the second film 412 to output a proportional voltage. Thus, an applied voltage may exist on the first film 411 (due to the direct application of RF energy) and the added voltage produced by the piezoelectric effect in the second film 412 . Such a configuration may build voltage higher than what would be expected from simple Coulomb charge on the first film 411 due to incident RF. Experimentally, in a near field test using 110 Vrms, 170 Vrms values have been demonstrated into a 10 Mohm load.
FIG. 5 is a graph of voltages output from an embodiment of the present invention including a PVDF film and stack capacitors. The voltages, in this example, are generated by a PVDF film and stored in five stack capacitors by percentage of total output. This percentage may be based on the ratio of film element capacitance to total element capacitance using the element sizing depicted in, for example, FIGS. 2A–2C . If a circuit such as the one shown in FIG. 1 is employed, the voltages across the individual capacitors ( 131 , 132 , 133 , 134 , and 135 ) may vary as shown in corresponding proportional voltages ( 531 , 532 , 533 , 534 , and 535 ) depicted as waveforms. In this example, capacitor 131 's proportional voltage 531 is 25.7% of the total output voltage 536 (also depicted as a waveform). Capacitor 132 's proportional voltage 532 is 22.9% of total voltage 536 . Capacitor 133 's proportional voltage 533 is 20.0% of total voltage 536 . Capacitor 134 's proportional voltage 534 is 17.1% of total voltage 536 . Capacitor 135 's proportional voltage 535 is 14.3% of total voltage 536 .
FIG. 6 is a schematic diagram of a two film, single element, charge device for capture of 50 to 60 HZ RF energy, such as the one depicted in FIG. 4 . This embodiment includes two piezoelectric elements ( 611 and 612 ) connected to one bridge network ( 621 ). The bridge network ( 621 ) may be connected to a diode ( 640 ) and a battery ( 650 ).
FIG. 7 is a circuit diagram of an alternative embodiment of the present invention, in which the apparatus may include signal phase delay elements, such as inductors ( 171 , 172 , 173 , 174 , and 175 ), for example, provided between the rectification bridges ( 160 , 161 , 162 , 163 , 164 , 165 , 166 , 167 , 168 , and 169 ) and the capacitors ( 131 , 132 , 133 , 134 , and 135 ). This alternative embodiment may be useful in adjusting the phase of the energy from each element in the stack and may aid in preventing the output of one element from canceling a portion of the output from another element.
Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and the practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
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The present invention relates to the field of battery and capacitor charging. In particular, the present invention provides pulsed current charging using changes, regardless of polarity, in the local energy environment to obtain power. The present invention relates, for example, to ambient energy charging thin film batteries, other batteries, or capacitors, via, for example, polyvinyladine fluoride homopolymer (PVDF), PVDF bi-axially poled, or other piezoelectric materials. Ambient energy may be defined as any change in energy within the local environment. Charging can be accomplished with, and is not limited to, positive or negative changes of the following energy types: thermal; visible light, including infrared and ultraviolet; mechanical motion or impact; triboelectric, including airflow or physical contact; movement in relation to a gravitational plane (increase or decrease in gravitational potential energy); and radio frequency (RF) electromagnetic energy, regardless of specific frequency.
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This application claims the benefit of provisional application No. 60/285,632 filed Apr. 20, 2001.
BACKGROUND OF THE INVENTION
The present invention relates to high surface area micro-porous fibers made from polymer solutions, and particularly high surface area fibers for filtration application where surface micro-cavities are used to retain solid and/or liquid reagents for selective filtration to reduce certain smoke components.
Current cellulose acetate (CA) fibers used in cigarette filters are made by a dry spinning process which allows a 20-25% acetone solution of CA to be pulled or squeezed through the bottom holes of spinerettes or jets, and slowly shrunken into final fiber form by removing acetone solvent in a long spinning column approximately 5-10 meters long. Dried with a pressurized hot air stream in the column, the thus formed fibers with cross-sections such as “R”, “I”, “Y”, and “X” depending on the shape of the holes through which they are pulled or squeezed have a continuous core cross-section and relatively limited outer surface areas because of the heat involved.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to increase the outer surface area of certain fibers made from polymer solutions by forming micro-cavities useful for retaining solid and/or liquid reagents for selective filtration in the reduction of certain smoke components in tobacco products such as cigarettes.
Another object of the present invention is a process for producing high surface area fibers for filtration application in tobacco products such as cigarettes.
Still another object of the present invention is a process of producing high surface area fibers from polymer solutions where micro-cavities on the fiber surface are used to retain solid and/or liquid reagents for selective filtration in the reduction of certain smoke components in tobacco products.
In accordance with the present invention, a polymer solution is allowed to pull through the spinneret of a dry spinning process. A rapid evaporating process at reduced pressure is applied to the initial form of the fibers after a certain degree of drying in air-spinning columns where a dried skin of polymer is formed on the fiber surface. A residual amount of solvent or a blowing agent inside this skin explodes or pops and quickly leaves the fiber through various micro-porous paths under reduced pressure, leaving behind high surface area fibers with micro-porous cavities and internal void volume. For cellulose acetate fibers, an evaporating temperature below 60° C. in the evaporating process is essential in order to preserve the thus formed micro-pores in the fiber surfaces.
The process can be extended to polymer materials other than cellulose acetate as well as solvents and so called popping agents other than acetone. Also, suitable fibers are fibers from a melt polymer dope with air trapped in a chilled hard outer skin. The low temperature evaporation process can be applied in an on-line or in a batch manner.
BRIEF DESCRIPTION OF THE DRAWINGS
Novel features and advantages of the present invention in addition to those mentioned above will become apparent to persons of ordinary skill in the art from a reading of the following detailed description in conjunction with the accompanying drawings wherein similar reference characters refer to similar parts and in which:
FIG. 1A is a microscopic surface image of a fiber produced according to Example 1 of the present invention;
FIG. 1B is a microscopic cross-sectional view of a fiber produced according to Example 1 of the present invention;
FIG. 2 is a microscopic surface image of a fiber produced according to Example 2 of the present invention;
FIG. 3 is a microscopic surface image of a fiber produced according to Example 3 of the present invention;
FIG. 4 is a microscopic surface image of a partially dried fiber produced according to Example 4 of the present invention;
FIG. 5 is a microscopic surface image of a fiber dried at approximately 65° C. produced according to Example 4 of the present invention;
FIG. 6A is a microscopic surface image of a fiber dried at approximately 45-55° C. produced according to Example 4 of the present invention; and
FIG. 6B is a microscopic cross sectional view of the fiber shown in FIG. 6 A.
FIG. 7 is a microscopic surface and cross-sectional view of fiber produced according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following are specifics and examples of the present invention.
A. Preparation of CA/acetone solution. To a 100-ml three-necked round bottom flask equipped with mechanical stirring and glass plugs, 50-ml of acetone (Fisher Scientific, 99.6%) is added and then 11.88 g of CA tow fiber under medium stirring. After the addition, the bottle was plugged, and the added fiber was slowly dissolved into the solvent forming a homogenous white viscous solution overnight.
B. Dry spinning process to form fiber. About 10-ml of above solution was slowly transferred into a 10-ml extrusion barrel via a plastic syringe equipped with plastic tubes. The barrel was then installed onto a DACA 9-mm Piston Extruder Model 40000 with a round single hole 0.75-mm die and extruded at room temperature with a piston speed of 20 mm/minute. The extruded fiber was collected in an aluminum tray after dropping vertically in a 21-cm solvent venting distance created by the combination of two air blowing nozzles and an exhaust-venting hood. The residual of the solvent was further rapidly evaporated either by high vacuum in a vacuum oven or high airflow in a hood.
EXAMPLE-1
Fibers Obtained After Drying at 60° C. under Vacuum
In this example, the above fiber was collected on a metal pan and then put into a vacuum oven at 60° C. A mechanical pump generated a high vacuum inside this oven through a dry-ice trap. The trapped solvents rapidly evaporated and formed micro-pores on the fiber surfaces. FIGS. 1A and 1B show the microscopic surface and cross sectional views of the formed fiber after drying at 60° C. under vacuum for 20 minutes. It is clear that pores in the diameters of about 1-micrometer were formed. These pores are so small that they can only be observed in a 1000× images (1 micrometer/division) not in a 400× images (2.5 micro meters/division). The porous structure was also found stable in storage for more than 3 months.
The fiber samples in this example did not maintain their round cross section as shown in FIGS. 1A and 1B because they are collected and dried in horizontal positions. They shrink anisotropically into flat dog bone-shapes with cross sectional dimensions from 25-150 micrometers. It is possible to shrink the fibers into the round cross sections by handling them vertically without touch in the process. This example and the following examples are only used to demonstrate the spirit of modifying the surface porosity of the cellulose acetate fiber and is not used to limit the scope of the invention. The resultant porous fiber can be of any cross sectional shape.
EXAMPLE-2
Porous Fibers Obtained from Lower Temperature Evaporating Process
In this example, the above spun fiber samples was further dried at a no-heating process. The residual solvent was removed by rapid pumping in a vacuum oven without heat or in a highly vented hood at room temperature for 25 minutes. The typical surface images of the resulted samples are shown in FIG. 2 . Larger pores with diameters up to 3 micrometers are visible in even in a 400× image. It is obvious, the temperature and the pressure are playing significant roles in the final form of porosity on the fiber surface.
EXAMPLE-3
Experiments with Solid Ammonium Hydrogen Carbonate (AHC) Agents
Ammonium hydrogen carbonate (NH 4 HCO 3 , AHC) is known blowing agent in the manufacture of porous plastics. It decomposes at about 60° C. to give off CO 2 , NH 3 and H 2 O. In this example, a solid form of this agent is used to form large pores in the fiber. The setup of preparation and spinning of fiber is the same as Example 1. The experiments started with mixing 2.0 g of solid AHC powder (Aldrich, 99%) with 40 ml cellulose acetate acetone solution, as described for example 1. After mechanically stirring overnight, all the solid particles were mixed into the solution. 10 ml of this mixture was then spun in the DACA piston extruder. When a 1.25 mm dies was used, no continuous filament could be drawn. When a 0.5-mm round cross section die was used at a speed of 30.4 mm/minutes, the formed contiguous fiber filament was collected by manually winding on a80-mm bobbin after a 130 cm long dropping distance. However, there are large solid particles found deposit on the bottom of the barrel before passing through die. It may be that only a small amount of the agent was actually passed through the die to be incorporated into the fiber in this case. After decomposing the regents and removing the residual solvents under vacuum at a temperature of about 60° C. for 25 minutes, pores with diameters up to 2.5 micrometers are observed on the fiber surface as shown in FIG. 3 . The pores formed in this example are much larger than those in Example 1 because of the existence of small amount of blowing agent. To have an even larger effect, additional blowing agent must pass through the die without breaking the fiber. This can be incorporated by using blowing agents in sub-micrometer solid particulate form or dissolved forms in following example.
EXAMPLE 4
Experiments with Dissolved Ammonium Hydrogen Carbonate (AHC) Agents
A. Preparation of NH 4 HCO 3 /H 2 O solution. 2.0 g of above AHC solid was slowly added into a beaker containing 10.0 g of distilled water at room temperature under magnetic stirring. After the solid particles were dissolved, the formed solution was stored at a low temperature in a closed vial.
B. Preparation of CA/acetone solution containing NH 4 HCO 3 /H 2 O. To a 100-ml three-necked round bottom flask equipped with mechanical stirring and glass plugs, 50-ml of acetone (Fisher Scientific 99.6%) was added and then 12.5 g of CA tow fiber under medium stirring. After the addition, the bottle was plugged, and the added fiber was slowly dissolved into the solvent and a homogeneous white viscous solution formed overnight. Then, 1-ml of the above prepared AHC solution was added to the solution under vigorous mechanical stirring. After the addition, the mixture was continued to be stirred moderately for at least 1 h before use.
C. Dry spinning process to form fiber with large pores. About 10-ml of above solution was transferred into a 10-ml extrusion barrel by plastic syringe through a plastic tube. The barrel was then installed onto the DACA 9-mm Piston Extruder Model 40000 with a round single hole 1.5-mm die and extruded at room temperature at a piston speed of 20 mm/minute. The extruded fiber was collected in an aluminum tray after dropping vertically in a 130-cm pre-drying distance created by the combination of two air blowing nozzles and an exhaust-venting hood. Due to the decomposition of AHC in the mixture, large pores with diameters up to 5-10 micrometers are observed on the surface this partially dry sample as shown in FIG. 4 . However, this structure was not stable because of the existence of residual solvent. It relaxed back to a more stable structure with smaller pores as shown in FIG. 2 after storage at room temperature at atmospheric are pressure.
To fully remove the residual of solvent, 105.6 mg of above collected fiber was further treated in a vacuum oven at a temperature from 60-65° C. for 30 minutes 99.6 mg of dry fiber was obtained after about 6% of residual solvent was removed. The surface of the fiber is shown in FIG. 5 . Due to heating, the portion of the original big pores were destroyed by the polymer chain motion and relaxed back to smaller pores with diameters of about 1 micrometer similar to that in Example 1. Interestingly, some of the super large pores with diameter of 10-15 micrometers survived the process.
To preserve the formed porous structure, the fiber should be treated at a lower temperature with shorter time under high vacuum. Residual solvents (about 5-7%) can be effectively removed in a 5 minutes high vacuum oven treatment at a temperature about 50° C. For example, 1.7580 g of the above partially dried fiber was treated in the vacuum oven only for 5 minutes at 45-55° C., resulting in 1.6333 g of dried fiber. As shown in FIGS. 6A and 6B, large pores with diameters from 3-5 micrometers were formed in the dry fiber surface. This porous structure was also found to be stable at room temperature for long time storage.
A further embodiment includes cellulose acetate fibers prepared from a viscous acetone solution containing NH 4 HCO 3 /H 2 O solution that is completely dried at 59-62° C./Vac, as shown in FIG. 7 .
In summary, the above examples demonstrate that pores with diameters from 1-15 micrometers may be formed by evaporating rapidly residual solvents or blowing gasses through the fiber surface skin during or after a dry spinning process. These pores render higher accessible contacting surface area for the fiber to contact gas phase adsorbates, and also provide a inner fiber space to accommodate additional adsorbents/reagents for filtration application. To preserve the formed pores larger than 1 micrometer in diameter, a low temperature evaporating process with reduced pressure are preferred.
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Fibers are produced from an acetone solution of cellulose acetate by pulling or extruding such material through a spinneret in a dry spinning process. A vacuum is applied to the thus formed fibers after a certain degree of drying. A dried outer skin is formed, and the vacuum causes the solvent inside the skin to explode or pop and exit the fiber along micro-porous paths thereby producing high surface area fibers with micro-porous cavities and internal void volume. Such micro-cavities are particularly useful for retaining solid and/or liquid reagents in a cigarette filter for selective filtration of various smoke components.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Patent Application No. 62/009,621 filed on Jun. 9, 2014, entitled “MyHeart: An Intelligent mHealth Home Monitoring System Supporting Congestive Heart Failure Self-Care”, the entire disclosure of which is incorporated by reference herein.
FIELD
[0002] The invention relates to an application for home monitoring of congestive heart failure patients.
BACKGROUND
[0003] Congestive heart failure (CHF) is a chronic condition that is common among individuals older than 65[1]. A report published by the American Heart Association indicated that CHF is the most frequent cause for hospital readmissions such that 21.2% of Medicare patients diagnosed with CHF were readmitted to the hospital within 30 days of discharge and the estimated cost of diagnosis and treatment was 37.2 billion dollars in 2009 [2]. CHF is not curable but evidence shows that the quality of life and life expectancy of patients could be improved if the condition is managed by adhering to medications, monitoring symptoms, and salt intake in diet. Still, individuals with CHF are faced with increasing complexity in self-managing their care in their homes [3].
[0004] Prior studies have shown that providing better support for patients in the home could have a dramatic effect on cost and efficacy of healthcare [5, 6]. Recently a few technical systems have been tried to assist CHF patients [12, 13].
[0005] The problem is that self-care requires behavior change and support from clinical personnel. In theory, three elements must converge at the same time for a behavior to change [7]. These elements are: 1) motivation; 2) ability; and 3) trigger. According to Fogg's Behavior Model [7], when at least one of those three elements is missing, behavior doesn't change. Typically people have low motivation and a low ability to change. If one's ability is high then change can occur. Similarly if one's motivation factor is high, change can occur. What leads to higher motivation? If the activity is pleasurable instead of painful, if there is hope as opposed to fear, and if doing the activity leads to acceptance as opposed to rejection. Our ability to do something is higher when it takes less time, less effort, and less cost. However, Fogg states that an external “behavior trigger” is required to propel a person to change. We believe “just-in-time” texting can act as effective triggers and our recent work has provided support for this hypothesis [14].
[0006] Clinicians are key for providing personalized interventions however the growing number of cases and the limited number of clinicians drives the need to find more effective strategies to support self-care. Home telemonitoring has the potential to improve the outcomes of chronic disease self-management [7, 13]. A huge problem that SACHS Medical center is currently facing is with hospital readmission. About 30% of their CHF patients are readmitted within 30 days while nearly 50% are readmitted after 60 days. We design and build a novel home telemonitoring system, MyHeart, to support CHF self-care.
[0007] Therefore, there is a need in the art for home telemonitoring system that facilitates CHF self-care.
REFERENCES
[0008] [1] Masoudi, F., Havranek, E., & Krumholz, H. (2002). The burden of chronic congestive heart failure in older persons: Magnitude and implications for policy and research. Heart Failure Reviews, 7(1), 9-16. doi: 10.1023/A:1013793621248
[0009] [2] AHA, Lloyd-Jones, D., Adams, R., Carnethon, M., De Simone, G., Ferguson, T. B., . . . Stroke Statistics Subcommittee. (2009). Heart disease and stroke Statistics-2009 update: A report from the american heart association statistics committee and stroke statistics subcommittee. Circulation, 119(3), e101-e104. doi: 10.1161/CIRCULATIONAHA.108.191261
[0010] [3] Center for Disease Control and Prevention. (2012). Heart failure fact sheet. Retrieved from http://www.cdc,gov/dhdsp/data statistics/fact sheets/fs heart failure.htm
[0011] [4] Riegel, B., Carlson, B. (2002). Facilitators and barriers to heart failure self-care. Patient Education and Counseling, 46(4), 287-295.
[0012] [5] Rockwell, J. M., & Riegel, B. (2001). Predictors of self-care in persons with heart failure. Heart Lung: The Journal of Critical Care, 30(1), 18-25. doi: 10.1067/mh1.2001.112503
[0013] [6] Kutzleb, J., & Reiner, D. (2006). The impact of nurse-directed patient education on quality of life and functional capacity in people with heart failure. Journal of the American Academy of Nurse Practitioners, 18(3), 116-123. doi: 10.1111/j.1745-7599.2006.00107.x
[0014] [7] Fogg, B. (2009). A behavior model for persuasive design. Proceedings of the 4 th International Conference on Persuasive Technology , Claremont, Calif. 40:1-40:7. doi: 10.1145/1541948.1541999
[0015] [8] Pare, G., Jaana, M., & Sicotte, C. (2007). Systematic review of home telemonitoring for chronic diseases: The evidence base. Journal of the American Medical Informatics Association, 14(3), 269-277.
[0016] [9] http://www.myglucohealthstore.com/ProductDetails.asp?ProductCode=Q%2D2NETKIT2
[0017] [10] http://www.highcharts.com
[0018] [11] http://www.google.com/analytics/
[0019] [12] Ferguson, G., Allen, J., Galescu, L., Quinn, J., & Swift, M. (2009). CARDIAC: An intelligent conversational assistant for chronic heart failure patient health monitoring. AAAI Fall Symposium Series: Virtual Health Care Interaction (VHI 09), Arlington, Va.
[0020] [13] Guidi, G., Iadanza, E., Pettenati, M. C., Milli, M., Pavone, F., & Biffi Gentili, G. (2012). Heart failure artificial intelligence-based computer aided diagnosis telecare system. Proceedings of the 10 th International Smart Homes and Health Telematics Conference on Impact Ananlysis of Solutions for Chronic Disease Prevention and Management , Artimino, Italy. 278-281. doi: 10.1007/978-3-642-30779-9 — 44
[0021] [14] Samir Chatterjee, Kaushik Dutta, Qi Xie, Jongbok Byun, Akshay Pottathil, and Miles Moore, “Persuasive and Pervasive Sensing: a New Frontier to Monitor, Track and Assist Older Adults Suffering from Type-2 Diabetes”, in Proceedings of IEEE Hawaii International Conference in System Sciences (HICSS-46), Maui, HI, Jan 7-10, 2013.
SUMMARY
[0022] A telehealth system for monitoring the health of a CHF patient has a communication application operating on an electronic device, in communication with a medical authority, a scale connected to the application and configured to provide weight of the patient, a glucometer connected to the application and configured to provide a glucose measurement of the patient, a blood pressure meter connected to the application and configured to provide a blood pressure measurement of the patient, a database in communication with the application configured to store the weight measurement, glucose measurement and blood pressure measurement data, a rule-based expert system in communication with the monitoring database and with the application, wherein the expert system provides a risk assessment based on the weight, glucose reading and blood pressure of the patient.
[0023] In an embodiment the communication application is also in communication with a community health worker. The system may have a knowledge base in communication with expert system, wherein the medical authority provides rules to the knowledge base. In an embodiment, the expert system provides analysis to the medical authority. The analysis is provided through a dashboard, wherein the dashboard provides medical history and trends.
[0024] The risk assessment comprises a determination of whether a risk parameter is a medium or high risk parameter, an addition of a risk factor to a risk score, a determination of whether the risk score is above a high risk threshold, a determination of whether the risk score is within a medium risk threshold, and a determination of whether the risk score is below a low risk threshold, wherein the expert system sends an alert.
[0025] A method for monitoring the health of a CHF patient has the steps of measuring a weight of the patient and communicating the weight to an application on an electronic device, measuring a glucose reading of the patient and communicating the glucose reading to the application on the electronic device, measuring a blood pressure of the patient and communicating the blood pressure reading to the application on the electronic device, the application communicating data comprising the weight, glucose and blood pressure to an expert system, and the expert system providing a risk assessment based on the data.
[0026] In an embodiment, the step of measuring the heartrate and communicating a heartrate measurement to the application, and wherein the data further comprises heartrate. The application may communicate the data to a medical authority. The medical authority may provide rules to a knowledge base, and the knowledge base informs the expert system. The expert system may provide analysis to the medical authority.
[0027] The medical authority may contact the patient through SMS text. The app may present a dashboard on the application providing a patient history to the patient.
[0028] The risk assessment may have the steps of determining if a risk parameter is a medium or high risk parameter, if medium risk, adding a medium risk factor to a risk score, if high risk, adding a high risk factor to the risk score, determining if the risk score is above a high risk threshold, and if so, sending a high risk alert, determining if the risk score is within a medium risk threshold, and if so, sending a medium risk alert, and determining if the risk score is below a low risk threshold, and if so, sending a low risk alert.
DESCRIPTION OF FIGURES
[0029] FIG. 1 is a functional diagram showing the system architecture, according to an embodiment of the present invention;
[0030] FIG. 2 is a drawing of some screen shots and devices on which the application may run, according to an embodiment of the present invention;
[0031] FIG. 3 is a drawing of the application dashboard, according to an embodiment of the present invention;
[0032] FIG. 4 is a functional diagram showing the system architecture, according to an embodiment of the present invention; and
[0033] FIG. 5 is a representation of a risk assessment algorithm, according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0034] The present invention is a multifaceted system designed to enhance data flow and communication between CHF patients and healthcare providers through a secure and reliable channel. It is comprised of three major components: 1) a patient facing data collection suite including sensors and a mobile app; 2) a data aggregator with rule based expert system; 3) a healthcare provider's dashboard and data.
[0035] With reference to FIGS. 1 and 4 , the individual with CHF 2 may be at home or another location, and is connected to a scale 5 , glucometer 7 and blood pressure monitor 9 . The scale 5 , glucometer 7 and blood pressure meter 9 provide health parameters, respectively weight, blood glucose level and blood pressure, of an individual and are connected to a wireless communication device 10 such as a computer or a smartphone, which runs an application that monitors and records the individual's health parameters. The blood pressure monitor may also provide heartrate, and these are collectively patient data. It is not necessary to use scale 5 , glucometer 7 and blood pressure monitor 9 at the same time, but it is preferred. The data is transmitted to the home monitoring data database 15 . Health parameter information may also be transmitted to a community health worker 20 or community health command center. Further, the information may be communicated directly by the device 10 to a hospital 25 or from the community health worker 20 to the hospital 25 , where a nurse may monitor or assist the individual 2 . Information processed by the hospital is transferred to a knowledge base 30 that incorporates clinical guidelines and expert rules. Both the knowledge base 30 and the home monitoring data 15 are in communication with the rule-based expert system 40 with which they share some or all of their data, wherein the expert system produces analysis, including risks and recommendations 50 , that is transmitted to the hospital, and education information 55 that is transmitted to the individual 2 through the app on the device 10 .
[0036] All patient data that flows from the homes to Cloud to the Clinician's dashboard is encrypted as per HIPAA requirements. The following sections describe each component.
[0037] With regard to the method of monitoring, the patient facing data collection suite is a set of consumer accessible electronic devices paired with a custom build mobile application to collect patient's vitals and symptoms on a daily basis. Patient's vitals such as blood pressure, weight, and blood glucose are measured using Bluetooth, Wi Fi or ZigBee enabled FDA approved devices which connect via Bluetooth or other wireless connection through a communication hub. Data transmission utilizes cellular technology and is initially collected at a health data repository. Patient's symptoms are collected via a smartphone app (in an embodiment called MyHeart) running on Android OS. Symptom measurements, such as chest pain, shortness of breath, swollen feet etc., are collected and stored in local database at the IDEA Lab at Claremont Graduate University. Each of these parameters are provided by patients using a sliding scale from 0-10 on the app itself. Data communication is established once the mobile application authenticates itself via web services API. Additional functionalities such as measurements display, trending, messaging, and notification are also available for the patient via the mobile application.
[0038] FIG. 2 shows the sensors, such as a scale 5 , glucometer 7 blood pressure monitor 9 and mobile application screen shots. The application is designed to collect symptoms and display vitals and messages to encourage self-care behaviors. In a first screen 75 the health parameters are collected within the device through the app. In screen 80 , a questionnaire is used to further determine the symptoms, such as “feeling chest pain in last 24 hrs?” or “feeling more tired than usual?” In screen 85 , the app reminds the individual to input the data on his or her condition. In screen 90 , behavior change messages are provided to encourage healthy behaviors. Example behavior change message would be “Great job for getting your weight under 215 lbs”, “Take your medication every day” or “God loves you”.
Rule Based Expert System
[0039] The rule-based expert system 40 sits in the cloud (See FIG. 1 ) processes daily incoming data points (i.e., weight, blood pressure, blood glucose, and symptoms) and calculates a risk score. This risk score is used to help inform healthcare providers 20 , 25 of any possible relapse of a given patient on a daily basis. In addition, the risk score also triggers urgent notifications to both healthcare providers 20 , 25 about the patient's current health status.
[0000]
TABLE 1
Expert System Data Ranges for Rules Creation (based on input from
Cardiac Nurse)
High
High
Medium
Medium
Risk-
Risk-
Risk-Below
Risk-Above
Below
Above
Normal
Average
Average
Average
Average
Heart Rate
60-79
50-59
80-99
=<49
>=100
Systolic
90-129
80-89
130-139
=<79
>=140
BP
Diastolic
60-79
50-59
80-89
<=49
>=90
BP
Weight
+/−1 pound
−1.5 #
+1.5 #
−2 #
+2 #
Blood
60-200
<60 and >50
>200 and
<50
>250
Glucose
<240
[0040] The rule-based expert system is designed to be flexible and scalable. The rules in Table 1 summarize the assessment a human nurse would conclude on when she sees the health data.
[0041] With reference to FIG. 5 , an example risk assessment algorithm is shown. At step 100 , the parameter is assessed for medium risk. If medium risk, at step 105 , a medium risk factor such as 10 is added to the risk score. At step 110 , the total score is compared with 100, and if greater than a high risk threshold such as 100, at step 115 a high risk alert is sent. If the total is not greater than 100, then it is compared with 10 at step 120 . If greater than 10, or within a medium risk range or threshold, a medium risk alert is sent at step 125 , otherwise the value is below a low risk threshold and a message that the patient is fine is sent at step 130 . If the parameter is not medium risk, it is assessed for high risk at step 135 , and if high risk then a high risk factor such as 100 is added to the risk score at step 140 . At step 110 the total score is compared to 100.
[0042] Ancillary to the expert system, is the notification system. The notification system utilizes email and SMS messages to send important messages to the heart failure nurses 20 , 25 , and Cloud Messaging to communicate with patients via the mobile application, for example.
[0043] With reference to FIG. 3 , the information dashboard is shown. This dashboard is designed to display information that is collected daily from the patient collection suite. Each data point is analyzed by the rule engine and transformed for display. The information dashboard is presented in a tabular format with color indicators to highlight noteworthy data points. In addition, historical trending is accessible with drill down functionality.
[0044] Because of the sensitive nature of the data, security measurements are implemented at data collection, transfer, transformation, and display. At data collection point, a unique key is generated at the patient's mobile application side. In conjunction with the patient's phone number, the unique identifier is transferred to the central database every time the patient's phone communicates with the database. Data collection between the app and the database is established based on an automated scheduled method that runs daily. Security for the app is developed at the vendor's location.
[0045] All data are collected and stored on a server with authentication. Two different design philosophies drive the database design. First, patient and rule based metadata are stored with traditional transactional normalized design for scalability. With this approach, additional patients can be quickly added without overall impact to the system. Second, all reporting and information displays, such as the information dashboard, utilize a data mart design philosophy for speed and security purposes. Although a data mart design forces data transformation between raw data and final display, the data mart design presents two additional benefits, data traceability and data security.
[0046] The telehealth system for heart failure self-care aims to: 1) overcome the gap that occurs when patients transition from the hospital to home environment, and 2) reduce readmissions. The system builds on the behavior model such that it sends messages to patients that potentially trigger behavior change. It also facilitates daily communication among patients and heart failure clinicians so any deterioration in health could be identified immediately. Initial results show that the clinicians and patients are using the system and that some features of the system have been helpful while others need improvement. Future work will focus on incorporating feedback from the patients into the design of the system.
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A telehealth system for monitoring the health of a CHF patient has a communication application operating on an electronic device, in communication with a medical authority, a scale connected to the application and configured to provide weight of the patient, a glucometer connected to the application and configured to provide a glucose measurement of the patient, a blood pressure meter connected to the application and configured to provide a blood pressure measurement of the patient, a database in communication with the application configured to store the weight measurement, glucose measurement and blood pressure measurement data, a rule-based expert system in communication with the monitoring database and with the application, wherein the expert system provides a risk assessment based on the weight, glucose reading and blood pressure of the patient.
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This application is a continuation of application Ser. No. 442,448 filed Nov. 17, 1982, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a diaphragm pump for supplying fluid with a flow quantity control.
Diaphragm pumps are known in which the displacement or flow quantity can be controlled in such a manner that, for example, in a pump provided with crank drive the stroke of the displacement element can be changed. This construction, however, requires mechanical expenditures, is susceptible to failures and also is expensive. Other mechanical solutions for this purpose include, for example, a mechanical stepless control of the number of revolutions, or an electrical or electronic control of the number of revolutions of pump. These constructions are also complicated and expensive.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a diaphragm pump which avoids the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide a diaphragm pump which, without utilization of previously known expensive control devices, can provide for change of flow quantity or displacement quantity of fluid in a simple manner.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a diaphragm pump which has a damping chamber arranged to absorb pressure impacts of a fluid in aspiration region and having an adjustable fluid admission volume so as to change a fluid supply to the pump diaphragm.
Pumps with a damping chamber are already known. However, these damping chambers are provided exclusively for smoothing of aspiration and displacement of fluid in a pulsation free manner. In contrast to these solutions, the inventive diaphragm pump has a damping chamber arranged so that its admission volume or flow cross-section are adjustable so as to control the displacement quantity of the pump in a simple manner. The thus-designed damping chamber can serve for damping pulsations of the inflowing medium and at the same time serves for increasing the displacement quantity. Thereby the efficiency of the damping chamber can be deliberately changed and in some cases reduced to zero, so that to control the displacement quantity in accordance with flow techniques.
In accordance with another advantageous feature of the present invention, the admission volume of the damping chamber is limited by a displaceable damping diaphragm. The damping chamber in the region of this diaphragm can be elastically yieldable for compensation of pressure impacts, on the one hand, and the inner volume of the damping chamber can be changed for flow control by respective outside pressure action, on the other hand.
Still another advantageous feature of the present invention is that the rear side pressure action upon the damping diaphragm is performed by a relatively displaceable piston or other displacing element. In dependence upon the position of the above-mentioned piston, different admission volumes of the damping chamber can be obtained.
The diaphragm pump in accordance with the invention serves for displacement of fluid. With the above-described possibility to control the displacement quantity, different displacement volumes per stroke can be obtained in the displacement chamber of the pump. The pump diaphragm adapts automatically to these different displacement volumes. For providing a maximum grade control region without causing damaging actions such as cavitation, a further feature of the present invention is that the region of the differing stroke volumes of the diaphragm pump and the control region of the damping chamber are determined upon one another. This means that the value of the action of the variability of the damping chamber on the flow quantity of the diaphragm pump is brought in correspondence with the value of the volume per stroke which the pump diaphragm can provide. For example, by turning off the action of the damping chamber the flow quantity can be decreased only to such extent that with this minimum flow quantity in the displacement chamber no damaging lower pressure can be generated.
In accordance with still a further advantageous feature of the present invention, the above-mentioned results can be achieved by provision of the elastically deformable region of the pump diaphragm with the respectively great dimensions. The pump diaphragm thereby assumes a shape which corresponds to the minimum displacement quantity of a pump stroke.
Particularly for pumps having small dimensions, it is advantageous in accordance with a further feature of the present invention to form the pump diaphragm as a shaped diaphragm which in its central region at a side facing toward the displacement chamber is mounted on a piston rod in a clamp-free manner. Advantageously, the shaped diaphragm is mounted with the aid of vulcanized-in connecting piece. In this construction a mounting plate which is conventionally provided in the pump diaphragm at its side facing toward the displacing chamber, can be dispensed with. The advantage of this solution is that the pump diaphragm does not have at its side facing toward the displacement chamber metal parts such as screws which extend in the displacement medium unprotected or protected with difficulties. The thus-designed pump diaphragm does not possess the disadvantages of conventional pump diaphragms in which a great central region is clamped between a piston rod and a mounting plate, and only small elastically deformable region remains for adopting to volume conditions for different displacement volumes per working stroke to displace the respective fluid quantities. In the conventionally designed pump diaphragms with the above-mentioned small elastically deformable region cavitation can take place.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing a section of a diaphragm pump in accordance with the present invention;
FIG. 2 is a diaphragm showing a flow speed in an aspiration pipe in dependence upon a crank angle, of the inventive diaphragm pump;
FIG. 3 is a view substantially corresponding to the view of FIG. 1, but showing the diaphragm pump in accordance with another embodiment of the invention;
FIG. 4 is a view showing the diaphragm pump of FIG. 3 in a different position for controlling a flow quantity; and
FIG. 5 is a view substantially corresponding to the view of FIGS. 1 and 3, but showing a further embodiment of the inventive diaphragm pump.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A diaphragm pump shown in FIG. 1 is identified with reference numeral 1 and has a pump diaphragm 3 which is connected with a head 2 of a piston rod. A displacement or pumping chamber 4 is located above the pump diaphragm 3 and is bounded by a cylinder head 5. The cylinder head 5 has an inlet valve 6 and an outlet valve 7. A valve plate 8 serves as a closing element for the valves 6 and 7 and has tongue valves 26 and 27 of conventional type.
A damping or oscillating chamber 10 embodying distinctive features of the invention is provided above the cylinder head 5 inside a pump head 9. The damping chamber 10 communicates via a T-shaped connecting conduit 11 with an inlet pipe 12 and the outlet valve 6. The damping chamber 10 is limited at its one side by a damping diaphragm 13, whereas the other limit is formed by the cylinder head 5 and more particularly by a head plate 14 belonging to the cylinder head 5. The damping diaphragm 13 is clamped between the outer edge of the head plate 14 and an end edge 15 of a cup-shaped closing part 16.
In the embodiments shown in FIGS. 1, 3 and 4 the head plate 14 has a surface 28 which faces toward the damping chamber 10 and is concave so that the damping chamber 10 in the case of a round cylinder head has the shape of a spherical segment. A piston 17 or another movable element is arranged inside the closing part 16 and moves relative to the damping diaphragm 13 for providing rear-side pressure loading or displacing the diaphragm 13. The piston 17 has a substantially mushroom-like contour and is provided with a central threaded pin 18 which is screwed in a threaded opening 20 provided in a bottom part 19 of the closing member 16. The piston 17 is displaceable in its axial direction identified by double arrow Pf1 with the aid of an adjusting button 21 provided on the outer end of the threaded pin 18.
The piston 17 has a surface 22 which faces toward the damping diaphragm 13 and has a shape corresponding to the shape of the opposite surface 28 of the head plate. Therefore, the damping chamber 10 can be practically reduced to zero, in which case the damping diaphragm 13 lies on the concave surface 28 of the head plate 14 and is firmly held there by the piston 17 as shown in FIG. 4. Instead of the T-shaped connecting conduit 11, a branch line of another type can be provided which connects the inlet pipe with the inlet valve 6, on the one hand, and with the damping chamber 10, on the other hand, as shown in FIG. 5.
The damping diaphragm 13 in the embodiments shown in FIGS. 1, 3 and 4 is composed advantageously of an elastic material, for example rubber, so that the damping chamber 10 can be varied elastically yieldably in correspondence with the pulsating pressure loading from the inlet pipe 12, when it is not fixedly pressed against the concave surface 28 of the head plate 14. The elastically yieldable damping diaphragm can also act to smooth the pulsating inlet stream when it elastically swings, as shown in FIGS. 1 and 3, in communication with the damping chamber 10 and the T-shaped connecting conduit 11. Thereby an improvement of the efficiency of the pump is attained, inasmuch as the kinetic energy of the aspirated fluid is utilized better.
The supply stream produced during aspiration, for example, in the inlet pipe 12 is no longer stopped by closing of the inlet valve 6, but instead is directed in the damping chamber 10 and stored there under the supply pressure until the inlet valve 6 is again opened. Then displacement fluid from the damping chamber 10 and displacement medium from the inlet pipe 12 flow in the compression or displacement chamber 4, so that the latter is filled faster than in the event when the inlet pipe 12 without communication to a damping chamber supplied the fluid directly to the inlet valve 6 or to the displacement chamber 4.
FIG. 2 clearly shows the ratio between the respective aspiration and displacement volume with different adjustment of the damping chamber 10. In this diagram the ordinate represents a flow speed V in the inlet opening 23 to the displacement chamber, and the abscisse represents the position of the pump diaphragm 3 via the crank of its crank drive. In zero point of both coordinate axes, the crank drive is in its upper dead point. When the damping chamber 10 is adjusted in its volume by abutting of the damping diaphragm 13 against the concave surface 28 of the head plate 14 and practically provides no action as shown in FIG. 4, the course of curve shown in solid lines in FIG. 2 takes place. It can be clearly recognized that during an initial region of the stroke movement of the pump diaphragm 3, only an insignificant inflow of the displacement fluid in the displacement chamber 4 takes place. As known for the pump expert, the fluid standing in the inlet region must be first driven in movement by the stroke movement of the pump diaphragm 3. Correspondingly, it can be clearly recognized from FIG. 2 that over an initial region of the stroke movement of the diaphragm 3, first only an insignificant flow of the fluid in the displacement chamber 4 takes place. The flow speed increases then gradually until approximately in the lower dead point shown in FIGS. 1, 3 and 4 it goes again to zero by closing of the inlet valve 6. The area F1 between the abscisse and the solid line represents the aspiration volume V1 of the diaphragm pump 1 when it operates practically without the diaphragm chamber 10. This corresponds to the working mode in the event of closed throughflow cross-section 45 in FIG. 5.
When the damping chamber 10 is determined optimally in accordance with the inflow condition, the course of curve shown in broken line in FIG. 2 substantially takes place. It can be seen that in the beginning of the aspiration step a fast increasing supply flow of the fluid takes place, so that in the region available for aspiration between the upper dead point and the lower dead point a considerably greater aspiration volume V2 shown in FIG. 3 is available. With this adjustment a total aspiration volume per working stroke is produced which is represented by both areas F2 and F1 in FIG. 2. It is especially advantageous in the inventive diaphragm pump that in addition to the pulsation damping in a simple manner by changing the damping chamber 10 (FIGS. 1, 3 and 4) or its throughflow cross-section 45 (FIG. 5) also an adjustment of the displaced quantity with the same number of revolutions or number of strokes of the diaphragm pump 1, 1a, and 1b is achieved. An intermediate position is shown in FIG. 2 in dash-dot lines. The respective intermediate position of the damping diaphragm 13 in FIG. 1 is also shown in dash-dot lines.
The rear partial loading of the damping diaphragm 13 must not necessarily be produced mechanically by the plunger 17 as shown in the described embodiment. It can also be produced by a gas pressure cushion. For example, the inner chamber 24 of the closing part 16 is open outwardly via an opening 25, so that a rear side of the damping diaphragm 13 is acted by atmospheric pressure. In some cases, this opening 25 can be closed and the inner chamber 24 can be loaded with different pressures.
In dependence upon the utilization of the pump 1 and in dependence upon the requirement made to the damping and adjusting properties of the damping chamber 10, the damping diaphragm 13 can be composed of different materials. Especially in the event of a gaseous fluid, a preferable embodiment is when the diaphragm is composed of polytetrafluoro ethylene which is flexible, chemically neutral, considerably temperature resistant and has a mechanical stability. There is also a possibility to produce the damping diaphragm 3 of metal, which can be advantageous, for example in the event of high temperatures and/or working pressures or supply pressures because of its high strength. The utilization of the damping diaphragm 3 of rubber, synthetic plastic material or other elastic material has the advantage of a relatively great adjustment amplitude and a fast response of the damping diaphragm. In this case correspondingly a wider adjustment region is provided under the same conditions. With utilization of considerably non-elastic or low elastic materials, expansion formations can be provided in the damping diaphragm 13, for example formed as wave-like formations arranged concentrically around its center to improve its resiliency.
When a diaphragm pump is provided with a controllable damping chamber 10, a diaphragm pump 1 shown in FIGS. 1 and 3 is obtained which is controllable relative to its displacement volume per second by the adjustability of the damping chamber 10 without the need of changing the stroke height of the piston rod or its rotary speed. Since the pump diaphragm 3 has its inherent flexibility, it can be adapted in predetermined limits to different aspiration volumes.
In accordance with a further embodiment of the invention, the control region of the diaphragm pump 1 can be increased, or it can be taken care that inside the operative control region undesirable operation phenomena, for example cavitation are reliably excluded. For this purpose, the region of different suction volumes, on the one hand, and the control region of the damping chamber 10, on the other hand, can be determined upon one another. Also, various methods can be taken which are shown in FIGS. 3 and 4 for a diaphragm pump 1a.
The piston rod 32 of the diaphragm pump 1a must be located in the lower dead point. Simultaneously, the damping diaphragm 13 must have a certain swinging freedom corresponding to the shown position of the piston 17, and with this adjustment the compression chamber 4 must obtain an optimum filling with the suction volume V2 per each stroke. The diaphragm pump 1a operates then with the maximum flow quantity per time unit, which corresponds to the combined areas Fl and F2 of FIG. 2. When it is desired to reduce the flow quantity per time unit, for example for minimum controllable flow quantity per second, the piston 17 is displaced to a position shown in FIG. 4. Thereby the function of the damping chamber 10 is practically terminated. The pump works when considerably smaller suction volume V1 per pump stroke as shown in FIG. 4.
A comparison of a shaped diaphragm 3a in FIGS. 3 and 4 shows that the pump diaphragm with its elastic region 33 adopt to the smaller suction volume V1 in accordance with FIG. 4. Since all pump diaphragms of diaphragm pumps have an elastic and/or flexible region 33, a certain adaptation to the respective suction volume per stroke is inherently provided in the diaphragm pump. In dependence upon the design of the diaphragm pump 1 and its diaphragm chamber 10 and upon the flow condition during flowing of the displacement medium into the displacement chamber 4, in the event of reduction of the flow quantity such an operational condition can be attained in which the suction volume V1 in FIG. 4 is so small that the elastically deformable region 33 of the diaphragm 3 or 3a can no longer be adjusted to this suction volume V1. By its diaphragm movement, this diaphragm 3 provides more pump chamber than the aspirated fluid is available. The membrane pump has then a tendency to generate a negative pressure which can cause cavitation phenomenon. For preventing this, the aspiration volume and the control region of the damping chamber 10 are determined upon one another. In particular, it can be provided that the elastically deformable region 33 of the pump diaphragm 3 has correspondingly great dimensions. This is carried out, for example, so that the pump diaphragm is formed as the shaped diaphragm 3a with relatively great elastically deformable region 33. This also can be achieved in the same condition when the shaped diaphragm 3a in its central region 31 at the side of the displacement chamber 4 is mounted on the connecting rod in a clamp-free manner.
In the embodiment shown in FIGS. 3 and 4 this is achieved in that the shaped membrane 3a in its central region has a connecting part 35 facing toward the connecting rod 32, and a metallic mounting piece 36 is vulcanized in this connecting part. The mounting piece 36 has a mounting pin 37 through which it is connected with a shaft 38 of the connecting rod. As a result of this, not only the diaphragm side facing toward the displacement chamber 4 is free from metallic mounting parts, which in some cases provided with a chemically resistant layer 100 shown in dash-dot lines in FIG. 3, but also this prevents that a mounting plate 29 connected by a screw 30 with the connecting rod head 2 shown in FIG. 1 renders a great part of the central region 31 of the membrane nondeformable and makes the elastically deformable region of the pump diaphragm very small, under the same condition.
A further advantageous embodiment is provided when a supporting ring 39 is mounted on the connecting rod 32. The supporting ring 39 is arranged with its ring-shaped supporting surface 40 in a central zone of the elastically deformable region 33 of the pump diaphragm 3 or 3a. In normal conditions it does not contact the diaphragm pump 3 in its outer surface 41 facing toward the connecting rod. However, this outer surface 41 can be supported when necessary, so that the pump diaphragm 3 cannot "turn over", or in other words bulge downwardly. It is thereby guaranteed that the diaphragm 3 assumes in the vicinity of the displacement chamber 4 at least a substantially flat shape as shown in FIG. 3 or a convex shape toward the displacement chamber 4 as shown in FIG. 4. An instability of the diaphragm 3 which is unfavorable for the aspiration volumes V1 or V2 is avoided.
As can be clearly seen from FIGS. 3 and 4, the supporting ring 39 is connected via a cup-shaped or basket-shaped lower part 42 with the shaft 38 of the connecting rod. Advantageously, the mounting piece 36 with its mounting pin 37 can be used for this purpose. As can be seen from FIG. 3, the diameter D1 of the damping chamber 10 substantially corresponds to the diameter D2 of the displacement chamber 4. Experiments have shown that with such a design of the displacement chamber it can be easily carried out structurally, flow conditions in the region of the inlet pipe 12, the inlet valve 6 and the damping chamber 10 are such that a good control possibility for the flow quantity of the diaphragm pump 1 and 1a per time unit is obtained.
FIG. 5 shows a further somewhat different embodiment of the diaphragm pump 1b. In the above-described embodiments of the diaphragm pump 1 and 1a in accordance with FIGS. 1, 3 and 4 the respective volume quantitites which are received by the damping chamber 10 in each aspiration step depend upon the position of the piston 17 in connection with the elastic deflectability of the damping diaphragm 13. In accordance with the embodiment of FIG. 5, the volume of the displacement medium aspirated during each aspiration stroke and flowing in a damping chamber 10b is changed by a controllable throughflow cross-section 45. A two-end branch conduit 46 leading from the inlet pipe 12 to the inlet valve 6, on the one hand, and to the damping chamber 10b, on the other hand, is formed so that its end portion 47 which leads to the damping chamber 10b ends centrally in a closing surface 48 located, advantageously centrally, in the damping chamber 10b. The closing surface 48 cooperates with a displaceable closing element 49 which is a part of a displacing element 50 connected with the adjustment button 21. The displacing element 50 extends through a diaphragm 13b, as well as clamps it there tightly and hold it firmly. A valve plate-like closing element 49 which belongs to the displacement element 50 is located at that side of the damping diaphragm 13b which faces toward the damping chamber 10b. By rotation of the adjustment button 21, the closing element 49 can move toward or away from the closing surface 48 in direction of the arrow Pf2 in FIG. 5. Correspondingly, the throughflow cross-section 45 which is available for the pulsating displacement medium in the end portion 47 of the branch conduit 46, is changed. The above-described effect of the variable extension chamber principle in connection with FIGS. 1-4 which leads to increase or reduction of the supply flow of the displacement medium at the inlet valve 6, is achieved in the embodiment of the diaphragm pump 1b of FIG. 5 particularly with cooperation of low technical features, namely by closing or more or less opening of the throughflow cross-section 45.
This solution has several advantages. For fully covering the control region of the diaphragm pump 1b, it is required to deflect the damping diaphragm 13b by only relatively small amounts. When the damping diaphragm 13b is composed, for example, of polytetrafluoro ethylene or the like chemically inert material which is desirable in the most cases, there is the advantage that great deflection for covering the control region of the diaphragm pump 1b is not required. In correspondence with this, there is not an undesirable great loading, particularly expansion of such material as for example polytetrafluoroethylene which is considerably flexible, but a little elastically expandable and in the event of respective loading has a tendency to cold flowing. Unfavorable expansion loads which can be recognized for example by comparison of the damping diaphragm 13 in FIGS. 3 and 4 can be avoided in the embodiment of FIG. 5.
In the closed position which is not shown in FIG. 5, in which the closing element 49 abuts against the closing surface 48, there is a condition which is described in connection with FIG. 4 for the diaphragm pump 1a. The described embodiment of FIG. 2 is applicable for the embodiment of FIG. 5. With the damping chamber 10b of FIG. 5, the change of the volume of the damping chamber 10b proper or first of all the actual change of the volume admission by the control of the flow cross-section 45 does not matter or matters only unimportantly. What is common for the embodiments of the diaphragm pumps 1, 1a and 1b is that the quantity of the fluid which flows to the damping chamber per aspiration stroke of the pump or flows out of the damping chamber 10 or 10b is selectively adjusted and thereby the displacement volume of the diaphragm pumps 1, 1a and 1b can be controlled.
The inventive design of the diaphragm pumps 1, 1a and 1b with the damping chamber 10 is applicable advantageously for small or smallest pumps with a displacement efficiency of advantageously approximately 0.2 liter per minute--20 liter per minute. With very simple not flow susceptible means, the diaphragm pump is provided with a built-in flow quantity control corresponding to flow techniques, and the operation of the diaphragm pump is considerably improved in the working region. The diaphragm pump 1 is particularly usable because of the damping chamber 10 in a through flow quantity region which is located above the standard displacement quantity of these pumps. The term "standard displacement quantity" is used here to identify the diaphragm pumps without the damping chamber. It is possible to have a relatively small and respectively inexpensive pump whose displacement quantity per time unit can be increased in a simply controllable manner by addition of the adjustable damping chamber.
It is to be understood that the diaphraqm pump 1 with its pump diaphragm 3 is designed so that with the damping chamber 10 adjusted to zero can operate in disturbance-free manner and without cavitation.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a diaphragm pump, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of the present invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
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A diaphragm pump for fluids has a housing, a fluid displacement part including a displacement chamber and a pump diaphragm, and a flow control including a damping chamber arranged to absorb pressure impacts a fluid in aspiration region and having an adjustable fluid admission volume so as to change a fluid supply to the pump diaphragm.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a cemented annulus in an oil and gas well. More specifically, but not by way of limitation, this invention relates to a method for repairing leaks to a cemented annulus in a well.
[0002] Oil and gas wells are constructed using steel pipe known as casing to line and structurally support the wellbore. Typically, a drive pipe is driven into the ground followed by a large surface casing that is run a few hundred feet into a drilled hole. As well understood by those of ordinary skill in the art, cement is pumped around the surface casing to seal the space between the casing and the drive pipe. The cement supports the casing, isolates the subterrean reservoirs and protects ground water zones. The operator then drills a deeper wellbore and a smaller diameter casing, known as the intermediate casing, is run into the surface casing to the bottom of the wellbore. The intermediate casing is also cemented into the ground, with the cement being placed in the intermediate casing annulus all the way to surface in most instances.
[0003] The wellbore may be drilled further to a specified depth through a productive zone. At this point, the operator may run in the wellbore with a smaller diameter casing, known as a production casing, through the productive zone. The production casing may be cemented all the way to the surface.
[0004] The operator will then place a wellhead over the wellbore. In some instances, the operator may place the wellhead over some, but not all, of the casing annuluses. For instance, the production casing and the intermediate casing may be covered by the wellhead, but not the surface casing annulus. Under this scenario, the surface casing annulus must rely on the cement to isolate the subterranean zones. Gas leaks can occur in this surface casing annulus which ultimately can escape into the environment. As readily understood by those of ordinary skill in the art, these leaks can lead to problems. Also, these surface leaks can be present in old wells as well as recently drilled wells.
[0005] Possible sources of the leaking gas include a shallow gas zone penetrated by the surface casing or a leak allowing communication from the intermediate casing to the surface casing. In either case, the cement in the surface and intermediate casing annulus must have a flow path to allow the gas to reach the surface.
SUMMARY OF THE INVENTION
[0006] A method of providing pressure containment of a well having a well annulus cemented to the surface and without the mechanical isolation of a wellhead is disclosed. In one embodiment, the well annulus contains a set cement, and the cement contains flow paths which communicate a well pressure. The method comprises creating a reception area at the top of the well, placing a containment cement slurry in the reception area and installing an injection delivery system within the reception area. The method may further include preparing a settable fluid for injection into the flow paths and injecting the settable fluid through the injection delivery system into the flow paths of the well annulus. In one embodiment, the settable fluid is a resin selected from the group consisting of: Bisphenal F type resin with a diluent such as Epodil and catalyzed with an epoxide catalyst such as Ancamide 506, Ancamide 2386 or W Hardener. In another embodiment, the settable fluid may be a micro-fine cement slurry comprising: microfine cement such as MC500 and water; the micro-fine cement slurry may also contain a dispersant, a fluid loss additive and a retarder. Also, the containment cement slurry may comprise: a Class A cement, between 0% to about 15% BWOC Gypsum, and between 0% to about 3% BWOC CaC12;. In one disclosed embodiment, the injection delivery system may include a series of injection tubulars configured to deliver the settable fluid to the flow paths. The injection delivery system may include a template having a first, second, third and fourth injection tubular. The injection may include applying a squeeze pressure of resin that is injected into the tubular above an established breakdown pressure and below a burst/collapse pressure of the well casing. According to this disclosure, the method may also include allowing the settable fluid to set, monitoring the pressure of the well annulus, observing a pressure increase in the well annulus, and then repeating the steps of injecting the settable fluid. If no pressure increase is observed, the injection delivery system may be removed from the reception area.
[0007] In another embodiment, a method of providing pressure containment of a well is disclosed. The well may contain a surface casing having a surface annulus, an intermediate casing having an intermediate annulus, and a production casing having a production annulus, and wherein the surface annulus, the intermediate annulus and the production annulus contains cement. The surface annulus contains flow paths capable of releasing pressure from a subterranean zone. The method includes placing a containment cement slurry in a reception area at the top of the well, installing a first tubular member within the reception area, and placing a valve on the first tubular member. The method may include fluidly connecting the first tubular member to a pump member, preparing a settable fluid, and pumping the settable fluid through the first tubular member into the flow paths of the surface annulus. The step of pumping the settable fluid may include creating a squeeze pressure and the method further includes maintaining the squeeze pressure until the settable fluid hardens within the flow paths of the surface annulus. The settable fluid may be selected from a group consisting of a resin and a micro-fine cement slurry.
[0008] In yet another embodiment, a method of providing pressure containment of a well having a well annulus containing cement is disclosed, wherein the cement contains flow paths. The method comprises placing a containment cement slurry in a reception area at the top of the well, installing a tubular member within the reception area, and preparing a resin, wherein the resin is selected from the group consisting of Bisphenal F type resin with a diluent such as Epodil and catalyzed with an epoxide catalyst such as Ancamide 506, Ancamide 2386 or W Hardener. The method may further comprise injecting the resin through the tubular member into the flow paths of the well annulus.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 is a schematic illustration of a prior art wellbore having a plurality of casing strings extending into subterranean zones.
[0010] FIG. 2 is a schematic illustration of an embodiment of the present invention adapted to a wellbore.
[0011] FIG. 3 is a top view of the schematic illustration of the embodiment of FIG. 2 taken along line 3 - 3 of FIG. 2 .
[0012] FIG. 4 is a top view of the template of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring now to FIG. 1 , a schematic illustration of a prior art wellbore 2 is depicted, wherein the wellbore 2 contains a plurality of casing strings extending into subterranean zones. More particularly, an operator will drive a drive pipe “DP” or conductor pipe and thereafter drill an initial hole with a drill bit. Next, the operator will place a surface casing 4 within the drive pipe DP. The operator will then place cement into the surface casing annulus 6 through known techniques and allow the cement to set. A typical cement slurry for the surface casing annulus 6 is commercially available from Halliburton Energy Services under the name HalCem™. As well understood by those of ordinary skill in the art, the depth of the surface casing will vary, but generally is placed from 300′ to about 2000′.
[0014] Next, the operator will drill within the surface casing 4 , and concentrically place the intermediate casing 8 within the newly drilled hole. After placement of the intermediate casing 8 , the intermediate casing annulus 10 is filled with a cement slurry, and wherein the cement slurry is allowed to set. The operator may continue drilling to a deeper depth within the intermediate casing 8 . As shown in FIG. 1 , a production casing 12 is then placed in the well thereby creating a production casing annulus 14 . The production casing 12 intersects a subterranean zone 16 that may contain hydrocarbons. The production casing 12 is run all the way to the surface in the embodiment shown. The production casing annulus 14 is filled with a cement slurry of similar composition to the surface annulus cement and the intermediate casing annulus cement. The wellbore 2 may be perforated at the subterranean zone 16 so that the subterranean zone 16 is placed in communication with the inner bore 18 for production of hydrocarbons, as well understood by those of ordinary skill in the art.
[0015] FIG. 1 also depicts the wellhead, seen generally at 20 . The wellhead 20 , sometimes referred to as the Christmas tree 20 , contains a series of valves for controlling flow out of the wellbore 2 as well as flow into the wellbore 2 via the inner bore 18 . The wellhead 20 may include a master valve 22 as well as wing valves 24 , 26 . The wellhead 20 covers and seals the intermediate casing annulus 10 as well as the production casing annulus 14 . However, the surface casing annulus 6 is not covered by the wellhead and thus open to the atmosphere. Hence, in the event that flow paths develop in surface casing annulus 6 , hydrocarbon liquids and gas (as well as in-situ water) may be leaked to the surface. Also, if there is communication between the intermediate casing annulus 10 and the surface casing annulus 6 , liquids and gas can be channeled to the surface casing annulus 6 and into the environment. These leaks pose many safety and health risks.
[0016] FIG. 1 is exemplary of a wellhead and casing implementation. However, it is possible that some changes may occur. For instance, for reasons pertaining to engineering and reservoir specifics, a number of additional casing strings may be employed. Moreover, some casing strings (besides the surface casing) may not be covered by the wellhead 20 . The disclosure herein is applicable to any casing annuluses cemented to surface and not covered by a wellhead.
[0017] Referring now to FIG. 2 , a schematic illustration of an embodiment of the present invention adapted to a wellbore 30 will now be discussed. In the various figures, like numbers in the figures refer to like components. More specifically, a drive pipe DP, a surface casing 32 , an intermediate casing 34 , and a production casing string 36 is shown. The surface casing 32 and drive pipe DP form the surface casing annulus 38 and the intermediate casing 34 and surface casing 32 form the intermediate casing annulus 40 . The surface casing annulus 38 has a set cement therein and the intermediate casing annulus 40 has a set cement therein, and the composition of the set cement may be the composition previously mentioned. As noted earlier, the cement in the surface annulus may contain flow pathsrepresentively shown at 42 , that serve as a path for liquids and gas.
[0018] FIG. 2 further depicts the reception area, seen generally at 44 , for placement of a containment barrier as will be more fully explained later. Generally, the reception area 44 is the area on top of the surface casing annulus area at the surface, and wherein the operator would clean-out this area. This area could be at the surface of a land well as well as a subsea well. A containment cement slurry is placed in the reception area 42 as will be more fully explained later. The containment cement slurry is seen generally by the cross-hatched area of the reception area 44 . FIG. 2 further depicts the squeeze pipes 46 , 48 disposed through the containment cement slurry and within the reception area 44 . As will be described later in this disclosure, in one embodiment, four (4) squeeze pipes are positioned within the reception area 44 . Additionally, a valve member 50 is operatively associated with the pipe 46 and a valve member 52 is operatively associated with pipe 48 are included, wherein the valve members 50 , 52 regulate the flow into and out of pipes 46 , 48 respectively. The valves 50 , 52 are commercially available from North Houston Valve and Fitting under the name Swagelok.
[0019] Referring now to FIG. 3 , a top view of the schematic illustration of the embodiment depicted in FIG. 2 will now be described. The surface casing 32 and the intermediate casing 34 are shown along with the squeeze pipe 46 and squeeze pipe 48 , wherein the squeeze pipe 46 and squeeze pipe 48 are in a 180 degree phase (i.e. opposite each other). Also shown is the squeeze pipe 54 and the squeeze pipe 56 . In the embodiment depicted in FIG. 3 , the four pipes are in a 90 degree phase 58 .
[0020] Referring collectively to FIGS. 2 and 3 , the method herein disclosed creates a pressure containment barrier. In one of the disclosed methods, a relatively small area at the top of the surface casing annulus 38 , which in one embodiment is 15″ deep, should be free of set cement. The method includes creating the pressure containment barrier 44 with the containment cement slurry. A template for the squeeze pipes may be placed within the reception area 38 . The materials for the containment cement slurry may comprise: a Class A cement, about 0 to about 15% BWOC Gypsum, and about 0% to about 3% BWOC CaC12 at 15.6 pound per gallon; water is mixed with the cement, Gypsum and CaC12 to form a slurry with a density between 12-18 pounds per gallon. The containment cement is commercially available from Lehigh under the name Class A or Type I. The gypsum is commercially available from US Gypsum and CaC12 is commercially available from JT Products. The containment cement slurry is then poured into the reception area 38 . The method includes placing the four (4) squeeze pipes, with the pipes being ±24″ long stainless steel pipes in one embodiment, into the containment cement slurry and within the template. In one embodiment, the pipes are evenly spaced around the center of the surface casing annulus 38 and held in place with the template. The cement containment slurry is allowed to set and firmly hold the pipes into place. As noted earlier, the squeeze pipes provide a contained path to squeeze the settable fluid into the flow paths while the containment cement provides a squeeze barrier. At this point, it is probable that the gas may permeate through the fresh cement around the squeeze pipes. This is not an issue since the containment cement still provides a sufficient pressure barrier for a successful squeeze.
[0021] In one embodiment, the settable fluid is a two part resin system. The resin is selected from the group consisting of: Bisphenal F type resin with a diluent such as Epodil and catalyzed with an epoxide catalyst selected from the group consisting of amidoamines and modified polyamidomines The amidoamines are commercially available from Riteks under the names Ancamide 506 and Ancamide 2386; the modified polyamidomine is commercially available from Riteks under the name W Hardener. Also note that the diluent Epodil is commerically available from Air Products. A weighting agent may be added, wherein the weighting agent is selected from the group consisting of barite, silica flour and silica sand. In one embodiment, the resin is commercially available from Riteks under the name BFE170. In one preferred embodiment, the resins do not contain any solids. This allows the resin to penetrate the extremely small leak paths in the surface cement and still be able to set. The resin is injected into the four stainless steel pipes in a specified sequence of rates and pressures. The resin is forced into the leak paths and allowed to set. Resin squeezes are applied to the squeeze pipes as needed until the gas leaks are stopped.
[0022] In another embodiment, the settable fluid is a low viscosity, micro-fine cement. The micro-fine cement comprises microfine cement, dispersant, fluid loss additive, retarder, and water. The micro-fine cement is commercially available from De Neef Construction Chemicals under the name MC500. The micro-fine cement is forced into the leak paths and allowed to set.
[0023] In one embodiment, the procedure includes ensuring that a depth of about 15″ is clear in the surface casing annulus 6 above the top of the primary cement. If not, then the operator would chip away the primary cement to the approximately 15″ depth. Next, the operator checks to ensure that the four squeeze pipes can be spaced 90 degrees apart (as seen in FIG. 3 ). The operator mixes the containment cement slurry. As noted earlier, in one embodiment, the containment cement slurry comprises a Class A cement, about 0-15% BWOC Gypsum and about 0-3% BWOC CaC12 at 15.6 pound per gallon. Once the containment cement slurry is mixed, the slurry can be poured into the reception area.
[0024] With this embodiment, the operator places the squeeze pipes into the containment cement slurry as shown in FIG. 3 . In one embodiment, the support template may be used to brace the squeeze pipes and hold the squeeze pipes upright until the containment cement is set. FIG. 4 is a top view of the template structure “T” of the present disclosure. The template “T” includes four (4) openings therein for the injection tubulars, namely openings 80 , 82 , 84 , 86 , as well as the opening 88 for the casing 32 . Generally, the containment cement will set in about 24 hours. Next, according to this embodiment, the valve members (such as valves 50 , 52 seen in FIG. 2 ) are attached to the squeeze pipes. The operator can then rig-up the pump, pump lines, and pressure vessels to the squeeze pipes. In this embodiment, the operator can then perform a communication-breakdown test with water on each of the squeeze pipes. Hence, the communication-breakdown test may include the operator closing all of the valve members on the squeeze pipes, pump water into each squeeze pipe one at a time (i.e. open a valve member of one of the squeeze pipes being injected), and establish which squeeze pipe has the most pressure at a specific flow rate such as 200 mL/min. The test results may be recorded. With this embodiment and based on the specifics of these test, the operator may begin squeezing the squeeze pipes in those squeeze pipes where an injection rate was recorded. This may be accomplished by closing the valves (for instance valves 50 , 52 ) on the other squeeze pipes while squeezing. The order in which to squeeze may be based on the pressure obtained from the communication/breakdown test with water, as noted above. Next, the operator would squeeze the pipe with the lowest breakdown pressure first and then move to the next lowest and so on.
[0025] Once an injection schedule is arranged, the operator will mix the settable fluid thoroughly and load the settable fluid into the pressure vessel holding cell. The operator will squeeze the settable fluid into the pipes according to the squeeze schedule determined earlier. Generally, the operator will allow the settable fluid to cure for about 24 hours, but this may vary depending on the specific settable fluid used and other environmental factors. The operator will also monitor for leaks. If leaks are observed, the operator will perform another communication/breakdown test and repeat the earlier steps of injecting the settable fluid. If no leaks are observed, the operator may sever the squeeze pipes at the level of the surface casing. The operator may then fill the remaining annular space with settable fluid for an added leak barrier, and thereafter, allow the settable fluid to set.
[0026] Experimental tests were performed on the method herein disclosed. The tests consisted of a 24″ tall section of 16″ casing with a 9-⅝″ casing located inside. The casings are vertically oriented and a plate is welded to the bottom to hold pressure from beneath. A source of pressurized air is plumbed into the side of the 16″×9-⅝ annulus just above the bottom plate to simulate the leaking gas. The primary cement is poured into the annulus and allowed to set. Pressurized air bubbles were created through the primary cement as it sets to serve as the gas leaks paths. the leaking annulus was then repaired by applying this invention. A total of 20 full size test set-ups were built and used to test different materials and methods of this disclosure.
[0027] The first fifteen (15) full size tests were used to determine the ideal squeeze pipe placement, pressure containment material, squeeze resin composition, and squeeze schedule (pressure and rates). Each completed full size test was cut open to determine the path of the settable squeeze fluid. Once the initial 15 test were completed, an optimized combination of squeeze pipe placement, pressure containment material, squeeze resin recipe, and squeeze schedule (pressures and rates) was established. This procedure was tested five additional times to ensure the success of the method and its repeatability. Each of the confirmation tests were monitored for at least 30 days to ensure long-term leak containment. Every final procedure confirmation test confirmed the sealing effect of the disclosed method. The treatment data from one of the final confirmation tests is shown in the table below.
[0000]
Annulus #17 Resin Squeeze Schedule and Results
Pressure (psi)
Pipe #
Volume (mL)
Rate (mL/min)
Initial
End
1
500
200
300
400
500
100
650
820
500
20
330
700
500
5
500
550
2
500
20
300
420
500
5
380
680
3
500
20
1300
830
(breakdown)
500
5
600
740
4
0
—
Injection into the tubular
was unable to be established
(the tubular did not connect
to any of the leak flow paths
to allow injection).
[0028] An aspect of the present disclosure is to create a pressure containment system in order to force a settable fluid into the flow paths, thereby allowing the settable fluid to set and stop the gas by blocking the leak paths.
[0029] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained therein.
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A method of providing pressure containment of a well having a well annulus. The well annulus contains a set cement, and the cement contains flow paths which communicate a well pressure to the surface. The method includes placing a containment cement slurry in a reception area at the top of the well and installing an injection delivery system within the reception area. The method may further include preparing a settable fluid for injection into the flow paths and injecting the settable fluid through the injection delivery system into the flow paths. In one disclosed embodiment, the injection delivery system may include a series of injection tubulars configured to deliver the settable fluid to the flow paths. The injection delivery system may include a template having a first, second, third and fourth injection tubular. According to this disclosure, the method may also include allowing the settable fluid to set, monitoring the pressure of the well annulus, and performing remedial well action based on the observed pressures.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a wall structure using a bearing wall panel for houses built by a timber framework construction method.
[0003] 2. Description of Related Art
[0004] Conventionally, it is prescribed that when designing the structure of a building, the design be such that the building as a whole is safe in terms of structural resistance to its own weight, live load, accumulated snow, wind pressure, earth pressure, and water pressure; and earthquakes and other vibrations and impacts by effectively arranging pillars, beams, floors, walls, and the like so as to withstand certain levels of wind force and seismic force.
[0005] Moreover, it is prescribed that in a building in which walls, pillars, and horizontal members are made of wood, frameworks having a wall or a brace be arranged in a well-balanced manner in a span direction and a ridge direction on each floor for the safety against horizontal forces in all directions.
[0006] In regard to installation of a brace, if connecting portions at both ends of the brace loosen, the brace fails to function as a brace, and in the case where the brace is used in a wall that withstands a large horizontal load, design and construction of the connecting portions are complicated. Therefore, in order to ensure that the construction is performed properly, a method in which, instead of the brace or in combination with the brace, a bearing wall panel is nailed to the frameworks for reinforcement has been employed.
[0007] In a building, a wall that has the capability to resist a horizontal load “i.e. a lateral force” such as that from an earthquake or wind is referred to as a bearing wall, and a wall that is not structurally fixed is referred to as a non-bearing wall.
[0000] Moreover, in a wooden building, a wall that resembles the bearing wall but that is imperfectly fixed and has a low resistance “e.g., a partition wall or the like” is referred to as a semi-bearing wall.
[0008] Since connecting portions of a wooden building are easily rotated, it is not possible for the building to resist the horizontal load such as that from an earthquake or wind only with pillars and beams. For this reason, it is required to provide a predetermined amount of bearing walls on each floor. A building with many bearing walls has excellent resistance to earthquakes and wind. Furthermore, the earthquake resistance can be enhanced when various members of the building are properly bound together with metal fittings.
[0009] The bearing wall can be produced by attaching a brace to a framework with metal fittings or securing a bearing wall panel composed of a board such as structural plywood to a framework with predetermined nails. On the other hand, a wall in which only a moisture-permeable waterproof sheet or a siding is attached to a framework is not a bearing wall.
[0010] An example of a numerical value representing the performance of a bearing wall is a wall strength factor. A wall strength factor of 1.0 times indicates the ability to resist a horizontal load “i.e. a lateral force” of 1.96 KN per meter of wall length. The higher this value, the higher the performance and the larger the horizontal load the bearing wall can withstand. With respect to the timber framework construction method, Article 46 of the Order for Enforcement of the Building Standard Law and the Notification No. 1100 of the Ministry of Construction prescribe that the wall strength factor for several specifications of bearing walls be fall within a range of 0.1 to 5.0.
[0011] In regard to the earthquake resistance of a house, a seismic force acts on the center of gravity of the house, and the house deforms in a horizontal direction and also rotates on the center of rigidity. Therefore, if the center of gravity and the center of rigidity are too far from each other, excessive deformation occurs in part of the house, resulting in damage to structural members. As a result, load-bearing capacity of the house decreases, and the load of the seismic force is concentrated on the other portions, which may lead to collapse of the house in the worst case. Therefore, it is preferable that the center of gravity and the center of rigidity of the house coincide with each other.
[0012] Here, the center of gravity is the center of a planar shape of a building and is the center of the weight of the building. The center of rigidity is the center of forces that counteract a horizontal force and is the center of rigidities of bearing walls. The center of rigidity can be determined from horizontal rigidities of earthquake-resistant elements such as bearing walls and their coordinates. Furthermore, a discrepancy between the center of gravity and the center of rigidity of a building is defined by an eccentric distance and an eccentricity. The eccentricity that can be calculated from the eccentric distance is the ratio of the distance between the center of gravity and the center of rigidity to torsional resistance.
[0013] The center of gravity on each floor of the building can be calculated from an axial force due to sustained loading that occurs in principal members in terms of structural resistance, such as pillars that support vertical loads, and coordinates X, Y of those members. However, in the case of the timber framework construction method, it is supposed that the centroid of a plane coincides with the center of gravity assuming that the dead load and the live load on each floor are uniformly distributed in a plane and there is no imbalance. The center of rigidity can be calculated from horizontal rigidities of the earthquake-resistant elements such as bearing walls in each direction of calculation and their coordinates. Here, the horizontal rigidity can be calculated from the actual wall length and the wall strength factor, and the eccentricity can be calculated from the above-described center of gravity and center of rigidity.
[0014] Even when sufficient bearing walls are secured, there is a risk that the building may be deformed or twisted when an earthquake occurs, leading to collapse of the building, unless the bearing walls are arranged in a well-balanced manner without being concentrated on one side of the building. Generally, a building having many bearing walls in the vicinity of the periphery thereof is resistant to torsion. On the other hand, a so-called U-shaped arrangement in which, for example, the north side is fully constituted by bearing walls and the south side is fully constituted by openings is susceptible to torsion and can easily lead to the collapse when an earthquake occurs.
[0015] An example of a value representing the imbalance of bearing walls is the eccentricity. The larger the value of eccentricity, the larger the imbalance of bearing walls it represents. In the Notification No. 1352 of the Ministry of Construction in 2000, it is prescribed that the eccentricity of a wooden building specified by Article 46, Section 4 of the Order for Enforcement of the Building Standard Law should be 0.3 or less, and generally, it is said that a house whose eccentricity is 0.15 or less is particularly preferable.
[0016] As described above, in order to build an earthquake-proof building, it is necessary to provide a bearing wall. Conventionally, in the case of building a house using the timber framework construction method, a plate-like body referred to as a bearing wall panel has been used instead of a brace or in combination with a brace to form a bearing wall that counteracts a force acting in the horizontal direction such as that from an earthquake, wind pressure, or the like.
[0017] 2. Background Art
JP 2001-90184A JP 11-71828A JP 10-152922A JP 3129745U JP 10-280580A JP 55-132839A JP 9-250192A
SUMMARY OF THE INVENTION
[0025] Conventionally, it has been known that in the case of building a house using the timber framework construction method, a bearing wall in which a bearing wall panel is nailed to a framework instead of a brace provides greater ease of construction than a bearing wall in which a brace is used.
[0026] In order to increase the earthquake resistance, it is desirable that the bearing walls are arranged on the entire periphery of the house. However, openings such as a window, a front door, and other entrances are necessary for a person to reside in the house, and so there are non-bearing walls as places where the bearing walls cannot be provided. Therefore, when designing a house, it is necessary to arrange the bearing walls and the non-bearing walls in a well-balanced manner. For this reason, the Building Standard Law provides the eccentricity as an indicator for arranging the bearing walls and the non-bearing walls in a well-balanced manner in order to keep good earthquake resistance of a house.
[0027] In the case where the bearing wall is configured by fixing an outer plate-like body such as a bearing wall panel to an outer face of a structural frame member formed by assembling horizontal members and pillar members into the shape of a square frame, the surface of the bearing wall panel protrudes from the outer face of the structural frame member by a distance corresponding to the thickness of the bearing wall panel. Thus, irregularities occur between the bearing wall in which the bearing wall panel is provided and the non-bearing wall in which the bearing wall panel is not provided. When attaching the exterior building material, a base for the exterior building material should not have unevenness, and therefore an extra process for smoothing the base has conventionally been necessary.
[0028] It is also possible to provide a non-bearing wall panel that is not a bearing wall panel but has the same thickness as the bearing wall panel in the non-bearing wall in order to prevent the occurrence of unevenness in the above-described base. However, in this case, an extra material cost or construction cost has been required due to the use of the non-bearing wall panel, which is not necessary.
[0029] The present invention has been made in view of problems as described above, and it is an object thereof to provide a wall structure in which even though a bearing wall panel is used in a bearing wall, the surface of the bearing wall panel does not protrude from outer faces of framework structural members and an adjacent non-bearing wall on the exterior side, and therefore the necessity of adjusting unevenness during subsequent attachment of an exterior building material can be eliminated, the bearing wall can sufficiently exhibit the function of a bearing wall, and the bearing wall panel can be accurately and efficiently attached to the structural frame member.
[0030] There is another problem as follows. The bearing wall composed of the bearing wall panel is generally constructed using a stud wall framing finished on both side construction method because of the convenience of construction. However, there has been a problem in that with the bearing wall panel attached to the framework with nails or the like using the stud wall framing finished on both side construction method, when the condition of the framework is to be inspected for maintenance after building, the condition of the pillars and the horizontal members, which are the most important structural members for the timber framework construction method, cannot be inspected without removing the bearing wall panel.
[0031] In order to continue to use a wooden house for a long period of time, periodic inspections of the structural members, in particular, the pillars and the sills, of the house are important. In order to easily realize the inspections of the pillars and the sills, there has been a demand for a bearing wall structure in which the bearing wall panel does not cover the structural members, thereby allowing easy inspection of the structural members.
[0032] A first aspect of the invention is a wall structure for a wooden building, the wall structure including a bearing wall, a non-bearing wall, a furring strip, and an exterior building material,
wherein in the bearing wall in which receiving members are fixed to inner side faces enclosed by structural members including pillars and horizontal members of a wooden building and a bearing wall panel is fixed to an exterior side of the receiving members, a face of the bearing wall panel on the exterior side is flush with faces of the structural members on the exterior side and a face of an adjacent non-bearing wall on the exterior side.
[0035] According to the first aspect of the invention, in the bearing wall, the receiving members that have been firmly integrated with the structural members with fixing members based on predetermined specifications and that contribute to the structure of the bearing wall are fixed to the inner side faces of the structural members, and the bearing wall panel is fixed to the exterior side of the receiving members. In this bearing wall, the receiving members are fixed at positions set back from an external surface of the structural members on the exterior side by a distance corresponding to the thickness of the bearing wall panel so as to prevent the face of the bearing wall panel on the exterior side from protruding to the exterior side from the faces of the structural members on the exterior side.
[0036] The bearing wall panel is placed in such a position that end portions of the bearing wall panel are on the inside of the inner side faces of the structural members, and fixed to the receiving members using fixing members such as nails in the vicinity of peripheral end portions of the bearing wall panel.
[0037] In the case where it is desired to achieve good air permeability inside the bearing wall, when vent portions penetrating the receiving members from an interior side to the exterior side are provided in the receiving members fixed to the structural members, the air permeability of the receiving members improves.
[0038] Furthermore, when the bearing wall panel is fixed to the receiving members with a gap between the structural members and end portions of the bearing wall panel so as not to block openings of the vent portions of the receiving members, the air permeability of the bearing wall is further improved.
[0039] Since the bearing wall panel is fixed to the receiving members in the vicinity of the peripheral end portions of the bearing wall panel, the bearing wall panel and the receiving members are in an integrated state in which they are integrated. Moreover, the fixing members for fixing the receiving members to the structural members are made stronger than the fixing members, such as nails, for fixing the bearing wall panel to the receiving members. Thus, even when a shear force acts on the fixing members for fixing the receiving members, plane shear deformation of the structural members, the receiving members, and the fixing members is small, and therefore the receiving members can be regarded as being completely integrated with the structural members. As a result, the structural members, the receiving members, and the bearing wall panel are brought into an integrated state. It should be noted that the spacing of the fixing members for fixing the bearing wall panel to the receiving members and the spacing of the fixing members for fixing the receiving members to the structural members are set in accordance with the required wall strength factor.
[0040] When the vent portions are provided in the receiving members fixed to the structural members, ventilation inside the bearing wall is ensured. Thus, even if external water intrudes into the inside of the bearing wall or water condensation occurs, the water or condensed water is discharged and the inside of the bearing wall is quickly dried by ventilation. Therefore, it is possible to improve the durability of the structural members. Moreover, the necessity to perform cutting of the receiving members during construction is eliminated by forming the vent portions in the receiving members beforehand.
[0041] Therefore, overall construction of the wall is facilitated, and thus construction time and cost can be reduced. Also, a bearing wall having a high wall strength factor can be obtained while improving the durability of the structural members by maintaining the air permeability inside the wall.
[0042] Materials accepted by Article 46 of the Order for Enforcement of the Building Standard Law, such as structural plywood, particle board, oriented strand board (OSB), hardboard, hard wood fiber reinforced board, gypsum board, pulp cement flat sheet, sheathing board, and others, can be used as the bearing wall panel, and a wall in which such a material is fixed to the structural members using an accepted method serves as the bearing wall.
[0043] After the bearing wall panel has been attached to the structural members, waterproof paper such as a moisture-permeable waterproof sheet is provided in a stretched manner on the surface of the bearing wall panel on the exterior side, and then furring strips are placed on top of the waterproof paper and fastened to the building frame including the pillars and the horizontal members via the waterproof paper. Subsequently, the exterior building material is fastened to the furring strips with nails or fastening metal fittings. A vent layer is formed between the exterior building material and the bearing wall panel by interposing the furring strips between them.
[0044] Even if moisture on the interior side intrudes into the inside of the bearing wall through an interior building material, the moisture passes through the bearing wall panel if the bearing wall panel is a plate-like body having moisture permeability or passes through the vent portions provided in the receiving members if the bearing wall panel is a less moisture-permeable plate-like body, and is released or allowed to penetrate to the exterior building material side through the waterproof paper. As a result, the moisture on the interior side is released into the vent layer between the exterior building material and the bearing wall panel.
[0045] Furthermore, since there is no step between the bearing wall and the non-bearing wall, the necessity of processing the base, for example, using a wood strip or the like for eliminating the step or unevenness between the bearing wall and the non-bearing wall or using furring strips of different thicknesses is no longer necessary. Thus, it is possible to rationalize the attachment of the furring strips.
[0046] As described above, since the bearing wall panel, which exhibits the strength as a wall of a building, is disposed on the inside of the exterior building material via the furring strips, the bearing wall panel is protected by the exterior building material against rainwater or the like, and therefore a decrease in the strength due to corrosion or the like is prevented. Accordingly, the durability of the bearing wall is improved.
[0047] As the method for constructing the wall structure according to the first aspect of the invention, in addition to the method in which the receiving members are fixed to the inner side faces enclosed by the structural members including the pillars and the horizontal members before fixing the bearing wall panel to the receiving members, there is a method as described below.
[0048] A method for constructing a bearing wall of a wall structure for a wooden building,
the wall structure including a bearing wall in which receiving members are fixed to inner side faces enclosed by structural members including pillars and horizontal members of a wooden building and a bearing wall panel is fixed to an exterior side of the receiving members; a non-bearing wall; a furring strip; and an exterior building material, and a face of the bearing wall panel on the exterior side being flush with faces of the structural members on the exterior side and a face of an adjacent non-bearing wall on the exterior side, the method including: attaching the receiving members that have been attached to the bearing wall panel beforehand to the inner side faces of the pillars or the horizontal members integrally with the bearing wall panel.
[0052] According to the above-described construction method, the receiving members are attached to the structural members in a state in which the bearing wall panel has been attached to the receiving members beforehand, and therefore the necessity of attaching the bearing wall panel to the receiving members at the construction site is eliminated. Thus, the construction time can be reduced.
[0053] Furthermore, in order to maintain the performance of the bearing wall, it is necessary to attach the bearing wall panel to the receiving members with a specified number of fixing members disposed at predetermined spacing. If the bearing wall panel is attached with a smaller number of fixing members than the specified number, it is not possible to maintain a specified wall strength factor. In construction of a bearing wall, in the case where nails are adopted as the fixing members for attaching the bearing wall panel, an enormous number of nails are used, and nailing management for maintaining the construction quality is very important. Performing this nailing management, that is, fixing the bearing wall panel to the receiving members at a factory separate from the construction site can significantly contribute to maintenance of the construction quality of the bearing wall and can also reduce the construction time.
[0054] With the above-described construction method as well, providing the vent portions in the receiving members and attaching the bearing wall panel to the receiving members with a gap between the structural members and the end portions of the bearing wall panel so as not to block the vent portions of the receiving members makes it possible to ensure good air permeability inside the constructed bearing wall.
[0055] A second aspect of the invention is a wall structure for a wooden building, the wall structure including a bearing wall, a non-bearing wall, a furring strip, and an exterior building material,
wherein in the bearing wall in which a bearing wall panel is fixed to faces of structural members including pillars and horizontal members of a wooden building on an exterior side, recesses having a depth corresponding to the thickness of the bearing wall panel are formed at positions where the bearing wall panel is fixed to the structural members, and a face of the bearing wall panel on the exterior side is flush with the faces of the structural members on the exterior side and a face of an adjacent non-bearing wall on the exterior side.
[0059] According to the second aspect of the invention, the recesses having a depth corresponding to the thickness of the bearing wall panel are formed at positions where the bearing wall panel is fixed to the structural members, and the bearing wall panel is fixed to those recesses, and therefore the necessity to use the receiving members as in the first aspect of the invention is eliminated. Thus, the necessity to prepare the receiving members is eliminated, and furthermore, it is no longer necessary to fix the receiving members at the construction site. Accordingly, it is possible to streamline construction work and reduce costs.
[0060] With the wall structure that uses the bearing wall in which the bearing wall panel is fastened to the faces of the structural members on the exterior side, in the case where the bearing wall and a non-bearing wall are designed and constructed next to each other based on a design giving consideration to eccentricity, it has been necessary to attach a non-bearing wall panel having the same thickness as the bearing wall panel and having no load-bearing capacity to the non-bearing wall in order to eliminate the step or unevenness between the bearing wall and the non-bearing wall. Thus, a wasteful material cost has been generated, and also time and effort for attaching the non-bearing wall panel have been generated, resulting in more construction costs. On the other hand, in the case where all the walls are designed as bearing walls in an attempt to prevent generation of a step or unevenness between a bearing wall and a non-bearing wall, more bearing wall panels than necessary will be used, and accordingly the material cost and the construction cost will increase. Furthermore, if all the walls are designed as bearing walls, it will be difficult to maintain a specified eccentricity, and earthquake resistance will deteriorate conversely.
[0061] As described above, according to the structure of a bearing wall for a wooden building of the first aspect of the invention, a bearing wall and a non-bearing wall can be freely arranged so as to keep an optimum eccentricity, and furthermore, since there is no step or unevenness between the bearing wall and the non-bearing wall, processing of the base for eliminating the step or unevenness between the bearing wall and the non-bearing wall during attachment of an exterior building material is no longer necessary, and thus the ease of construction improves.
[0062] Furthermore, according to the construction method in which the receiving members are attached to the structural members in a state in which the bearing wall panel has been attached to the receiving members beforehand, it is possible to process the receiving members and the bearing wall panel at a place other than the construction site, and therefore the construction quality of the bearing wall is improved.
[0063] According to the structure of a bearing wall for a wooden building of the second aspect of the invention, the receiving members are not used, the bearing wall and the non-bearing wall can be arranged so as to keep an optimum eccentricity, and furthermore, a step or unevenness between the bearing wall and the non-bearing wall does not occur. Thus, processing of the base for eliminating the step or unevenness between the bearing wall and the non-bearing wall during attachment of the exterior building material is not necessary, and the ease of construction further improves.
[0064] With a bearing wall of a conventional stud wall structure, in order to inspect the condition of pillars and horizontal members, which are the most important structural members, it has been necessary to remove the bearing wall panel. However, with the bearing walls of the first and the second aspects of the invention, the bearing wall panel does not cover the structural members, and thus it is possible to inspect the framework without removing the bearing wall panel even when an inspection of the framework is performed after a long period of time has elapsed since the building was built by the timber framework construction method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1 is a perspective view of Embodiment 1 of the present invention.
[0066] FIG. 2 is a vertical cross-sectional view of Embodiment 1 of the present invention.
[0067] FIG. 3 is a horizontal cross-sectional view of Embodiment 1 of the present invention.
[0068] FIG. 4 is a horizontal cross-sectional view in which an exterior building material is attached in a state in which a bearing wall of Embodiment 1 of the present invention and a non-bearing wall are adjacent to each other.
[0069] FIG. 5 shows a receiving member that is used in Embodiment 2 of the present invention and provided with vent portions penetrating the receiving member from an interior side to an exterior side.
[0070] FIG. 6 is a perspective view of Embodiment 2 of the present invention in which receiving members provided with the vent portions penetrating the receiving members from the interior side to the exterior side are used and a bearing wall panel is fixed to the receiving members in such a manner that the bearing wall panel does not block the vent portions.
[0071] FIG. 7 is a horizontal cross-sectional view of Embodiment 2 of the present invention.
[0072] FIG. 8 is a horizontal cross-sectional view in which the exterior building material is attached in a state in which a bearing wall of Embodiment 2 of the present invention and the non-bearing wall are adjacent to each other.
[0073] FIG. 9 is a perspective view of Embodiment 3 of the present invention.
[0074] FIG. 10 is a vertical cross-sectional view of Embodiment 3 of the present invention.
[0075] FIG. 11 is a horizontal cross-sectional view of Embodiment 3 of the present invention.
[0076] FIG. 12 is a horizontal cross-sectional view in which the exterior building material is attached in a state in which a bearing wall of Embodiment 3 of the present invention and the non-bearing wall are adjacent to each other.
[0077] FIG. 13 is a perspective view of a building frame of a wooden building of a conventional example.
[0078] FIG. 14 is a vertical cross-sectional view of the building frame of the wooden building of the conventional example.
[0079] FIG. 15 is a horizontal cross-sectional view of the building frame of the wooden building of the conventional example.
[0080] FIG. 16 is a perspective view of a bearing wall of a stud wall structure of a conventional example.
[0081] FIG. 17 is a vertical cross-sectional view of the bearing wall of the stud wall structure of the conventional example.
[0082] FIG. 18 is a horizontal cross-sectional view of the bearing wall of the stud wall structure of the conventional example.
[0083] FIG. 19 is a horizontal cross-sectional view in which the exterior building material is attached in a state in which the bearing wall of the stud wall structure of the conventional example and the non-bearing wall are adjacent to each other.
[0084] FIG. 20 is a horizontal cross-sectional view in which the exterior building material is attached in a state in which the bearing wall of the stud wall structure of the conventional example and the non-bearing wall to which a non-bearing wall panel has been fastened are adjacent to each other.
[0085] FIG. 21 is a diagram showing a joint of a connecting metal fitting (an inverted V-shaped plate) and a bearing wall panel of the bearing wall constructed by a stud wall framing finished on both side construction method of the conventional example.
[0086] FIG. 22 is a diagram showing a joint of the connecting metal fitting (the inverted V-shaped plate) and a bearing wall panel of Embodiment 1 of the present invention.
[0087] FIG. 23 is a diagram showing a joint of a connecting metal fitting (a corner metal fitting) and the bearing wall panel of the bearing wall constructed by the stud wall framing finished on both side construction method of the conventional example.
[0088] FIG. 24 is a diagram showing a joint of the connecting metal fitting (the corner metal fitting) and the bearing wall panel of Embodiment 1 of the present invention.
[0089] FIG. 25 shows good examples (A) (B) and bad examples (C) (D) of arrangement of bearing walls.
[0090] FIG. 26 is a diagram for illustrating the balance of earthquake resistance of a building.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0091] Hereinafter, embodiments of the present invention will be described based on FIGS. 1 to 25 .
[0092] FIGS. 1 to 3 are diagrams showing the structure of a bearing wall 31 according to Embodiment 1 of the present invention, and two mutually parallel pillars 3 extending vertically are connected to each other by a horizontal member (a girth) 1 and a horizontal member (a sill) 2 at a vertical end portion and an intermediate portion, and the pillars 3 and the horizontal members 1 and 2 all serve as structural members.
[0093] On inner side faces enclosed by the above-described pillars 3 and horizontal members 1 and 2 , which serve as the structural members, receiving members 7 A extending vertically, parallel to the pillars and receiving members 7 B extending horizontally, parallel to the horizontal members 1 and 2 are fixed to the structural members by fixing members 6 .
[0094] A bearing wall panel 10 is secured to faces of the receiving members 7 A and 7 B on an exterior side with nails 21 , and thus the bearing wall 31 is formed. Therefore, the area of the bearing wall panel 10 is smaller than the area defined by the inner side faces enclosed by the structural members.
[0095] In order to prevent a face of the bearing wall panel 10 on the exterior side from protruding to the exterior side (the side A) from faces of the structural members on the exterior side when the bearing wall panel 10 is nailed to the receiving members 7 A and 7 B, the receiving members 7 A are fixed with the fixing members 6 to the pillars 3 , which serve as the structural members, at a position set back to an interior side (the side B) by a distance corresponding to the thickness of the bearing wall panel 10 . Also, the receiving members 7 B are fixed with the fixing members 6 to the horizontal members 1 and 2 , which serve as the structural members, at a position set back to the interior side by the distance corresponding to the thickness of the bearing wall panel 10 .
[0096] FIG. 3 is a diagram showing a horizontal cross-sectional view of the bearing wall 31 of Embodiment 1 in which the bearing wall panel 10 is nailed to the receiving members 7 A and 7 B.
[0097] As shown in FIG. 4 , even when the bearing wall 31 of Embodiment 1 is constructed next to a non-bearing wall 30 A, a face of the bearing wall 31 on the exterior side (the side A) is flush with a face of the non-bearing wall 30 A on the exterior side (the side A), and accordingly the surface of a base required for exterior wall construction is flat.
[0098] Therefore, it is possible to attach waterproof paper 15 to the structural members and the bearing wall panel 10 without concerning about a step at a junction between the bearing wall 31 and the non-bearing wall 30 A.
[0099] Regarding furring strips 13 that are necessary for attachment of an exterior building material 16 , it is possible to use furring strips 13 of the same thickness for both the bearing wall 31 and the non-bearing wall 30 A.
[0100] Therefore, it is possible to attach the exterior building material 16 without concern for the step or unevenness at the junction between the bearing wall 31 and the non-bearing wall 30 A. It should be noted that the above-described non-bearing wall 30 A is illustrated using a building frame of a conventional example shown in FIGS. 13 to 15 .
[0101] Next, a bearing wall 31 B according to Embodiment 2 of the present invention will be described with reference to FIGS. 5 to 8 .
[0102] Vent portions 19 formed in a receiving member 8 is provided by forming paths penetrating an interior face and an exterior face of the receiving member 8 , in order to allow airflow between the interior side and the exterior side. With respect to the shape of the vent portions 19 , although rectangular grooves are formed in the present embodiment, any shape, such as arcuate notches or circular or rectangular holes, can be used as long as it enables ventilation.
[0103] FIG. 6 shows vent portions 19 A formed in a receiving member 8 A to be attached to the pillar 3 and vent portions 19 B formed in a receiving member 8 B to be attached to the horizontal member 2 .
[0104] A constructed state in which the receiving members 8 A and 8 B having the vent portions 19 A and 19 B have been attached will be described with reference to FIG. 6 . A bearing wall panel 10 B is nailed to the receiving members 8 A and 8 B with end portions of the bearing wall panel 10 B spaced from the pillar 3 and the horizontal member 2 , which serve as the structural members, so as not to block the vent portions 19 A of the vertically extending receiving member 8 A and the vent portions 19 B of the horizontally extending receiving member 8 B.
[0105] The receiving members 8 A and 8 B are fixed to the pillar 3 and the horizontal member 2 , respectively, with fixing members 6 in such a manner that openings of the vent portions 19 A and 19 B are in contact with the inner side faces of the structural members. Since the openings of the vent portions 19 A and 19 B are in contact with the inner side faces of the pillar 3 and the horizontal member 2 , which serve as the structural members, the receiving members 19 A and 19 B are fixed to the structural members while securing maximum areas of the vent portions 19 A and 19 B and minimizing the distances between the end portions of the bearing wall panel 10 B and the structural members.
[0106] In Embodiment 2, similarly to Embodiment 1, in order to prevent a face of the bearing wall panel 10 B on the exterior side (the side A) from protruding to the exterior side (the side A) from the faces of the structural members on the exterior side (the side A) when the bearing wall panel 10 B is nailed to the receiving members 8 A and 8 B, the receiving members 8 A and 8 B are fixed, with the fixing members 6 , to the horizontal member 2 and the pillar 3 at positions set back to the interior side (the side B) by a distance corresponding to the thickness of the bearing wall panel 10 B.
[0107] FIG. 7 is a diagram showing a horizontal cross-sectional view of the bearing wall 31 B of Embodiment 2 in which the bearing wall panel 10 B is nailed to the receiving members 8 A and 8 B having the vent portions 19 A and 19 B.
[0108] As shown in FIG. 8 , even when the bearing wall 31 B of Embodiment 2 is constructed next to the non-bearing wall 30 A, a face of the bearing wall 31 B on the exterior side (the side A) is flush with the face of the non-bearing wall 30 A on the exterior side (the side A), and accordingly the surface of the base for attachment of the exterior building material 16 is flat.
[0109] Therefore, it is possible to attach the waterproof paper 15 to the structural members without concerning about the step or unevenness at a junction between the bearing wall 31 B and the non-bearing wall 30 A.
[0110] Regarding the furring strips 13 that are necessary for attachment of the exterior building material 16 , furring strips 13 of the same thickness can be used for both the bearing wall 31 B and the non-bearing wall 30 A.
[0111] Therefore, it is possible to attach the exterior building material 16 without concern for the step or unevenness between the bearing wall 31 B and the non-bearing wall 30 A. It should be noted that the above-described non-bearing wall 30 A is illustrated using the building frame of the conventional examples shown in FIGS. 13 to 15 .
[0112] Next, a bearing wall 31 C of Embodiment 3 of the present invention will be described with reference to FIGS. 9 to 12 .
[0113] FIGS. 9 to 11 show the structure of the bearing wall 31 C according to Embodiment 3 of the present invention, and the two mutually parallel pillars 3 extending vertically are connected to each other by the horizontal members 1 and 2 at a vertical end portion and an intermediate portion, and the pillars 3 and the horizontal members 1 and 2 all serve as the structural members.
[0114] A bearing wall panel 10 C is fixed to the faces of the above-described pillars 3 and horizontal members 1 and 2 , which serve as the structural members, on the exterior side (the side A), and thus the bearing wall 31 C is formed. In the faces of the structural members on the exterior side (the side A) to which the bearing wall panel 10 C is fixed, recesses 11 having a depth corresponding to the thickness of the bearing wall panel 10 C are formed. Thus, when the bearing wall panel 10 C is secured to the recesses 11 of the structural members with the nails 21 , the face of the bearing wall panel 10 C on the exterior side (the side A) does not protrude to the exterior side (the side A) from the faces of the structural members on the exterior side (the side A).
[0115] FIG. 11 is a diagram showing a horizontal cross-sectional view of the bearing wall 31 C in which the bearing wall panel 10 C is nailed to the pillars 3 having the recesses 11 of a depth corresponding to the thickness of the bearing wall panel 10 C.
[0116] As shown in FIG. 12 , even when the bearing wall 31 C of Embodiment 3 is constructed next to the non-bearing wall 30 A, a face of the bearing wall 31 C on the exterior side (the side A) is flush with the face of the non-bearing wall 30 A on the exterior side (the side A), and accordingly the surface of the base required for exterior wall construction is flat.
[0117] Therefore, it is possible to attach the waterproof paper 15 to the structural members and the bearing wall panel 10 C without concerning about a step or unevenness at a junction between the bearing wall 31 C and the non-bearing wall 30 A.
[0118] Regarding the furring strips 13 that are necessary when attaching the exterior building material 16 , furring strips 13 of the same thickness can be used for both the bearing wall 31 C and the non-bearing wall 30 A.
[0119] Therefore, it is possible to attach the exterior building material 16 without concern for the step or unevenness at the junction between the bearing wall 31 C and the non-bearing wall 30 A. It should be noted that the above-described non-bearing wall 30 A is illustrated using the building frame of the conventional examples shown in FIGS. 13 to 15 .
[0120] Next, a bearing wall based on a stud wall structure of a conventional example will be described with reference to FIGS. 16 to 20 .
[0121] FIGS. 16 to 18 show the structure of a bearing wall 31 D based on a stud wall structure of a conventional example, and the two mutually parallel pillars 3 extending vertically are connected to each other by the horizontal members 1 and 2 at a vertical end portion and an intermediate portion, and the pillars 3 and the horizontal members 1 and 2 all serve as the structural members.
[0122] A bearing wall panel 10 D is fixed to the faces of the above-described pillars 3 and horizontal members 1 and 2 on the exterior side (the side A), and thus the bearing wall 31 D is formed. In regard to the bearing wall 31 D based on the stud wall structure of the conventional example, when the bearing wall panel 10 D is secured to the structural members with the nails 21 , a face of the bearing wall panel 10 D on the exterior side (the side A) protrudes to the exterior side (the side A) from the faces of the structural members on the exterior side (the side A) by a distance corresponding to the thickness of the bearing wall panel 10 D.
[0123] FIG. 19 is a diagram showing a state in which the bearing wall 31 D based on the stud wall structure of the conventional example has been constructed next to the non-bearing wall 30 A composed of only a building frame.
[0124] As shown in FIG. 19 , when the bearing wall 31 D based on the stud wall structure of the conventional example is constructed next to the non-bearing wall 30 A, a face of the bearing wall 31 D on the exterior side (the side A) protrudes to the exterior side (the side A) from the face of the non-bearing wall 30 A on the exterior side (the side A) by a distance corresponding to the thickness of the bearing wall panel 10 D. Thus, the surface of the base for attachment of the exterior building material 16 is not flat, and a step having a height corresponding to the thickness of the bearing wall panel 10 D or unevenness occurs between the bearing wall 31 D and the non-bearing wall 30 A.
[0125] Therefore, the waterproof paper 15 is attached in a state in which there is the step having the height corresponding to the thickness of the bearing wall panel 10 D between the bearing wall 31 D and the non-bearing wall 30 A, and this makes it difficult to attach the waterproof paper 15 . Furthermore, in regard to the attachment of the exterior building material 16 , the base on which the exterior building material 16 is attached is required to be flat, and therefore it is necessary to prepare two types of furring strips having different thicknesses, that is, the furring strips 13 for bearing walls and furring strips 13 A for non-bearing walls.
[0126] Therefore, it is necessary to carefully attach the waterproof paper 15 , the furring strips 13 and 13 A, and furthermore the exterior building material 16 with concern for the step or unevenness between the bearing wall 31 D and the non-bearing wall 30 A. It should be noted that the above-described non-bearing wall 30 A is illustrated using the building frame of the conventional example shown in FIGS. 13 to 15 .
[0127] FIG. 20 is a diagram showing a state in which the bearing wall 31 D of the stud wall structure of the conventional example and a non-bearing wall 30 B of a stud wall structure composed of a non-bearing wall panel 9 have been constructed next to each other.
[0128] As shown in FIG. 20 , if the bearing wall 31 D of the stud wall structure of the conventional example is constructed next to the non-bearing wall 30 B of the stud wall structure composed of the non-bearing wall panel 9 , the face of the bearing wall 31 D on the exterior side (the side A) is flush with the face of the non-bearing wall 30 B of the stud wall structure on the exterior side (the side A), and accordingly the surface of the base for exterior wall construction is flat.
[0129] Therefore, it is possible to attach the waterproof paper 15 to the structural members without concerning about a step or unevenness at a junction between the bearing wall 31 D and the non-bearing wall 30 B. It is possible to use the furring strips 13 of the same thickness for both the bearing wall 31 D and the non-bearing wall 30 B for fastening to the structural members. However, in the case of the non-bearing wall 30 B of the stud wall structure composed of the non-bearing wall panel 9 , the non-bearing wall panel 9 , which is not necessary under normal conditions, is used, and therefore an extra material cost is required, and furthermore, extra time and effort for construction are also required.
[0130] Next, a joint of a connecting metal fitting such as an inverted V-shaped plate 25 A or a corner metal fitting 25 B, which are commonly used to firmly assemble the structural members, and a bearing wall will be described.
[0131] In the case of attaching the inverted V-shaped plate 25 A or the corner metal fitting 25 B, which are connecting metal fittings, to the bearing wall 31 D of the conventional stud wall structure, as shown in FIGS. 21 and 23 , in order to prevent the bearing wall panel 10 D from interfering with the connecting metal fitting, it has been necessary to make a cut such as a cut 26 A or a cut 26 B in the bearing wall panel before attaching the bearing wall panel to the structural members.
[0132] Furthermore, forming the cut 26 A or 26 B in the bearing wall panel 10 D makes it impossible to drive a sufficient number of nails required to maintain the performance of the bearing wall, and therefore it has been necessary that a number of additional nails 22 equal to or more than the number of nails that can no longer be driven due to the cut be additionally driven in the vicinity of the cut portion.
[0133] On the other hand, according to the bearing wall of the invention disclosed in this specification, the structural members are not covered with the bearing wall panel, and the faces of the structural members on the exterior side are exposed. Thus, as shown in FIGS. 22 and 24 , it is possible to attach the connecting metal fitting to the structural members of the bearing wall without the necessity to cut the bearing wall panel 10 nor to drive in the additional nails 22 .
[0134] As the method for constructing the wall structure of Embodiment 1 of the present invention, it is common to use a method in which the structural members including the pillars 3 and the horizontal members 1 and 2 are assembled at a construction site, and then, after the receiving members 7 A and 7 B are fixed to the inner side faces enclosed by the structural members, the bearing wall panel 10 is fixed to the receiving members 7 A and 7 B. However, there is another construction method, which will be described below.
[0135] The bearing wall panel 10 is attached to the receiving members 7 A and 7 B beforehand in a factory or the like, and a resulting panel in which the bearing wall panel 10 is integral with the receiving members 7 A and 7 B is fixed to the inner side faces of the structural members at the construction site. This construction method eliminates the necessity of attaching the bearing wall panel 10 to the receiving members 7 A and 7 B at the construction site and can reduce the construction time. Furthermore, in order to maintain the performance of the bearing wall, it is necessary to drive a number of nails that is determined from the wall strength factor at specified spacing to attach the bearing wall panel 10 to the receiving members 7 A and 7 B. If the number of nails driven is smaller than the determined number, a prescribed wall strength factor can no longer be maintained. In construction of the bearing wall, an enormous number of nails are used to attach the bearing wall panel, and nailing management in site operation has been a very important management item in maintaining the construction quality.
[0136] Performing this nailing management, that is, fixing the bearing wall panel to the receiving members in a factory separate from the construction site can significantly contribute to the maintenance of the bearing wall quality and also enables a reduction in the construction time.
[0137] It should be noted that the above-described construction method can also be adopted in construction according to Embodiment 2 of the present invention.
[0138] Next, attachment of an exterior building material after construction of the bearing wall of the present invention will be described.
[0139] After the bearing wall panel has been fixed to the receiving members and the structural members, the waterproof paper 15 is horizontally attached to an outer side (the exterior side) of the framework. At this time, overlapping margin portions of adjacent sheets of waterproof paper 15 are superposed on top of each other and fixed. It should be noted that the positions at which superposed portions of left and right overlapping margins of the waterproof paper 15 are attached are preferably located on a pillar or a stud.
[0140] After the waterproof paper 15 has been fixed to the base, the exterior building material 16 is placed using the furring strips 13 in a state in which a space of 12 mm or more is secured on the outer side of the waterproof paper 15 , thereby forming a vent layer 14 , which is a space for ventilation, between the waterproof paper and the exterior building material. Moreover, an interior finishing wall is provided on an inner side (the interior side) of the framework, and an insulating material is disposed inside the interior finishing wall so as to keep the indoor temperature environment constant. Ventilation within the wall is ensured by fixing the structural members, the bearing wall panel, the waterproof paper 15 , and the exterior building material 16 in this manner.
[0141] In the case where a bearing wall panel with inferior air-permeation performance is used, it is desirable to use the receiving members 8 A and 8 B in which the vent portions 19 A and 19 B are provided in order to transfer damp on the interior side to the above-described vent layer 14 . Even if a bearing wall panel having poor air-permeability is used, use of the receiving members having the vent portions allows moisture in a space within the wall to be released to the exterior side (the side A) of the bearing wall through the vent portions 19 A and 19 B of the receiving members, to pass through the waterproof paper 15 , and to be discharged outdoors through the vent layer 14 , which is formed between the waterproof paper and the exterior building material. Thus, the inside of the bearing wall is always dry, corrosion and the like of the structural members can be prevented, and it is possible to increase the lifetime of the building. Moreover, although the waterproof paper 15 allows water vapor to be discharged outside the wall, it prevents movement of air and also prevents a drop of water that has intruded from the exterior wall side from intruding into the wall.
[0142] The waterproof paper used in the present invention is, for example, a sheet in which multiple small pores having a size of about several tens micrometers are formed. The waterproof paper has durability, water resistance, and corrosion resistance and has the property of not allowing large particles such as raindrops to pass through while allowing small particles such as water vapor to pass through. Therefore, the waterproof paper has air permeability as well as waterproofness and also has an insulation effect of preventing movement of air. Tyvek manufactured by DuPont can be used as an example of this waterproof paper.
[0143] In regard to the shape of the vent portions of the receiving members having the vent portions used in the present invention, any shape can be used as long as the wall and the exterior wall side are in communication with each other. Vent portions having various shapes, such as circular holes, rectangular holes, and circular arc-shaped holes, other than the vent portions as defined by a board and teeth on the bottom of the board, as introduced in Embodiment 2 of the present invention, can be still used, as long as the size and the number of the holes are such that the required strength of a receiving member of a bearing wall is not compromised.
[0144] Although embodiments of the present invention have been described above, the specific configuration of the present invention is not limited to these embodiments, and changes of design and the like that fall within the scope of the gist of the invention are also embraced by the present invention.
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In building a house, it is necessary to arrange bearing walls and non-bearing walls in a well-balanced manner. However, in the case where a bearing wall is configured by fixing a plate-like body such as a bearing wall panel to the exterior-side face of a structural frame member formed by assembling horizontal members and pillar members into the shape of a square frame, the surface of the bearing wall panel protrudes from the face of the structural frame member on the exterior side by a distance corresponding to the thickness of the bearing wall panel. Thus, the exterior-side face of the bearing wall in which the bearing wall panel is provided is not flush with the exterior-side face of the non-bearing wall in which the bearing wall panel is not provided, and so there is a step. Accordingly, processing of the base during attachment of an exterior building material has been necessary. Furthermore, there has been a problem that in the case where the condition of the framework is to be inspected after building, the inspection cannot be performed unless the bearing wall panel is removed.
Receiving members are fixed to inner side faces enclosed by structural members including pillars, studs, and horizontal members, of a building so as to allow a face of a bearing wall panel on the exterior side to be flush with faces of the structural members on the exterior side and a face of an adjacent non-bearing wall on the exterior side.
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TECHNICAL FIELD
The present invention relates to magnetorheological fluids. More particularly, the present invention pertains to methods for producing and treating particles used in producing magnetorheological fluids.
BACKGROUND OF THE INVENTION
Magnetorheological (MR) fluids are responsive to magnetic fields and contain a field polarizable particle component and a liquid carrier component. MR fluids are useful in a variety of mechanical applications including, but not limited to, shock absorbers, controllable suspension systems, vibration dampeners, and electronically controllable force/torque transfer devices.
The particle component of MR fluids typically includes micron-sized magnetic-responsive particles. In the presence of a magnetic field, the magnetic-responsive particles become polarized and are organized into chains or particle fibrils which increase the apparent viscosity (flow resistance) of the fluid, resulting in the development of a solid mass having a yield stress that must be exceeded to induce onset of flow of the MR fluid. The particles return to an unorganized state when the magnetic field is removed, which lowers the viscosity of the fluid.
Oxidation of ferromagnetic particles is particularly pronounced at elevated temperatures. This makes the use of MR fluids in high temperature applications such as automotive fan and transmission clutches particularly problematic.
Thus it would be desirable to provide an MR fluid containing iron particles that are resistant to oxidation. It would also be desirable to provide particles useful in MR fluids that are oxidation resistant but exhibit significant magnetization response.
SUMMARY OF THE INVENTION
The present invention is directed to a method for producing a magnetorheological fluid that includes the steps of exposing a portion of the particulate component of the MR fluid to a nitrogen-rich environment for an interval sufficient to impart a nitrogen-rich surface on the particles. The resulting particles are integrated into a suitable carrier fluid. Also disclosed is a magnetorheological fluid that includes MR particles suspended in a carrier fluid. At least a portion of the particles in the MR fluid have regions of elevated nitrogen concentrations with at least a portion of these regions positioned on the particles in a manner which retards oxidative interaction between the particulate surface and the surrounding environment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process diagram of the method disclosed herein;
FIG. 2 is a thermogravimetric analysis of weight percent versus temperature in air for large and small particle iron powders;
FIG. 3 is a thermogravimetric analysis of the time rate of weight gain per unit surface area versus temperature in air for large particle and small particle iron powders;
FIG. 4A is a graph of weight gain versus temperature in air for HS iron particles treated by nitriding at 400° C. for various lengths of time;
FIG. 4B is a graph of weight gain versus temperature in air for HS iron particles treated by nitriding at 500° C. for various lengths of time;
FIG. 5 is a graph of magnetization as measured by vibrating sample magnetometer (VSM) versus magnetic field strength;
FIG. 6 is a graph of yield stress (psi) versus volume fraction of monomodal size distribution carbonyl iron particles in an MR fluid mixture under a magnetic flux density of 1 Tesla for monomodal suspensions of large (dark square) and small (dark diamond) particles; and
FIG. 7 is a graph of the yield stress versus viscosity at various magnetic flux densities and various ratios of large to small carbonyl iron microspheres.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The disclosed magnetorheological fluid and method for preparing the same is predicated, at least in part, upon the discovery that particulate magnetorheological material can be treated in a manner which reduces oxidation without significantly compromising magnetic or magnetic-responsive characteristics of the particles. The present disclosure is also predicated, at least in part, upon the discovery that MR fluids containing magnetorheological particles can be enhanced or rendered more efficient by providing that at least a portion of the magnetorheological particles have a surface region which exhibits elevated levels of nitrogen over that found in the general particle.
In the method as illustrated in FIG. 1 magnetorheological particles are exposed to a nitrogen-rich environment as at reference numeral 20 for an interval sufficient to impart a region of elevated nitrogen content at least proximate to the surface on the ferromagnetic particles. The ferromagnetic particles having the nitrogen-rich region are integrated into a suitable magnetorheological carrier fluid as at reference numeral 30 .
As broadly construed, the magnetorheological particles or solids which can be treated in the method disclosed herein and employed in an MR fluid are those which are prone to undergoing oxidation and are composed of materials which can permit or facilitate uptake of nitrogen into the material. Suitable MR particles will exhibit at least some magnetorheological activity upon exposure to a suitable magnetic field. As used herein the term “magnetorheological activity” is defined as the ability of particles to be maintained in suspension and to align or cluster upon exposure to a magnetic field and to increase the effective viscosity or decrease the flowability of the associated magnetorheological fluid.
The particular solids suitable for use in the MR fluids as disclosed herein are magnetizable, ferromagnetic, low coercivity (i.e., little or no residual magnetism when the magnetic field is removed), finely divided particles of iron, nickel, cobalt, iron-nickel alloys, iron-cobalt alloys, iron-silicon alloys and the like. The materials may be spherical or nearly spherical in shape and have a diameter in the range of about 0.01 to about 100 microns with diameters in a range between 0.01 and 1 microns being preferred. Where the particles are employed in noncolloidal suspensions, it is preferred that the particles be at the small end of the suitable range, preferably in the range of 0.5 to 30 microns in nominal diameter or particle size, with diameters between about 1 and about 10 microns being preferred.
In the method and material as disclosed herein, the magnetorheological particles are preferably an iron powder. The iron powder may be any form of powdered iron, particularly carbonyl iron, reduced carbonyl iron, crushed iron, milled iron, melt-sprayed iron, low carbon steel, silicon steel, potato iron, iron alloys, or mixtures of any of the previously recited materials. In the method and material disclosed herein, the preferred particle materials are carbonyl iron and reduced carbonyl iron. Suitable carbonyl iron is derived from the thermal decomposition of iron pentacarbonyl (Fe (CO) 5). Carbonyl iron materials typically contain greater than 97% iron with carbon content less than about 1%, oxygen content less than 0.5% and nitrogen content less than 1%.
Examples of other iron alloys which may be used as magnetorheological particles include iron-cobalt and iron-nickel alloys. Iron-cobalt alloys may have an iron-cobalt ratio ranging from about 30:70 to about 95:5 and preferably from about 50:50 to about 85:15, while the iron-nickel alloys have an iron-nickel ratio ranging from about 90:10 to about 99:1 and preferably from about 94:6 to 97:3. The iron alloys maintain a small amount of other elements such as vanadium, chromium, etc., in order to improve ductility and mechanical properties of the alloys. These other elements are typically present in amounts less than about 3.0 percent total by weight.
The magnetorheological particles are typically in the form of metal powders. The particle size of magnetorheological particles treated by the method and materials as disclosed herein are selected to exhibit bimodal characteristics when subjected to a magnetic field. Average particle diameter distribution size of the magnetorheological particles is generally between about 1 and about 100 microns, with ranges between about 1 and about 50 microns being preferred.
The magnetorheological particles may be present in bimodal distributions of large particles and small particles with large particles having an average particle size distribution between about 5 and about 30 microns. Small particles may have an average particle size distribution between about 1 and about 10 microns. In the bimodal distributions as disclosed herein, it is contemplated that the average particle size distribution for the large particles will typically exceed the average particle size distribution for the small particles in a given bimodal distribution. Thus, in situations where the average particle distribution size for large particles is 5 microns, for example, the average particle size distribution for small particles will be below that value. Examples of suitable magnetorheological fluids having bimodal particle distributions include those disclosed in U.S. Pat. No. 5,667,715 to Foister, the specification of which is incorporated herein.
The particles may be spherical in shape. However, it is also contemplated that magnetorheological particles may have irregular or nonspherical shapes as desired or required. Additionally, a particle distribution of nonspherical particles as disclosed herein may have some nearly spherical particles within its distribution. Where carbonyl iron powder is employed, it is contemplated that a significant portion of the particles will have a spherical or near spherical shape.
The magnetorheological particles can be integrated into a suitable carrier fluid. Suitable carrier fluids can suspend the MR particles but are essentially nonreactive. Such fluids include, but are not limited to, water, organic fluids or oil-based fluids. Examples of suitable organic and/or oil based carrier fluids include, but are not limited to, cyclo-paraffin oils, paraffin oils, natural fatty oils, mineral oils, polyphenol ethers, dibasic acid esters, neopentylpolyol esters, phosphate esters, polyesters, synthetic cyclo-paraffin oils and synthetic paraffin oils, unsaturated hydrocarbon oils, monobasic acid esters, glycol esters and ethers, silicate esters, silicone oils, silicone copolymers, synthetic hydrocarbon oils, perfluorinated polyethers and esters, halogenated hydrocarbons, and mixtures or blends thereof. Hydrocarbon oils, such as mineral oils, paraffin oils, cyclo-paraffin oils (also as napthenic oils), and synthetic hydrocarbon oils may be employed as carrier fluids. Synthetic hydrocarbon oils include those oils derived from the oligomerization of olefins such as polybutenes and oils derived from higher alpha olefins of from 8 to 20 carbon atoms by acid catalyzed dimerization, and by oligomerization using tri-aluminum alkyls as catalysts. Such poly-alpha olefin oils can be employed as preferred carrier fluids. It is also contemplated that the oil may be a suitable material such as oils derived from vegetable materials. The oil of choice may be one amenable to recycle and reprocessing as desired or required.
The carrier fluid of choice may have a viscosity between about 2 and about 1,000 centipoises at 25° C. with a viscosity between about 3 and about 200 centipoises being preferred and a viscosity between about 5 and about 100 centipoises being particularly preferred. It is contemplated that the carrier fluid portion and magnetorheological particles can be admixed to provide a composition having magnetorheological particles in an amount between about 5 and about 50 percent by volume, with amounts between 10 and 45 percent by volume being preferred, and amounts between about 20 and 45 percent by volume being particularly preferred. This corresponds to about 30 to about 90 percent by weight, with amounts between 45 and 90 percent by weight being preferred, and amounts between 65 and 90 percent by weight being particularly preferred based on the carrier fluid and particle component of the magnetorheological material having specific gravities in the range of 0.8-0.9 and 7.5-8.0, respectively.
In preparing the MR fluid according to the method disclosed herein, it is contemplated that at least a portion of the magnetorheological particles employed will have surface characteristics that prevent or minimize oxidative reaction between the particles and the surrounding environment. The magnetorheological particles exhibiting minimized oxidative interaction will be characterized by elevated nitrogen concentrations in at least at one portion of the matrix. Typically, the elevated nitrogen content is incorporated by diffusion into the particulate matrix. The diffused nitrogen material may be distributed uniformly or non-uniformly throughout the magnetorheological particle matrix. Where the nitrogen distribution is non-uniform, it is contemplated that the particles will be present with elevated nitrogen levels proximate to outer surface regions of the particles.
In the method as disclosed herein, the particles are exposed to a nitrogen-rich environment for an interval sufficient to impart a nitrogen-rich surface on the particles so exposed. As used herein, the term “nitrogen-rich environment” is taken to mean an environment in which nitrogen or a nitrogen-containing compound is present, preferably in gaseous form, in sufficient quantity or concentration to provide nitrogen for diffusion into the magnetorheological particles. The nitrogen-rich environment may be composed of nitrogen-donating materials such as nitrogen gas, ammonia, and the like. It is also contemplated that the nitrogen-rich environment may include other nonoxidative gases that do not impede the diffusion or integration of nitrogen into the magnetorheological particles. In a non-limitative example embodiment, the nitrogen-rich environment has a major portion of nitrogen and a minor portion of a gaseous material inert to interaction with the ferromagnetic particles. In another embodiment of the method as disclosed, a nitrogen-rich environment composed solely of nitrogen gas is preferred.
The magnetorheological particles are maintained in a state that permits or facilitates solubility of nitrogen in the metallic matrix of the particles for an interval sufficient to permit nitrogen uptake. In the method as disclosed herein, magnetorheological particles may be maintained at a pressure at or above standard atmospheric pressure during residence in the nitrogen-rich environment. The pressure is preferably one that will facilitate diffusion or uptake of nitrogen into the magnetorheological particles.
The magnetorheological particles are maintained at a treatment temperature, which facilitates nitrogen diffusion and/or uptake. In the process as disclosed herein, the nitrogen-rich environment is maintained at a temperature in the range of 400° C. to 500° C. at or above ambient pressure. It is to be understood that a lower processing temperature may be utilized in certain processing situations, for example when using plasma enhanced nitriding processes in a vacuum. The magnetorheological particles can be maintained in the nitrogen-rich environment for an interval sufficient to impart a nitrogen-rich diffused region in the treated ferromagnetic particles. It is contemplated that the diffused nitrogen region that results can range from several atomic layers thick to a thickness that constitutes between 5 and 25 percent of the total particulate depth. The amount of nitrogen diffusion is such that significant portions of the magnetic characteristic are maintained. Processing times can be for any interval that does not compromise the magnetic-responsive nature of the particles. As disclosed herein, the processing interval is up to 100 hours. Processing intervals between 10 and 100 hours are preferred, with processing intervals between 20 and 50 hours being most preferred.
The particulate material being treated can be maintained in the treatment environment in a manner that promotes the nitrogen diffusion process. Thus the particles may be placed in a bed of appropriate thickness to permit contact between the particles and sufficient nitrogen to facilitate nitrogen diffusion into the particulate matrix. The particles may be static or fluidized as required to permit nitrogen diffusion and/or integration.
It has been found that magnetorheological particulate materials such as carbonyl iron treated according to the method as disclosed herein exhibit elevated oxidation resistance. Without being bound to any theory, it is believed that the presence of even small percentages of integrated nitrogen can act to retard oxidative processes associated with MR fluid usage.
It has been found, quite unexpectedly, that integration of a portion of MR particles treated according to the method as disclosed herein results in an MR fluid having enhanced particulate oxidation resistance and more robust magnetic performance. The nitrogen-rich particles can constitute all or a portion of the particulate component of the MR fluid. The quantity of treated or nitrogen-rich MR particles employed will be that which maintains the magnetorheological responsiveness of the associated MR fluid within desired parameters.
The MR particles can be either monomodal or bimodal in particulate distribution. The term “bimodal” is employed to mean that the population of solid particles employed in the fluid possesses two distinct maxima in their size or diameter. The bimodal particles may be spherical or generally spherical. In bimodal compositions, it is contemplated that the particles will be in two different size populations—a small diameter size and a large diameter size. The large diameter size particle group will have a large mean diameter size with a standard deviation no greater than about two-thirds of said mean diameter size. Likewise, the smaller particle group will have a small mean diameter size with a standard deviation no greater than about two-thirds of that mean diameter value.
Preferably, the small particles are at least one micron in diameter so that they are suspended and function as magnetorheological particles. The practical upper limit on particle size is about 100 microns since particles of greater size usually are not spherical in configuration but tend to be agglomerations of other shapes. However, for the practice of the embodiments disclosed herein, the mean diameter or most common size of the large particle group preferably is 5 to 10 times the mean diameter or most common particle size in the small particle group. The weight ratio of the two groups may be within 0.1 to 0.9. The composition of the large and small particle groups may be the same or different. Carbonyl iron particles are preferred. Such materials typically have a spherical configuration and work well for both the small and large particle groups.
In MR fluids for use in high temperature applications, it is anticipated that at least a portion of particles that are more readily oxidized will be treated according to the process disclosed herein to provide nitrogen diffusion regions. In bimodal MR fluid compositions, it is contemplated that at least a portion of one particle class will be treated according to the method disclosed herein. In bimodal MR fluids, it is preferred that at least a portion of particles having small average particle distributions sizes will be treated prior to integration into the MR carrier fluid.
In an embodiment, the MR particles exposed to the nitrogen-rich environment are small ferromagnetic particles having an average particle size distribution ranging between about 1 micron and about 10 microns. It is to be understood that the method may include integrating these smaller particles with larger ferromagnetic particles prior to exposing the smaller ferromagnetic particles to the nitrogen-rich environment. In an alternate embodiment of the method, the integration of the smaller particles with the larger particles occurs after exposure to the nitrogen-rich environment. In a further embodiment, the small particles are admixed with ferromagnetic particles having an average size distribution ranging between about 5 microns and about 30 microns. In this embodiment, the admixture occurs after the small particles have been exposed to the nitrogen-rich environment. In still a further embodiment, the small particles are admixed with ferromagnetic particles having an average particle size distribution greater than about 10 microns. It is to be understood that this admixture occurs after the small particles have been exposed to the nitrogen-rich environment.
The magnetorheological fluid composition as disclosed herein will comprise magnetorheological particles of at least one average size distribution in a carrier fluid in which at least a portion of the MR particles exhibit at least one region of elevated nitrogen content. It is further contemplated that MR fluid compositions may include magnetorheological particles of at least two different size distributions. In magnetorheological fluids having multiple size distributions, it is contemplated that at least a portion of the particles of at least one size distribution will have at least one localized region of elevated nitrogen concentration. The particles having elevated nitrogen concentrations will typically be iron-containing particles with iron-containing particulate microspheres composed in whole or part of carbonyl iron being preferred. Suitable carbonyl iron includes material such as carbonyl powder having the characteristics outlined in Table 1. Examples of such material are materials commercially available from BASF under the trade designations HS and CM.
TABLE 1
Characteristics and Properties of Carbonyl Iron Materials
Compound
BASF HS
BASF CM
Iron
>97.8%
>99.5%
Carbon
<1.0%
<0.05%
Oxygen
<0.5%
<0.2%
Nitrogen
<1.0%
<0.01%
Particle Size
Distribution:
d10
1.5 micrometer
4 micrometer
d50
2.0 micrometer
7 micrometer
d90
3.5 micrometer
22 micrometer
In order to more fully understand the process of the present invention, the following illustrative examples are provided. These examples are to be considered illustrative of the present invention and in no way limit the scope or breadth of the invention herein claimed.
EXAMPLE 1
Particulate material of specific bimodal distributions of large (5-30 micron) particle size and small (1-10 micron) particle size carbonyl iron commercially available from BASF under the trade designations BASF CM and BASF HS was analyzed and prepared. The large particle size material employed was a product commercially available from BASF Corporation under the trade designation CM. The producer describes the CM material as a relatively soft spherical powder made from iron pentacarbonyl and then reduced in a nitrogen atmosphere. The manufacturer lists the mean particle diameter of the CM material as seven microns with a tap density of 3.4 g/cc.
The small particle size material employed was a product commercially available from BASF Corporation under the trade designation HS. The HS material was described by the producer as a harder and smaller material than the CM material, and is prepared by the thermal decomposition of iron pentacarbonyl without further reduction. The listed mean particle size for the HS material was 3 to 6 microns with a tap density of 3.4 g/cc. Particulate material was exposed to elevated temperature in a standard atmospheric environment. It was determined by thermogravimetric (TGA) analysis that small particle iron oxidized much more rapidly than large particle iron (BASF CM) as illustrated in FIGS. 2 and 3 .
It can be seen from FIGS. 2 and 3 that small particle carbonyl iron exhibited marked increases in oxidation at temperatures above 250° C., while large particle material did not exhibit oxidation increases until approximately 400° C. as seen in FIG. 4. A more detailed analysis of rate of weight gain in air per unit surface area versus temperature is depicted in FIG. 5 . Both the large and small particle carbonyl materials appear to exhibit about the same weight gain per surface area below a temperature of about 300° C.
EXAMPLE 2
The various samples of small particle carbonyl iron commercially available as BASF HS were analyzed to determine weight gain due to oxidation versus temperature in air. Samples of carbonyl iron were exposed to a nitrogen rich atmosphere of 100 percent nitrogen at standard pressure for intervals of 24 hours, 48 hours, and 90 hours respectively. The various batches were processed at 400° C. or 500° C. The results are graphically illustrated in FIGS. 4A and 4B . As illustrated in FIGS. 4 A and 4 B, the treated materials exhibited decreased weight gain in air as compared to untreated HS carbonyl iron particles at temperatures greater than 250° C.
It can be surmised that nitriding HS iron is effective in increasing the resistance of the iron particles to oxidation as compared to untreated particles.
EXAMPLE 3
Magnetization of nitrided HS particles treated at 400° C. for intervals of 24, 48, and 90 hours were analyzed and measured with a vibrating sample magnetometer (VSM) and compared to untreated material. The results are set forth in FIG. 5 . It is determined from the data summarized in FIG. 5 that no apparent change in magnetic properties of the nitrided material was evidenced for nitriding treatments up to 90 hours at 400° C.
EXAMPLE 4
Magnetorheological materials are prepared according to the disclosure found in U.S. Pat. No. 5,667,715 to Foister utilizing bimodal particle iron pentacarbonyl in which the small particle distribution is treated according to the process outlined in Example 2.
MR fluids are prepared as follows. The MR vehicle used is a suitable hydrogenated polyalphaolefin (PAO) base fluid such as SHF 21, manufactured by Mobil Chemical Company. The material is a homopolymer of hydrogenated 1-decene. It is a paraffin-type hydrocarbon and has a specific gravity of 0.82 at 15.6° C. It is a colorless, odorless liquid with a boiling range of 375° C. to 505° C. In order to suspend the small iron particles in the polyalphaolefin, a miscible polymeric gel material that includes about nine parts of a paraffinic hydrocarbon gel with the consistency of Vaseline® and one part of a suitable surfactant is thoroughly mixed with PAO base fluid. Preweighed amounts of the PAO fluid base and the polymeric gel (33% of the weight of the PAO) are mixed under high shear conditions for approximately 10 minutes. The resultant mixture is degassed and under vacuum for about 5 minutes, and then preweighed solid iron microspheres (the CM product) are added in weighed amounts to form the several MR fluid volume fraction mixtures (0.1, 0.2 . . . 0.5, 0.55). The predicted data are summarized according to the formulations in FIGS. 6 and 7 . Several different fluids are formulated by adding the preweighed solid with mixing for six to eight hours, and the fluids are then again degassed before testing.
The predicted effect of increasing volume fraction of the iron carbonyl microspheres on the viscosity of the PAO vehicle base MR fluids is seen in FIGS. 6 and 7 . The predicted effect of volume fraction on yield stress at a magnetic field density of 1 Tesla is seen in FIG. 6 .
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law.
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A magnetorheological fluid containing magnetorheological particles which are resistant to oxidation having regions rich in diffused nitrogen located therein and a method for producing such magnetorheological fluid.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application No. 62/364,785 which was filed on Jul. 20, 2016, the contents of which are hereby incorporated by reference.
BACKGROUND
1. Field
[0002] The disclosed embodiments relate to networking devices. More specifically, the disclosed embodiments relate to mobile devices with multiple wireless channels and methods of using mobile devices with multiple wireless channels.
2. Related Art
[0003] Traditional mobile devices, or other devices that have a physical wireless communication channel, such as an “Internet of Things” (“IoT”) device, have a single channel that is used by any applications developed or running on the device. A typical mobile device, for example an Apple iPhone or an Android phone, has a shared single Wi-Fi, Bluetooth, or other wireless channel that any applications developed on the device must use to establish a wireless connection. With the proliferation of Wi-Fi connected devices, this presents a technical challenge of connecting to all the desired devices from a mobile device to run various applications on the mobile device.
[0004] Accordingly, methods and systems are needed to allow users to easily connect to multiple other devices and to perform tasks where the mobile device simultaneously connect to multiple other devices.
SUMMARY
[0005] The disclosed embodiments provide a method and system for connecting a mobile device to multiple other devices, allowing an application to use a specific wireless channel from a list of more than one wireless channel, and performing methods where a mobile device connects simultaneously to multiple other devices. In some embodiments, a mobile device operates with multiple Wi-Fi (wireless communication) networking devices, IoT devices, or other Wi-Fi enabled devices, and has multiple hardware Wi-Fi channels available. Each channel can be assigned to an executable application on the mobile device.
[0006] Prior to having multiple wireless channels on a mobile device, applications were forced to make a connection to a single available channel. For example, if an application needed to use an external device using a Wi-Fi channel, the settings on the mobile device had to be changed in a settings menu to assign the Wi-Fi channel to that external device (e.g. a Wi-Fi router, or IoT device). This was a cumbersome operation. If another application needed to connect to a separate external device, the settings on the mobile device had to be changed again to assign the Wi-Fi channel to the other external device (e.g. a Sonos controller). This warrants unnecessary overhead by the operator of the device if an application needs to connect to a specific Wi-Fi device.
[0007] With multiple wireless channels, for example multiple Wi-Fi channels, a specific software application can be assigned to a wireless channel. Another application can be assigned to a second wireless channel. Other applications may be assigned to a different wireless channel. And the mobile device itself can have a community wireless channel that any applications can use when running.
[0008] In one embodiment, a casino floor or each gaming machine can implement a Wi-Fi connection point that is meant to be used by a specific mobile application. The mobile application connects to the casino floor Wi-Fi connection point through one of the Wi-Fi channels available on the mobile device. The mobile application communicates to the casino floor through the specified mobile channel while all other applications on the mobile device use one or more of the remaining mobile channels for wireless communication.
[0009] In another embodiment, two applications on a mobile device may need to execute at the same time where one application may be in the foreground and the other application is running in the background. For example, the foreground application may be an application that operates a drone or accesses the Internet while the background application is a music application that plays music from a cloud source. Both applications require a Wi-Fi connection with the background application requiring use of a generic Wi-Fi connection (connection A) and the foreground application requiring a specific Wi-Fi connection (connection B) to a Wi-Fi router built into the drone. This can only be accomplished with more than a single Wi-Fi channel or multiple radios on the mobile device.
[0010] Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates an example embodiment of a mobile device.
[0012] FIG. 2 illustrates multiple Wi-Fi connections on a mobile device, according to an exemplary embodiment.
[0013] FIG. 3 shows a method of connecting to a network and a remote device simultaneously, according to one exemplary embodiment.
[0014] FIG. 4 shows a method of using simultaneous dedicated connections, according to an exemplary embodiment.
[0015] FIG. 5 shows a method of sending control instructions to a remote device using simultaneous connections, according to an exemplary embodiment.
[0016] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
DETAILED DESCRIPTION OF EMBODIMENTS
[0017] FIG. 1 illustrates an example embodiment of a mobile device. This is but one possible mobile device configuration and as such it is contemplated that one of ordinary skill in the art may differently configure the mobile device. The mobile device 100 may comprise any type of mobile communication device capable of performing as described below. The mobile device may comprise a PDA, cellular telephone, smart phone, tablet PC, wireless electronic pad, an IoT device, a “wearable” electronic device, or any other computing device.
[0018] In this example embodiment, the mobile device 100 is configured with an outer housing 104 configured to protect and contain the components described below. Within the housing 104 is a processor 108 and a first and second bus 112 A, 112 B (collectively 112 ). The processor 108 communicates over the buses 112 with the other components of the mobile device 100 . The processor 108 may comprise any type processor or controller capable of performing as described herein. The processor 108 may comprise a general-purpose processor, ASIC, ARM, DSP, controller, or any other type of processing device. The processor 108 and other elements of the mobile device 100 receive power from a battery 120 or other power source. An electrical interface 124 provides one or more electrical ports to electrically interface with the mobile device, such as with a second electronic device, computer, a medical device, or a power supply/charging device. The interface 124 may comprise any type electrical interface or connector format.
[0019] One or more memories 110 are part of the mobile device 100 for storage of machine readable code for execution on the processor 108 and for storage of data, such as image data, audio data, user data, medical data, location data, accelerometer data, or any other type of data. The memory 110 may comprise RAM, ROM, flash memory, optical memory, or micro-drive memory. The machine-readable code as described herein is non-transitory.
[0020] As part of this embodiment, the processor 108 connects to a user interface 116 . The user interface 116 may comprise any system or device configured to accept user input to control the mobile device 100 . The user interface 116 may comprise one or more of the following: keyboard, roller ball, buttons, wheels, pointer key, touch pad, and touch screen. A touch screen controller 130 is also provided which interfaces through the bus 112 and connects to a display 128 .
[0021] The display 128 comprises any type display screen configured to display visual information to the user. The screen may comprise a LED, LCD, thin film transistor screen, OEL CSTN (color super twisted nematic), TFT (thin film transistor), TFD (thin film diode), OLED (organic light-emitting diode), AMOLED display (active-matrix organic light-emitting diode), capacitive touch screen, resistive touch screen or any combination of these technologies. The display 128 receives signals from the processor 108 and these signals are translated by the display 128 into text and images as is understood in the art. The display 128 may further comprise a display processor (not shown) or controller that interfaces with the processor 108 . The touch screen controller 130 may comprise a module configured to receive signals from a touch screen which is overlaid on the display 128 .
[0022] Also part of this exemplary mobile device is a speaker 134 and microphone 138 . The speaker 134 and microphone 138 may be controlled by the processor 108 . The microphone 138 is configured to receive and convert audio signals to electrical signals based on processor 108 control. Likewise, the processor 108 may activate the speaker 134 to generate audio signals. These devices operate as is understood in the art and as such are not described in detail herein.
[0023] Also connected to one or more of the buses 112 is two or more Wi-Fi transceivers 140 with respective antennas 148 . One or more additional wireless transceivers 144 are also provided with respective antennas 152 . The transceivers 140 , 144 are configured to receive incoming signals from a remote transmitter and perform analog front-end processing on the signals to generate analog baseband signals. The incoming signal maybe further processed by conversion to a digital format, such as by an analog to digital converter, for subsequent processing by the processor 108 . Likewise, the transceivers 140 , 144 are configured to receive outgoing signals from the processor 108 , or another component of the mobile device 108 , and up convert these signal from baseband to RF frequency for transmission over the respective antenna 148 , 152 .
[0024] It is contemplated that the mobile device 100 , and hence the Wi-Fi transceivers 140 and additional wireless transceiver 144 may be configured to operate according to any presently existing or future developed wireless standard. For example, the Wi-Fi transceiver may operate according standards including, but not limited to Wi-Fi such as IEEE 802.11 a, b, g, n, ac wireless LAN. The wireless transceiver may operate according to standards including, but not limited to, Bluetooth, NFC, WMAN, broadband fixed access, WiMAX, any cellular technology including CDMA, GSM, EDGE, 3G, 4G, 5G, TDMA, AMPS, FRS, GMRS, citizen band radio, VHF, AM, FM, and wireless USB.
[0025] Also part of the mobile device is one or more systems connected to the second bus 112 B which also interface with the processor 108 . These devices include a global positioning system (GPS) module 160 with associated antenna 162 . The GPS module 160 is capable of receiving and processing signals from satellites or other transponders to generate location data regarding the location, direction of travel, and speed of the GPS module 160 . GPS is generally understood in the art and hence not described in detail herein. A gyroscope 164 connects to the bus 112 B to generate and provide orientation data regarding the orientation of the mobile device 104 . A magnetometer 168 is provided to provide directional information to the mobile device 104 . An accelerometer 172 connects to the bus 112 B to provide information or data regarding shocks or forces experienced by the mobile device.
[0026] One or more cameras (still, video, or both) 176 are provided to capture image data for storage in the memory 110 and/or for possible transmission over a wireless or wired link or for viewing at a later time. The one or more cameras 176 may be configured to detect an image using visible light and/or near-infrared light. The cameras 176 may also be configured to utilize image intensification, active illumination, or thermal vision to obtain images in dark environments.
[0027] A flasher and/or flashlight 180 , such as an LED light, are provided and are processor controllable. The flasher or flashlight 180 may serve as a strobe or traditional flashlight. The flasher or flashlight 180 may also be configured to emit near-infrared light. A power management module 184 interfaces with or monitors the battery 120 to manage power consumption, control battery charging, and provide supply voltages to the various devices which may require different power requirements.
[0028] FIG. 2 illustrates multiple Wi-Fi connections on a mobile device, according to an exemplary embodiment. In FIG. 2 , the mobile device 100 is shown to have three Wi-Fi transceivers 140 . This allows the mobile device 100 to connect simultaneously with several Wi-Fi enabled remote devices. In this example, the mobile device 100 is simultaneously connected to a router 210 to access a network or other device connected to the router, a drone 220 that is operated via a Wi-Fi connection with the mobile device 100 , and an internet connected thermostat 230 .
[0029] In some embodiments, software modules or applications running on the processor 108 may control the connection and/or data transmitted over the connection for each of the Wi-Fi transceivers 140 . In this example, a module A 202 may control the connection to the router 210 , module B 204 may control the connection to the drone 220 , and module C may control the connection to the thermostat 230 .
[0030] Stated more generally, the plurality of Wi-Fi transceivers allow the mobile device to connect to several Wi-Fi dedicated devices simultaneously to allow for multi-tasking or other new functionality of the mobile device. Such Wi-Fi devices may include devices controlled directly via a Wi-Fi connection such as the drone 220 controlled via the mobile device 100 . Typically, a user of a mobile device 100 would be required to disconnect from a network (such as from the router 210 ) to connect to the drone 220 to control the drone. With the configuration described herein, the mobile device 100 may maintain a connection with the network while controlling the drone 220 . This may facilitate a more user-friendly experience because the user does not need to change any Wi-Fi settings on the mobile device 100 to connect to the drone 220 . Other operations such as firmware updates for the drone 220 may easily be facilitated through the mobile device 100 connected to both a network and the drone 220 .
[0031] The configuration may also aid in a more user-friendly adoption of Internet of Things (IoT) devices. Typically, to set up an IoT device, a user must transfer network information to the IoT device so that the IoT device can access the network. This requires the user to disconnect from the network to connect the mobile device's Wi-Fi to the IoT device in order to set up the IoT device. Such a process may be difficult for a person who is not confident using technology. However, with the present configuration, the user may simply connect to the IoT device without the need to disconnect from a network. This may even be controlled by an application to easily set up an IoT device on a network.
[0032] Other types of functionality using multiple Wi-Fi connections is facilitated. For example, simultaneous connections to public and secure networks, peer to peer networks, and other various connections may be achieved.
[0033] Examples of methods facilitated through the above-described configurations will be described with reference to FIGS. 3-5 . These methods are not an exhaustive list of novel methods, and the methods may be modified and adapted for various applications.
[0034] FIG. 3 shows a method of connecting to a network and a remote device simultaneously, according to one exemplary embodiment. In step 302 , a mobile device connects to a network via a first Wi-Fi channel with a first Wi-Fi transceiver. For example, mobile device 100 may connect to a router 210 to gain access to a network. While connected to the network, the mobile device connects to a remote device via a second Wi-Fi channel on a second Wi-Fi transceiver. By utilizing the multiple transceivers, the mobile device 100 , for example, connects to both the router 210 and smart thermostat 230 simultaneously. As a result, in step 306 , the mobile device may send network information to the remote device via the second Wi-Fi transceiver.
[0035] The method above may provide several advantages. For example, when setting up an IoT device, such as the smart thermostat 230 , the smart thermostat 230 needs to be provided with network access information to connect to the Internet via the network. In order to do this, the mobile device 100 must connect to the thermostat using a Wi-Fi connection. With the above-described method, the mobile device 100 simply uses the second transceiver to connect to the thermostat 210 to provide network information to the thermostat 210 . This makes the process simple and intuitive for the user because the user does not need to disconnect from the network (e.g. router 210 ) to begin the process.
[0036] Other benefits are also possible. For example, the mobile device 100 may deliver firmware updates to the remote device through the simultaneous connection. The mobile device 100 may also serve as a Wi-Fi signal extender to increase the range of the router 210 to other remote devices. The remote device may also be second router connecting the mobile device to a second network. Additionally, the remote device may be another mobile device or other computing device allowing the mobile device to be connected to a router and to a peer-to-peer network simultaneously.
[0037] FIG. 4 shows a method of using simultaneous dedicated connections, according to an exemplary embodiment. In step 402 , the mobile device connects to a first network via a first Wi-Fi channel with a first Wi-Fi transceiver. In step 404 , the mobile device connects to a second network via a second Wi-Fi channel using a second Wi-Fi transceiver.
[0038] As an example, an establishment such as a casino, an amusement park, or other resort, may have different networks available for different purposes. A public Wi-Fi may be provided that allows access to the Internet for visitors of the establishment. Other networks may also be provided so serve specific purposes and may have additional security measures such as encryption, geofencing, password protection, and the like. For example, a casino may provide a secure network in a gaming area of the casino that allows wagers to made via the mobile devices on game outcomes being played or observed in the gaming area. Such a network may be encrypted and may require the mobile device to be within a certain distance of the gaming area. For security, such a network may not be connected to the Internet.
[0039] In step 406 of FIG. 4 , the mobile device assigns data communication from a first application to the first network, and in step 408 , the mobile device assigns data communication from a second application to the second network.
[0040] In the above example, the mobile device 100 may control communication from software module A 202 to be dedicated to the first network, and communication from software module B 204 to be dedicated to the second network. Software module A 202 , for example, may be an Internet browser and the processor 108 dedicates the data communication from the browser through the first network, which may be a public Wi-Fi network for accessing the Internet. Software module B may be gaming software provided by a casino. The processor 108 may run the gaming software such that data communication for the gaming software is through the second network. This allows a visitor of a casino, for example, to access email and websites via general public Wi-Fi while simultaneously connecting to a secured gaming network or to a specific casino gaming device for placing bets or playing a game in a gaming area of a casino.
[0041] Other functionality that is carried out on designated networks may be executed by the above method. The above method may allow a specific application to automatically connect to the second network without a user accessing Wi-Fi settings on his/her mobile device. Such other designated networks that may utilize the method include accounting networks, employee networks, game networks, etc.
[0042] FIG. 5 shows a method of sending control instructions to a remote device using simultaneous connections, according to an exemplary embodiment. In step 502 , a mobile device connects to a network via a first Wi-Fi channel through a first Wi-Fi transceiver. In step 504 , the mobile device connects to a remote device via a second Wi-Fi channel on a second Wi-Fi transceiver.
[0043] In one example, the mobile device 100 connects via a router 210 to a network, and then simultaneously connects to a dedicated Wi-Fi device such as a drone 220 . This allows the user to simply and easily connect to the drone 220 without accessing Wi-Fi settings in the mobile device 100 to disconnect from the network.
[0044] In step 506 , the mobile device sends control instructions to the remote device via the second Wi-Fi transceiver. The mobile device may also receive data from the remote device via the second Wi-Fi transceiver. The mobile device also sends and receives data from the network via the first Wi-Fi transceiver.
[0045] For example, the user may access an application from a mobile device 100 that controls a drone 220 and/or receives a video feed from a drone 220 . The application may control a connection to the drone 220 without disconnecting the mobile device 100 from a network, such as to a connection to router 210 . This allows the mobile device to send and receive information over the network and to and from the drone 220 simultaneously. An application controlling the drone 220 may also update drone firmware via the connection from the mobile device 100 to the network.
[0046] Other features are also possible. In one embodiment, an application with a user interface is provided to manage the two or more Wi-Fi connections to the various devices. The application may assign processor cores of the processor of the mobile devices to control data communication for each of the Wi-Fi transceivers. The application may also manage power consumption of each of the connections to prevent battery loss on the mobile device.
[0047] A user may use the application to create connection rules for each saved device. Such rules may be based on geolocation, time, or software accessed at the mobile device. The application may provide reports for data speed, security, and activity history for each of the connections via the Wi-Fi transceivers.
[0048] In the above description, reference is made throughout to a mobile device, such as a smart phone or tablet computing device. However, other Wi-Fi connected devices may operate similarly such as a laptop or desktop computer, a kiosk, a casino gaming machine, or the like. Additionally, the above description outlines systems and methods for utilizing multiple Wi-Fi transceivers in a mobile device. The description may also be applied to using multiple transceivers of other wireless protocols, such as Bluetooth, LTE, WiMAX, etc.
[0049] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. In addition, the various features, elements, and embodiments described herein may be claimed or combined in any combination or arrangement.
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The disclosed embodiments provide a method and system for connecting a mobile device to multiple other devices, allowing an application to use a specific wireless channel from a list of more than one wireless channel, and performing methods where a mobile device connects simultaneously to multiple other devices. In some embodiments, a mobile device operates with multiple Wi-Fi (wireless communication) networking devices, IoT devices, or other Wi-Fi enabled devices, and has multiple hardware Wi-Fi channels available. Each channel can be assigned to an executable application on the mobile device.
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RELATED APPLICATION
This application is a continuation of U.S. application Ser. No. 09/671,035, filed Sep. 27, 2000, now U.S. Pat. No. 6,406,337, issued Jun. 18, 2002, the entire teachings of which are incorporated herein by reference.
BACKGROUND
The windshield and/or rear window of automotive vehicles often have an electrical device such as an antenna or defroster formed on or in the glass. In order to electrically connect the electrical device to associated equipment, for example, a radio, telephone, or defroster control, an electrical terminal is first soldered to the glass in electrical communication with the electrical device. An electrical cable extending from the associated equipment is then secured to the electrical terminal for providing electrical communication therebetween. A problem with some current electrical terminals is that the terminals can be easily separated from the glass by peeling if accidental pulling forces are exerted on the electrical cable. In addition, some electrical terminal designs are prone to cause cracking of the glass during soldering because of heat related stress concentrations formed on the glass by the footprint of the terminal.
SUMMARY
The present invention provides an electrical terminal which is less readily separated from glass by accidental pulling forces than current terminal designs. In addition, the present invention electrical terminal has a design which causes little or no cracking of glass during soldering. The present invention is directed to an electrical terminal which includes a base pad for soldering to a surface. The base pad has a curved perimeter, and top and bottom surfaces. The electrical terminal also includes a securement portion having a deformable member for deforming around a conductor wire to capture and secure the conductor wire directly to the securement portion. The securement portion is configured relative to the base pad such that forces exerted by the conductor on the base pad are directed to a central region of the base pad.
In preferred embodiments, the base pad is formed of sheet metal and is generally circular in shape. The bottom surface of the base pad has a layer of solder thereon. In one embodiment, the securement portion includes a deformable strap located at the central region of the base pad formed by two opposed slits in the base pad. The slits allow the insertion of the conductor wire therethrough for capture between the top surface of the base pad and the strap.
In another embodiment, the securement portion includes an arm having proximal and distal ends extending from the central region of the base pad for directing forces exerted by the conductor wire to the central region. The proximal end extends from the central region and is defined by two opposed slots formed in the base pad extending from the perimeter of the base pad to the central region. The distal end has opposed crimping tabs for securing directly to the conductor wire. A portion of the arm is bent upwardly at an angle at about the perimeter of the base pad for absorbing forces exerted on the arm by the conductor wire. The distal end of the arm is bent to be parallel with the base pad.
The present invention also provides an electrical terminal assembly which enables easy soldering of multiple terminals with proper spacing therebetween. The terminal assembly includes at least two terminals, each having a base pad for soldering to a surface. Each base pad is secured to a conductor wire. A carrier strip is attached to the base pads by breakable regions.
The present invention further provides a method of soldering multiple electrical terminals to a surface, including providing an electrical terminal assembly having at least two terminals, each having a base pad for soldering to the surface. The base pads are secured to respective conductor wires and are attached to a carrier strip by breakable regions. The base pads are soldered to the surface with the carrier strip providing the proper spacing between the base pads. Once the base pads are soldered, the carrier strip is separated from the base pads by bending the carrier strip upwardly, thereby breaking the breakable regions.
In the present invention electrical terminal, by directing forces exerted by the conductor to the central region of the base pad, the strength of the solder joint between the base pad and the underlying surface, typically glass, is maximized. As a result, the terminal is not readily separated from the glass by accidental pulling forces. In addition, by having a generally circular base pad, the base pad of the present invention forms little or no heat related stress concentrations on the glass during soldering so that little or no cracking of the glass occurs. Consequently, the present invention provides a terminal that may be soldered to glass in a reliable manner and remain soldered thereto during normal use. Finally, the present invention electrical terminal assembly allows multiple electrical terminals to be quickly and easily soldered with the proper spacing therebetween, thereby allowing the manufacturing process to be conducted more quickly.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is a plan view of an embodiment of the present invention electrical terminal which is secured to an electrical cable.
FIG. 2 is a side view of the electrical terminal of FIG. 1 .
FIG. 3 is a side view of the electrical terminal of FIG. 1 soldered to a piece of glass.
FIG. 4 is a plan view of a multiple terminal soldering assembly having a series of electrical terminals attached to a carrier strip which are secured to electrical cables.
FIG. 5 is a side view of the multiple terminal soldering assembly soldered to a piece of glass.
FIG. 6 is a plan view of another embodiment of the present invention electrical terminal which is secured to an electrical cable.
FIG. 7 is a side view of the electrical terminal of FIG. 6 .
FIG. 8 is a side view of the electrical terminal of FIG. 6 soldered to a piece of glass.
FIGS. 9 and 10 are plan and side views, respectively, of a series of the electrical terminals of FIG. 6 which are attached to a carrier strip.
FIG. 11 is a plan view of another multiple terminal assembly.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, terminal 11 is an electrical terminal that is typically soldered to the windshield or rear window of an automotive vehicle in electrical communication with an electrical device, such as an antenna or defroster formed on or in the glass, so that the electrical device may be electrically connected to associated equipment by an electrical cable 18 . Electrical terminal 11 includes a generally flat or planar base pad 12 formed of sheet metal having a continuously curved outer perimeter or edge 12 a . Typically, base pad 12 is generally circular in shape (FIG. 1 ). The bottom surface 12 c of base pad 12 is precoated with a layer of solder (FIG. 2) for facilitating the soldering process. Two parallel slits 14 a in the central region of base pad 12 , made by lancing, form a deflectable or deformable strap 14 . The strap 14 is centrally located relative to base pad 12 . This allows the inner conductor wire 18 a of electrical cable 18 which extends beyond the outer insulation 18 b to be inserted through the slits 14 a and under strap 14 for assembly to base pad 12 . The diameter of the conductor wire 18 a pushes and deforms the strap 14 slightly upwardly relative to base pad 12 so that the strap 14 extends around the top surfaces of conductor wire 18 a . The conductor wire 18 a is thereby captured or pinched between the strap 14 and the top surface 12 b of base pad 12 . The electrical terminal 11 and the cable 18 are typically preassembled in a cable/terminal assembly 10 before soldering.
In use, electrical terminal 11 is typically soldered to glass 34 (FIG. 3) by positioning terminal 11 in the desired position on the glass 34 , usually a metallic terminal pad coated on the glass 34 , and heating base pad 12 to melt the layer of solder 20 on the bottom 12 c of base pad 12 . The solder 20 bonds base pad 12 to glass 34 as well as bonds conductor wire 18 a to both the base pad 12 and the glass 34 . The curved outer perimeter 12 a of the circular base pad 12 has no sharp corners and, as a result, forms little or no heat related stress concentrations on the glass during soldering. Typically, such stress concentrations, if formed, tend to cause cracks in the glass. Consequently, little or no cracking of the glass 34 occurs when electrical terminal 11 is soldered thereto.
Once terminal 11 is soldered to glass 34 , any accidental pulling forces F (FIG. 3) exerted on electrical cable 18 are transferred to about the center 16 of base pad 12 because the inner conductor 18 a of cable 18 is secured to base pad 12 at the center 16 . This maximizes the ability of terminal 11 to resist separating from the glass 34 due to accidental pulling of cable 18 . The reason for this is that a greater pulling force is required to pull terminal 11 from glass 34 when directed at the center 16 than if directed at the perimeter 12 a , for example, if cable 18 were secured to base pad 12 near the perimeter 12 a . A pulling force directed at the perimeter 12 a would separate the base pad 12 from the glass 34 by first lifting an edge from the glass 34 and then progressively peeling the base pad 12 from the glass 34 . As a result, an edge directed pulling force does not act on the whole solder joint at once, but instead is directed on a small area along the moving peel line. Only a portion of the solder joint is acted upon by the pulling force at a particular time. In contrast, by securing cable 18 to the center 16 of base pad 12 and directing pulling forces F to the center 16 of base pad 12 rather than to the perimeter 12 a , the pulling forces F do not lift an edge of base pad 12 in a peeling type action. Consequently, the centrally directed pulling forces F at any particular moment in time are resisted by the entire solder joint which makes it more difficult to pull base pad 12 from the glass 34 .
A more detailed description of terminal 11 now follows. As shown in FIG. 1, base pad 12 is preferably circular. Slits 14 a are formed through base pad 12 on opposite sides of the center 16 of base pad 12 . Slits 14 a extend parallel to each other across the central region of base pad 12 on either side of center 16 , and terminate about halfway between the center 16 and the outer perimeter 12 a . Terminal 11 is formed in a stamping and forming process by a forming die having a succession of progressive stations. Typically, the forming process produces a series of terminals 11 which are attached to a continuous carrier strip 22 . FIG. 4 depicts a section of such a configuration. The cables 18 may be attached when the terminals 11 are formed, or at a later time.
In one embodiment, base pad 12 is formed of C260 brass and is about 8 mm in diameter by 0.318 mm thick. Base pad 12 is tempered ½ hard about 0.22 mm thick. Slits 14 a are about 4 mm long and are located 1.5 mm apart from each other. Solder 20 is about 0.305 mm thick and contains about 25% Sn (tin), 62% Pb (lead), 10% Bi (bismuth) and 3% Ag (silver). Alternatively, solder 20 may contain about 30% Sn, 65% In (indium), 0.5% Cu (copper) and 4.5% Ag. The elements and percentages of solder 20 may be additionally varied to suit the situation at hand. Base pad 12 may also be formed of other suitable conductive metals such as copper or bronze. In addition, the length and spacing between slits 14 a may be varied to accommodate different diameter conductor wires 18 a . Furthermore, the diameter and thickness of base pad 12 may be varied to suit different applications.
Referring to FIGS. 4 and 5, multiple terminal soldering assembly 30 includes a series of cable/terminal assemblies 10 which are attached to a carrier strip 22 by a series of breakable regions 26 . In use, the soldering assembly 30 is placed upon the glass 34 in the desired location. The cable/terminal assemblies 10 are then soldered to the glass 34 while still attached to the carrier strip 22 . The cable/terminal assemblies 10 are attached to carrier strip 22 at the same distance apart from each other that is required when soldered on the glass 34 . Consequently, proper spacing of the terminals 11 on the glass 34 is consistently achieved. Once the terminals 11 are soldered to the glass 34 , the carrier strip 22 is separated from the terminals 11 by bending the carrier strip 22 upwardly and downwardly in the direction indicated by arrow 32 (FIG. 5) until the breakable regions 26 break along lines 28 . Thus, multiple cable/terminal assemblies 10 are quickly and easily soldered to glass 34 with the proper spacing therebetween.
Since terminals 11 are typically attached to carrier strip 22 when formed, the formation of soldering assembly 30 subsequently only requires attaching the electrical cables 18 to the terminals 11 and cutting the carrier strip 22 to a length that contains the desired number of terminals 11 . The spacing of terminals 11 relative to each other on carrier strip 22 may be selected to suit particular applications. Although six cable/terminal assemblies 10 are shown attached to carrier strip 22 in FIG. 4, any number of cable/terminal assemblies 10 may be employed depending upon the application at hand. Typically, carrier strip 22 is attached to at least two cable/terminal assemblies 10 .
Referring to FIGS. 6 and 7, electrical terminal 50 is another embodiment of the present invention. Terminal 50 may be preassembled with an electrical cable 18 to form a cable/terminal assembly 40 . Terminal 50 has a base pad 42 that is generally or substantially circular in shape. The outer perimeter or edge 42 a of base pad extends continuously in a circular manner for about 270° before being interrupted by an arm 48 having a proximal end 48 a extending from the center 16 of base pad 42 and which is defined by a pair of parallel slots 46 formed within base pad 42 (FIG. 6 ). Arm 48 extends beyond the outer perimeter 42 a of base pad 42 for crimping to cable 18 . The slots 46 extend from the outer perimeter 42 , inwardly about halfway to the center line 17 of base pad 42 , thereby forming two wings 52 thereof. The arm 48 has an intermediate portion 48 b which is bent upwardly at an angle from the proximal end 48 a at about the outer perimeter 42 a . The distal end 48 c of arm 48 includes a crimping portion 44 having two opposed crimping tabs 44 a for crimping to the inner conductor wire 18 a of cable 18 . Arm 48 is bent between the intermediate portion 48 b and the distal end 48 c so that the distal end 48 c is positioned parallel to and laterally offset from the base pad 42 as well as above the top surface 42 b . A layer of solder 20 coats the bottom surface 42 c of base pad 42 .
In use, referring to FIG. 8, terminal 50 is soldered to glass 34 in a manner similar to terminal 11 . As with terminal 11 , base pad 42 is generally circular in shape (FIG. 6) and does not tend to cause heat related stress concentrations in glass 34 , and therefore, little or no cracking occurs. The proximal portion 48 a of arm 48 lies along the same plane (FIG. 8) as the rest of base pad 42 such that slots 46 provide only minor interruptions in the circular shape of base pad 42 . Consequently, with regard to heat transfer from terminal 50 to glass 34 , base pad 42 is effectively circular in shape as shown by the dotted lines (FIG. 6) despite slots 46 . Once soldered, any accidental pulling forces F 1 /F 2 on cable 18 (FIG. 8) are transferred to the center 16 of base pad 42 because the proximal end 48 a of arm 48 extends therefrom. Consequently, terminal 50 is resistant to being separated from glass 34 in a similar manner as with terminal 11 . In addition, the upwardly angled intermediate portion 48 b at arm 48 is able to bend or deflect thereby absorbing forces exerted on terminal 50 by cable 18 . This may lessen the intensity of forces F 1 /F 2 exerted on base pad 42 by accidental pulling of cable 18 . For example, if a longitudinal pulling force F 1 was exerted on cable 18 , intermediate portion 48 b would bend slightly to the left and absorb some of the force. In addition, if an upward pulling force F 2 was exerted on cable 18 , intermediate portion 48 b would bend slightly upwardly and absorb some of the force. The angled intermediate portion 48 b is also able to absorb forces that are in the opposite direction of forces F 1 and F 2 , for example, forwardly and downwardly directed forces. Furthermore, the proximal end 48 a of arm may also bend or deflect to absorb forces.
In one embodiment, terminal 50 is formed of C260 brass and is about 8 mm in diameter by 0.381 mm thick. Base pad 12 is tempered ½ hard about 0.22 mm thick. Terminal 50 is about 13 mm in length. Slots 46 are about 8 mm wide and are spaced apart from each other to form a proximal end 48 a of arm 48 that is about 2.5 mm wide. Intermediate portion 48 b is bent at about a 45° angle to provide equal force absorbing capabilities for longitudinal and vertical forces. The distal end 48 c is bent to be above the proximal end 48 a about 1.5 mm. The crimping tabs 44 are about 4 mm wide. The same solder 20 used with terminal 11 may be employed with base pad 42 . As with terminal 11 , the dimensions of terminal 50 may be varied to suit particular circumstances. Although intermediate portion 48 b is preferably bent, alternatively, intermediate portion 48 b may be straight. In addition, the proximal end 48 a may be bent instead of intermediate portion 48 b.
Terminal 50 is formed by a stamping and forming process in a similar manner as with terminal 11 . As seen in FIGS. 9 and 10, after being formed, terminals 50 are attached to a carrier strip 22 by breakable regions 26 extending from crimping portion 44 . The carrier strip 22 may be cut into sections in similar fashion to that shown in FIGS. 4 and 5 to form a multiple terminal soldering assembly, so that multiple terminals 50 may be soldered to glass 34 at the same time. Cables 18 may be crimped to terminals 50 before soldering.
FIG. 11 depicts another configuration of a multiple terminal soldering assembly 60 where terminals 50 are attached to the carrier strip 22 by breakable regions 26 extending from the base pad 42 instead of from crimping portion 44 . Cables 18 may be also crimped to terminals 50 before soldering.
While this invention has been particularly shown and described with references to preferred 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 scope of the invention encompassed by the appended claims.
For example, although particular terms have been used to describe the present invention such as upwardly, downwardly, forwardly, etc., these terms are not meant to limit the orientation of the present invention terminal. In addition, although the base pads 12 and 42 are preferably generally circular in shape, base pads 12 / 42 may be generally oval, or may be other suitable curved shapes which do not have sharp corners. Such curved shapes may include linear perimeter portions. Furthermore, although base pads 12 / 42 have been depicted as generally flat or planar, alternatively, the base pads may have contoured bottoms for mating with contoured surfaces such as a curved surface. Solder layer 20 may be omitted if desired. Also, the present invention terminal may be soldered to surfaces other than glass.
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An electrical terminal including a base pad for soldering to a surface. The base pad has a curved perimeter, and top and bottom surfaces. The electrical terminal also includes a securement portion having a deformable member for deforming around a conductor wire to capture and secure the conductor wire directly to the securement portion. The securement portion is configured relative to the base pad such that forces exerted by the conductor on the base pad are directed to a central region of the base pad.
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BACKGROUND OF THE INVENTION
This invention relates to a swivel bracket holding mechanism for a marine propulsion device and more particularly to an improved, simplified tilt locking mechanism for an outboard drive.
Outboard drives such as an outboard motor or the outboard drive portion of an inboard-outboard drive are mounted for tiling movement about a generally horizontally extending tilt axis. The arrangement is such that the outboard drive may be tilted up so that its lower unit will be positioned out of the water. Some form of tilt locking mechanism is generally employed for locking the outboard drive in its tilted up position. The simplest of these tilt locking mechanisms require the operator to lift the outboard drive with one hand and, at the same time, operate the locking mechanism with his other hand so as to lock the outboard drive in its tilted up position. Such arrangements are obviously cumbersome, particularly when the outboard drive is heavy since the operator would prefer to be able to use both hands to lift the outboard drive.
Alternatively, arrangements have been provided in which the tilt locking mechanism may be prepositioned so that it will engage the outboard drive and lock it up in the tilted up position in response to the positioning of the motor in its tilted up position. Since the outboard drive also normally incorporates a reverse locking mechanism for holding the outboard drive against tilting up under reverse thrust, this reverse locking mechanism must also be released to permit the motor to be tilted up. Therefore, there are in some prior art arrangements devices that require the manipulation of several operating handles so as to permit an outboard drive to be tilted up and retained in its tilted up position. Although devices have been proposed for interrelating the tilt locking mechanism with the reverse lock, such devices have been very cumbersome, have required considerable linkage and also are at times awkward to operate.
It is, therefore, a principal object of this invention to provide an improved and simplified tilt locking mechanism.
It is a further object of this invention to provide a tilt locking mechanism that is interrelated with the reverse lock so as to provide a simple and yet highly effective arrangement.
It is a still further object of this invention to provide a reverse lock and tilt locking mechanism for an outboard drive that may be operated by a single handle and utilizing a minimum of linkage and interconnecting elements.
SUMMARY OF THE INVENTION
This invention is adapted to be embodied in a tilt locking arrangement for a marine outboard drive that is adapted to be mounted on a transom or the like of a watercraft for pivotal movement about a generally horizontally extending axis from a normal, tilted down running position to a tilted up, out of the water position. Reverse locking means are provided that are movable from a released position to an engaged position for retaining the outboard drive in its tilted down position in opposition to reverse thrust. An operating handle movable from a locked position to a released position is coupled to the reverse locking means for moving the reverse locking means between its engaged position and its released position in response to movement of the operating handle between its locked position and its released position. In accordance with the invention, a tilt locking element movable between a released position and an engaged position is provided. The tilt locking element is operative when in its engaged position to lock the outboard drive in its tilted up position. Means interrelate the tilt locking element and the operating handle for retaining the tilt locking element in its released position when the operating handle is in its locked position and for movement of the tilt locking element to its engaged position upon placement of the operating handle in its released position and upon movement of the outboard drive to its tilted up position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an outboard motor having a tilt locking mechanism constructed in accordance with an embodiment of the invention. The motor is shown in a tilted down position in solid lines and in a tilted up position in phantom lines.
FIG. 2 is an enlarged, cross-sectional view of the tilt locking arrangement, with portions shown in cross-section.
FIG. 3 is a top plan view looking generally in the direction of the arrow 3 in FIG. 2 and with a portion broken away to more clearly show the construction.
FIG. 4 is a front elevational view looking in the direction of the arrow 4 in FIG. 3.
FIG. 5 is an view showing the construction of the tilt locking mechanism.
FIG. 6 is an enlarged, cross-sectional view taken through a portion of the tilt locking mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 2, an outboard motor constructed in accordance with this invention is identified generally by the reference numeral 11. Although the invention is described in conjunction with an outboard motor, it is to be understood that it may be equally as well practiced with the outboard drive of an inboard-outboard unit. The application of the invention to such an outboard drive is believed to be clear to those skilled in the art based upon the following description of the application of this device to the outboard motor 11.
The outboard motor 11 includes a power head 12 in which a suitable internal combustion engine is positioned, a drive shaft housing 13 through which a drive shaft driven by the motor of the power head 12 extends and is supported and a lower unit 14. A propeller 15 is journalled in the lower unit 14 and is driven from the drive shaft in any suitable manner which may include a forward reverse transmission.
A steering shaft 16 (FIGS. 2 and 3) is affixed to the drive shaft housing 13 and is journalled for steering movement about a generally vertically extending axis in a swivel bracket 17. The swivel bracket 17 is, in turn, supported for tilting movement about a horizontally extending axis by means of a tilt pin 18, which is journalled in a clamping bracket assembly 19. The clamping bracket assembly 19 is, in turn, adapted to be affixed to a transom 21 of an associated watercraft in a known manner. The construction thus far described may be considered to be conventional and, for that reason, has not been described in great detail.
A reverse locking mechanism, indicated generally by the reference numeral 22, is provided for holding the outboard motor 11 in an adjusted trim condition and against movement in a tilting up direction when operating in reverse gear. As is well known with this type of mechanism, the reverse locking mechanism 22 is designed so as to release if the lower unit 14 strikes a submerged obstacle with sufficient force to permit it to pop up and prevent damage. As is also typical with these devices, the reverse lock mechanism 22 will reengage when the motor 11 returns down under its own weight when the underwater obstacle has been cleared.
The reverse locking mechanism 22 includes a reverse locking pin 23 that is adapted to be received in selected, aligned apertures in the clamping bracket 19 so as to permit adjustment of the trim position of the motor 11. Reverse locking mechanism 22 further includes a reverse locking lever 24 that is pivotally supported on the swivel bracket 17 by means of a pivot pin 25. A second lever 26 is pivotally supported at the forward end of the locking lever 24 by means of a pivot pin 27. The rear end of the second lever 26 is engaged by one end of each of a pair of tension springs 28, the other end of which is affixed to the swivel bracket 17 for exerting a force on the reverse locking mechanism in a direction to be described. The second lever 26 has a hooked end portion 29 that is adapted to coact with the reverse locking pin 23 so as to retain the motor 11 against popping up.
The locking lever 24 has a tang or tangs 31 that are engaged with the upper side of the lever 26 so that the lever 24 will be pivoted along with the lever 26 about the pivot pin 25 when the reverse locking mechanism 22 is released, in a manner to be described.
Control of the reverse locking mechanism 22 is afforded by means of an operating lever 32 that is journaled upon the tilt pin 18 and which is positioned so as to be readily accessible to the operator of the motor 11. One end of a link 33 is pivotally connected to the operating lever 32. The opposite end of the link 33 is pivotally connected to a second link 34 that is mounted for pivotal movement on a pivot pin 35 which is, in turn, affixed to the swivel bracket 17. A second link 36 is pivotally connected at one of its ends to the lever 34 and at its other end to the pin 27.
FIG. 2 shows the reverse locking mechanism 22 in its locked position. In the event the outboard motor 11 is being operated in a reverse mode, the interengagement between the hook portion 29 of the lever 26 and the pin 23 will hold the motor 11 against popping up. If, however, the motor 11 is being operated so as to drive the watercraft in a forward direction and the lower unit 14 strikes a submerged obstacle with sufficient force, the lever 26 will pivot free of its engagement with the pin 23 thus tensioning the spring 28 and permitting the motor 11 to pop up. Once the obstacle is cleared, the forward portion of the hook like part 29 of the lever 26 will engage the pin 23 and cause it to cam back to the locked position as shown in FIG. 2.
If it is desired to release the tilt locking mechanism 22 so that the motor 11 may be manually tilted up, the operating handle 32 is rotated in a counterclockwise direction as shown in FIG. 2 from its locked position to an unlocked position. It should be noted that the operation of the springs 28 is such so as to hold the operating lever 32 in its locked position. When the lever 32 is rotated in a clockwise direction to its unlocked position, a tension will be placed on the link 33 that rotates the lever 34 in a counterclockwise direction. Thus, the link 36 will be drawn upwardly and the levers 26 and 24 will rotate in a clockwise direction about the pin 25 so that the lever hook portion 129 is clear of the reverse locking pin 23. When this occurs, the levers 26 and 24 go to an over center condition so that the springs 28 will now exert a force through the levers on to the operating handle 32 so as to retain it in its unlocked condition. The motor 11 may then be tilted up by the operator.
Return of the operating lever 32 to its locked condition is achieved by rotating it in a clockwise direction and the operation of the remaining portion of this mechanism during return locking is believed to be readily apparent from the foregoing description.
In addition to the reverse locking mechanism 22, a tilt locking mechanism, indicated generally by the reference numeral 37 and shown in most detail in FIGS. 2, 3, 5 and 6, is provided. The tilt locking mechanism 37 includes a tilt locking pin having a large diameter cylindrical portion 38 that is slidably supported within a bore 39 of a anti-friction bushing 41 which is, in turn, supported in the swivel bracket 17 so that the pin 38 will reciprocate along an axis that is parallel to the axis of the tilt pin 18 (the tilting axis of the motor 11).
The tilt locking pin further has a smaller diameter cylindrical portion 42 that extends through an opening formed in a wall 43 of the bushing 41 at the base of the bore 39. A coil compression spring 44 is received within this area and engages a shoulder 45 formed between the cylindrical portions 38 and 42 and the wall 43 so as to normally urge the tilt locking pin to an engaged position. A coil tension spring 46 has one of its ends affixed to the projecting portion 42 of the tilt locking pin. The opposite end of the spring 46 is engaged with a tang 47 that is formed integrally with the reverse locking lever 32.
FIGS. 2, 3, 5 and 6 show the tilt locking mechanism in its released position. When in this position, the tension of the spring 46 is greater than the force of the compression spring 44 so that the tilt locking pin will be held in a released position. However, when the reverse locking lever 32 is rotated in the counterclockwise direction so as to release the reverse locking mechanism 22 in the manner previously described, the tension on the spring 46 will be substantially reduced. The compression spring 44 will then immediately urge the tilt locking lever in an axial direction into engagement with a cam surface 48 formed on the contiguous portion of the clamping bracket 19 (FIG. 5). The surface 48 is arcuate and is concentric with the axis of the tilt pin 18. Thus, when the motor 11 is tilted up after the reverse lock 22 has been released, the tilt locking pin will follow the surface 38 until the motor is tilted up sufficiently so that the tilt locking pin can enter above a surface 49 of the clamping bracket 19. Release of the motor 11, by an operator who has tilted it up, will cause engagement of the tilt locking pin with the surface 49 and will hold the motor 11 in the tilted up position as shown in the phantom line view of FIG. 1.
When it is desired to release the tilt locking mechanism 37 so as to permit the motor 11 to be tilted down, the operating lever 32 is rotated back from its released position to its engaged position. As has been previously noted, the springs 28 hold the lever 32 in both its released and engaged positions. When the operating lever 32 is rotated back to its engaged position, the spring 46 is again tensioned sufficiently so as to overcome the action of the compression spring 44 and the tilt locking pin will be withdrawn from engagement with the surface 49 of the clamping bracket 19. The motor 11 may then be lowered without the operator having to hold the lever 32. When the motor 11 reaches the set trim condition, the reverse locking mechanism 22 will reengage and the motor will be held in this position as aforenoted.
It should be readily apparent from the foregoing description that a relatively simple and yet highly effective mechanism has been provided for interrelating the tilt locking mechanism with the reverse locking mechanism so that the motor 11 may be tilted and locked up without the necessity of the operator using one of his hands to operate the lever 32 at the same time he is lifting the motor 11. In a like manner, the motor 11 may be lowered without the operator needing to use one hand to hold the lever 32 in its locked position. In addition, the mechanism which interrelates the elements is extremely simple and foolproof. Furthermore, the operating lever 32 is disposed in proximity to the operator and is retained in both of its positions through a simple and yet highly effective mechanism.
Although an embodiment of the invention has been illustrated and described, various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims.
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A reverse lock and tilt locking mechanism for an outboard drive embodying a simplified construction wherein a single operating handle controls both the reverse locking mechanism and the tilt locking mechanism. The construction is such that when the operating handle is moved to a position to release the reverse locking mechanism, the tilt locking mechanism can automatically engage when the outboard drive is tilted up.
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FIELD OF THE INVENTION
[0001] The present invention relates to a plastic composite material for cold molding and a process for obtaining it.
BACKGROUND ART
[0002] The use of plastic resins, such as polyester resins for obtaining high-performing materials is well known. A typical example is the so-called polymeric compounds, i.e. those materials deriving from the combination of two matrixes of different origins and with different characteristics, which when suitably combined with each other, form a material that maintains, at least partially, the characteristics of the matrixes of which it is composed. Most used materials include polyesters reinforced with glass fibers (Fiberglass™) or with polymeric materials or with a woven fabric, such as to give a multi-directional resistance thereto. Also known are vinyl ester resins, which due to their structure, have a good affinity with glass fibers. However, vinyl ester resins, despite their good resistance to chemical agents are not recommended for use in high-temperature applications.
[0003] The high performance of plastic materials such as polypropylene is also known. The drawback of these materials is, however, related to the molding process, which involves hot-molding operations being carried out in expensive steel molds, and with high tonnage presses.
SUMMARY OF THE INVENTION
[0004] The object of the present invention is to provide a high-performing material, which is particularly provided with a considerable break resistance, asepticity, hydrophobicity, resistance to acids, high characteristics of acoustic and heat insulation, and the like, and which can be obtained by means of a simple and cost-effective process.
[0005] This object is achieved by a polymeric compound and a process for obtaining the same, such as defined in the annexed claims.
[0006] Further features and advantages of the composite material being the object of the present invention will be better understood from the description of some exemplary embodiments thereof, which is given herein below by way of non-limiting illustration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic perspective view of a plant for preparing the composite material of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The composite material according to the invention consists of a vinylester resin, in which a filler being a polyolefin, preferably selected from polypropylene and polyethylene, is admixed. More preferably, this polyolefin is polyethylene.
[0009] The vinylester resin is preferably an epoxy vinylester resin based on a bisphenol-A epoxy resin cross-linked with styrene in. a styrene percentage ranging between 30% and 50% by weight, preferably 35% to 45% by weight. This vinylester resin preferably has a density of more than 1 g/cc, more preferably ranging between 1.1 and 1.2 g/cc and a glass transition temperature ranging between 110° C. and 130° C.
[0010] In a preferred embodiment, the polyolefin is in a micronized form and has a grain size ranging between 20 μm and 50 μm, more preferably between 22 μm and 30 μm. Among the possible shapes of micronized particles, the spheroid shape is preferred.
[0011] In the composite material of the invention, the polyolefin is preferably admixed in an amount less than 55% by weight, more preferably between 35% and 50% by weight, most preferably about 40% by weight of the vinylester resin. It has been surprisingly observed that the polyolefin is capable of providing the polymeric compound with high characteristics of mechanical and acid resistance; with polyethylene, particularly, a higher performance is obtained than with polypropylene, which is more commonly used as a filler in similar prior art applications.
[0012] The composite material of the invention will further contain a cross-linking catalyst and a primer, as will be better discussed herein below.
[0013] The polymeric compound of the invention may further contain a suitable pigment or colouring agent, such as to provide the same with the desired aesthetic appearance.
[0014] The process for preparing the polymeric composite material in accordance with the invention will be now described with the aid of FIG. 1 , which schematically shows a system 1 to be used for this process.
[0015] The system 1 consists of a first reservoir 2 for the vinylester resin (resin +styrenic crosslinker) and a second reservoir 3 for the polyolefin. These reservoirs 2 , 3 are communicated, through respective tubes 2 ′, 3 ′, with the bottom of a chamber 4 provided with a stirrer, in which vacuum is created by means of suitable air-exhausting means 5 . The bottom of the chamber 4 is also in fluid communication, through a tube 4 ′, with pump means 6 that provide to feed the material mixture to mixing means 7 , typically a dynamic mixer. The catalyst and the pigment or colouring agent, which are contained in respective reservoirs 8 , 9 , are also fed to the mixing means 7 . By means of a tube 7 ′, the mixing means 7 feed the reactant mixture directly to a mold (not shown), where the composite material is formed. Suitable valves and a command and control unit provide to control the material flows in accordance with the modalities of the process which will be described herein below.
[0016] Practically, the vinylester resin and the polyolefin are loaded, in the ratios indicated above, to the chamber 4 and are subjected to vacuum treatment (5 bar depression) under stirring for more than 2 hours, preferably more than 3 hours, most preferably about 4 hours. The vacuum treatment is very important for preventing the generation of bubbles during the crosslinking reaction. Thereby, the final characteristics of the composite are improved.
[0017] When this treatment has been completed, the mixture is transferred, by means of the pump means 6 , to the mixing means 7 , where it is added with the suitable amount of catalyst/primer and colouring agent or pigment. At the end of the addition, the reactant mixture is poured in the mold, where the crosslinking reaction and the consequent formation of the polymeric composite material will be completed. The reaction is exothermic, such that temperatures of 70-80° C. can be reached, and is normally completed in a rather short time (a few minutes). It is important to obtain a proper mixing of all the components provided in the mixing means 7 , particularly the resin and polyethylene in order to obtain an homogeneous composite material.
[0018] The colouring agent or pigment is mixed with the other components in a weight ratio ranging between 1% and 3%, preferably about 2% by weight.
[0019] The catalyst is admixed with the other components in a weight ratio ranging between 1% and 3%, preferably between 1.5% and 2% by weight. As the catalyst, a peroxide such as acetyl acetone peroxide or methyl ethyl ketone peroxide is normally used. Preferably, a suitable primer/accelerator will be also used, particularly a cobalt salt, preferably Co octanoate, in a ratio ranging between 6% and 12% by weight. The accelerator ratio can be changed according to the type of product desired to be produced, and the concentration thereof depends on the thickness of the product and time required for curing. When the thickness values are relatively thin, it has been found advantageous to use a concentration ranging between 2% and 3%, and preferably about 2.5% relative to the resin weight. In the case of very thick products, in which releasing the heat generated by the hardening reaction may result to be difficult, the use has been found advantageous of a catalyst formed by methyl ethyl ketone peroxide with weight ratios ranging between 0.5% and 5%, and particularly between 1% and 4% of the resin, with the aid of an accelerator formed by Co salts in a ratio ranging between 2% and 3%, and preferably about 2.5% by weight of the resin.
[0020] When desiring to manufacture light-coloured or transparent products, instead of Co salts as the accelerators, the use of N,N-diethylacetoacetamide is preferred in a concentration ranging between 0.05% and 0.4%, and preferably between 0.1% and 0.4% by weigh of the resin.
[0021] The polymeric composite material according to the invention is provided with such characteristics as to be used for high-performing applications. It is characterized, in fact, by high mechanical resistance and resistance to corrosive elements, it is aseptic, water-repellent, unscratchable and can be easily molded, milled, threaded or tapped. Accordingly, a typical application field for this material is furniture elements, and particularly kitchen worktops, and most particularly, counters in technical laboratories. For example, a surface can be molded with a sink being integrally modelled therein.
[0022] It has been surprisingly observed that the polymeric compound of the invention has considerable heat insulation characteristics. This characteristic is surprising, in that the vinylester resin is normally not recommended for high temperature applications. Due to this characteristic, the inventive material may be effectively used for manufacturing heat-insulating panels.
[0023] The inventive material also has considerable sound insulating characteristics and can be thus advantageously employed for manufacturing hi-fi speakers.
[0024] Due to the hydrophobicity and mechanical-chemical resistance, the inventive material can be efficiently used for manufacturing pots for flowers and plants.
[0025] A last, non-negligible advantage of the inventive material is its low cost, which is also a result of the simple manufacturing process thereof, which does not require using steel molds for high-temperature injection and high tonnage presses.
[0026] It will be appreciated that only some particular embodiments of the polymeric composite material being the object of the present invention and of the process for obtaining it have been described herein, to which those skilled in the art will be able to make any and all modifications required for adapting the same to specific applications, without however departing from the scope of protection of the present invention.
[0027] For example, it may be possible to further improve the performance of the composite material of the invention, by including therein, for example during the step of molding, fibers or woven fibers of different materials, such as glass fibers, within the molds.
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The present invention relates to a plastic composite material and a process for obtaining it. Particularly, the present invention relates to a polymeric composite material comprising an epoxy vinylester resin in which a filler is disupersed, said filler being polyethylene in particulate form, wherein said polyethylene is admixed in an amount less than 55% by weight relative to the epoxy vinylester resin, and a process for obtaining the same in which the resin/styrene mixture and the polyethylene is subjected to a treatment in vacuo and placed under stirring for more than 2 hours.
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FIELD OF THE INVENTION
This invention relates to the field of industrial vacuum cleaners and, more particularly, to a vacuum cleaner for the inside surface of particle tubes used in the manufacture of semiconductor devices.
BACKGROUND OF THE INVENTION
In the semiconductor field, integrated circuits are manufactured from large pieces of semiconductor material commonly known as wafers. The wafers have deposited on them various layers of conducting and non-conducting material. These layers are each separately deposited on the wafer as it is built up in a step-by-step process. The layers can be applied to the wafer using any one of several methods which are well known in the art.
One of these well-known deposition methods involves surrounding the wafer with a gas containing the desired material to be deposited on the wafer. The wafer and the gas are oppositely charged, and the material is electrically attracted to the wafer. This process is usually carried out within a sealed tube. One disadvantage of this process is that all of the material in the gas does not necessarily become attached to the wafer. As a result, some of the material settles onto the bottom of the tube. This extra material can later become mixed in with the material in the gas. The amount of suspended material is carefully controlled so that a precise amount will be evenly deposited on the wafer. Any accumulation of material within the tube is highly undesirable as it may eventually become depositised on the wafers. To prevent this accumulation, the tubes must be periodically removed and cleaned. However, removal of the tubes results in a loss of production time, thus adding to the cost of manufacturing the wafers. Also, the tubes used in the semiconductor manufacturing process are often made of a brittle material, such as quartz. When a quartz tube is removed, there is a risk that the tube may be broken. Moreover, the process of depositing a substrate material onto the wafers is usually conducted at a high temperature. Additional down time and cost are incurred in allowing the tube to cool before it is cleaned and in reheating the tube before it can be used again.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned difficulties by providing a vacuum device to clean the interior surface of manufacturing tubes used in the manufacture of semiconductor wafers. The vacuum device consists of a head which is designed to closely fit with the interior surface of the manufacturing tube to be cleaned. Guide wheels are provided to align the head with the manufacturing tube and to allow the vacuum device to easily roll in and out of the manufacturing tube. The wheels are made of material which does not scratch the interior surface of the manufacturing tube. The head is attached to vacuum tubing by means of flexible bellows. The vacuum tubing and head may be rotated to allow the head to clean the entire interior surface of the manufacturing tube.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of the present invention.
FIG. 2 illustrates the vacuum device of the present invention inserted within a manufacturing tube.
FIG. 3 is a perspective view of an alternative embodiment of the vacuum head used in the present invention.
FIG. 4 is an exploded view of the rotatable vacuum coupling used in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A vacuum device having particular application for cleaning the interior surface of tubes used during the manufacture of semiconductor wafers is disclosed. In the following description, numerous construction details and specific materials are set forth in order to provide a more complete description of the present invention. In other instances, well known elements such as vacuum tubes are not described in detail so as not to unnecessarily obscure the present invention. Throughout the following specification, a description of the present invention is made with reference to process tubes which are used in the semiconductor manufacturing industry. These particular tubes are provided only as an example to more clearly show the design and use of the present invention. The present invention is not limited to use in conjunction with these particular types of tubes. It will be apparent to those skilled in the art that the spirit of the present invention encompasses a vacuum device that can be used in a wide variety of manufacturing processes.
Referring first to FIG. 1, a perspective view of the preferred embodiment of the present invention is shown. A vacuum head 10 is provided. The head is shaped to conform to the interior surface of the tube to be cleaned. In the preferred embodiment, the head is in the shape of a half circle. This shape is chosen because the tubes used in the manufacture of semiconductor devices are cylindrical. It will be evident, however, that different shapes can be used as a matter of design choice. The head 10 has attached to it two guide wheels 12 which are supported by spring mounts 11. Mounted within the surface of the head 10 are positioning wheels 14. The guide wheels 12 and spring mounts 11 work together to align the head within the tube. The guide wheels 12 rest on the lower surface of the tube, and the spring mounts 11 push the head 10 against the upper surface of the inside of the tube. The positioning wheels 14 prevent the head from actually contacting the inner surface of the tube. Instead, the head rides slightly away from the tube surface so that a gap is formed between the head and the tube. This gap allows the vacuum to suction off particles more efficiently. Without the gap, there would be no space for an airflow to enter into the vacuum head. FIG. 2 shows the vacuum head inserted within a manufacturing tube. As shown, only the guide wheels 12 and positioning wheels 14 touch the tube's surface. The gap 15 is clearly illustrated.
The guide wheels 12 and the positioning wheels 14 are both made from a non-abrasive material. As noted, guide wheels 12 and positioning wheels 14 are the only elements of the present invention which actually touch the inner surface of the tube when the vacuum device is in use. By making the wheels out of a non-abrasive material, the risk of scratching or otherwise damaging the interior of the tube is minimized. Scratches on the interior surface of the tube are undesirable because they present a greater risk of damage to the tubes. In the semiconductor manufacturing process, the tubes are typically made of quartz and heated to a high temperature during the deposition process. In the present embodiment, the wheels are made of Vespel. Vespel is a resin containing a small amount of graphite. It will be apparent to those skilled in the art, however, that different materials may be employed as a matter of design choice. The preferred material is chosen because of its ability to withstand temperatures commonly found in the semiconductor manufacturing process, and because it will not scratch the interior of the quartz tubes.
The head 10 also incorporates a vacuum slot 20. The vacuum slot in the preferred embodiment covers the entire perimeter of the arcuate portion of the vacuum head 10. Airflow can pass through the vacuum slot 20 to the vacuum tubing 24 which is attached to the head 10. When the head is in operation, particles are lifted from the surface of the tube, and travel through the vacuum slot into the tube 24. The width of the slot is chosen so as to maximize the amount of vacuum that is exerted on the interior surface of the tube. In the preferred embodiment, the total area of the vacuum slot --its width times the arcuate length--is equal to 1.2 times the cross-sectional area of the vacuum tube 24.
The head 10 is connected to the rigid piece of vacuum tubing 24 by means of flexible bellows 18. Flexible bellows are chosen because they allow the head to be correctly aligned within the tube even though the vacuum tubing may not be positioned correctly with respect to the tube. Two mounting units, 28 and 36, are coupled to the tubing to support the vacuum unit while the head 10 is inserted into the tube.
The head 10 may be removed from the vacuum unit by detaching section 24a of the vacuum tubing from the rest of the unit. This is accomplished by means of retaining nut 26. The retaining nut uses a quick release design to allow the head 10 and tubing 24a to be detached. This element allows the head to be removed for cleaning or any necessary repairs. Also, alternate heads may be placed onto the vacuum tubing if it is necessary to clean tubes having different interior dimensions or different shapes.
FIG. 3 shows one such alternative vacuum head 40. In this embodiment, the head is completely circular. There are positioning wheels 41 disposed about the circumference of the head. There are no guide wheels. The vacuum slot 42 also extends along the circumference of the head 40. This embodiment may be particularly useful for circular tubes with small diameters.
The vacuum head 10 and vacuum tubing 24 may be rotated while the head is within the tube so as to allow the entire inner surface of the tube to be cleaned. A coupling means for rotatably connecting the vacuum tube 24b to the mounting means 28 is provided within coupling block 30. Referring next to FIG. 4, an exploded view of the coupling block 30 is shown. The vacuum tubing 24b is placed within the opening 31 of the coupling block 30. Bushing 33 is placed over the end of vacuum tubing 24b and held in place by means of a press fit. An O-ring seal 38 is placed within the coupling block 30 to provide a vacuum seal for the block. The O-ring 38, bushing 33, and vacuum tube 24b are held in place by cover plate 32. The cover plate is attached to the coupling block 30 by screws (not shown). In the preferred embodiment, the O-ring is made of material that is able to withstand the high temperatures normally found within the tubes used in the semiconductor manufacturing industry. The bushing 33 is made of a low friction material, such as Teflon, so that the vacuum tubing 24b may easily rotate within the coupling block 30. In the preferred embodiment, the coupling block is machined from a material such as aluminum. However, it will be apparent to those skilled in the art that alternative methods of manufacture such as injection molded plastic may be used as a matter of design choice.
Formed integrally with the coupling block 30 are one of the two support units 36 noted above. The support units consist of extended members which extend outward and away from the coupling block 30. A pair of knife edge mounts 37 are located on the peripheral edges of the members 36. These knife edges allow the vacuum device to be more easily mounted on an external stand (not shown in FIG. 4) when it is in use. Support unit 28 is similar in construction to support unit 36. However, it is not formed integrally with a coupling block. Instead, support unit 28 simply provides a point of support for the vacuum tube 24. The support units 32 and 28 act as a mounting means for mounting the entire vacuum device on the external stand.
The operational procedures of the present invention are simple. The vacuum device is placed on an external stand (not shown in FIG. 4) and supported by mounts 28 and 36. In the present embodiment, the external stand is the same device which is used to transfer the semiconductor wafers to and from the tube during the manufacturing process. The vacuum hose 40, which is connected to tubing 38 and powered to the vacuum compressor, is turned on. The vacuum device is lifted into approximate alignment with the tube and inserted into the tube. As the head 10 of the vacuum device is moved into the tube, guide wheels 12 and ramp 22 work to place the head in proper alignment with the tube surface. The ramp 22 is a slanted portion of the front side of the vacuum head as shown in FIG. 1. The guide wheels 12 and ramp 22 work as an alignment means for the vacuum head 10. The head is slowly moved along the entire length of the tube and then withdrawn. The head is then rotated 180° by means of retaining nut 26 and coupling block 30. The head is then reinserted into the tube and the remaining portion of the tube is cleaned. The vacuum device also includes a mechanical stop 35 which limits the travel of the head within the particle tube. In the present embodiment, the mechanical stop is a length of vacuum tubing which is disposed at right angles to the rest of the device. A flexible hose 40 attaches to mechanical stop 35 to connect the present invention with an external vacuum compressor. With this procedure, particles may be removed from the entire inner surface of the tube without necessitating the removal of the tube or allowing time for the tube to cool and then reheat.
Accordingly, a vacuum device having particular application in the semiconductor manufacturing process has been described. Throughout the foregoing description, the invention has been described with reference to specific exemplary embodiments. It will, however, be evident that various modifications and changes may be made without departing from the broader spirit and scope of the invention as set forth in the following claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than restrictive sense.
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The present invention overcomes the aforementioned difficulties by providing a vacuum device to clean the interior surface of particle tubes used in the manufacture of semiconductor wafers. The vacuum device consists of a head which is designed to closely fit with the interior surface of the particle tube to be cleaned. Guide wheels are provided to align the head with the particle tube and to allow the vacuum device to easily roll in and out of the particle tube. The wheels are made of material which does not scratch the interior surface of the particle tube. The head is attached to vacuum tubing by means of flexible bellows. The vacuum tubing and head may be rotated to allow the head to clean the entire interior surface of the particle tube.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/766,469, filed Jan. 20, 2006, which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] I. Field of the Invention
[0003] This invention relates generally to apparatus for use in snow removal and management, and more particularly to a snow pusher which allows increased accumulation of snow in front of a snow plow during operation while inhibiting lateral spillage of snow from the ends of the plow.
[0004] II. Discussion of the Prior Art
[0005] In the past, the standard implement used on work vehicles in the snow removal industry has been a straight blade, angle-type plow. This type of implement is extremely useful in clearing surfaces by primarily displacing snow laterally a short distance to one side of the blade. However, in certain situations it is advantageous to move larger amounts of snow a greater distance and to move it forward rather than sideways. This is especially true when areas designated for snow storage are not directly adjacent to the areas being plowed. Plowing a road or other surface that is contiguous to intersecting private driveways is an example of this type of situation. Once the snow on a road or other surface has been angle-plowed to a location close to the intersecting driveways, it is desirable to capture, contain, and relocate the plowed snow rather than to leave a windrow of snow at the entrance to each intersecting driveway.
[0006] To accomplish this type of task persons previously have used devices which primarily push snow forward. These devices are generally vehicles with containment members having forward facing openings which are mounted to the front of work vehicles. Existing snow pusher devices typically make use of some type of forwardly projecting panels on their sides to help prevent spillage of snow from either end of the plow and thereby to allow a greater amount of snow to be contained and transported to a desired location. Specifically, some previous attempts at capturing and containing plowed snow include pusher box designs, immobile or slightly mobile sides attached to a straight blade plow, and powered V shaped plows.
[0007] Pusher boxes are forward facing attachments which are joined to the front of work vehicles. While these boxes do provide an enhanced ability to relocate large amounts of snow, there are many drawbacks. First, these pusher boxes have the disadvantage of being stationary and non-angling. Therefore, the pusher box can only relocate snow forward in the direction of the vehicle's travel and cannot “plow” snow laterally across a surface. Second, this type of device is not designed to be convertible between plowing and pushing operations. For most snow removal jobs, in order to effectively remove snow from a given area a pusher box device could not be used exclusively. Therefore, a pusher box device would need to be used in close connection with a work vehicle equipped with some type of plow blade. Because these pusher boxes are not adapted to convert between plowing and pushing devices, multiple vehicles would be required to complete snow removal from a given site.
[0008] Other devices used in the past utilize immobile or slightly mobile sides attached to a straight blade plow. These devices generally have metal plates that bolt or attach to the side of a plow blade. One example of such a device is shown in U.S. Pat. No. 4,707,936 to Steinhoff. These devices have the disadvantage of requiring the operator of the plow to exit the vehicle in order to bolt on or to position the sides when switching from plowing mode to pushing mode and visa versa. This deficiency results in a waste of time and fatigue to the operator.
[0009] V shaped plows such as the power V plow are yet another type of device that can be used to aid in containing snow during plowing. These devices are capable of positioning a split plow blade so that it angles into a V shape to contain a greater amount of snow during use. This type of device is very expensive to purchase and to maintain. These devices are also known to have inherent structural problems which cause a high break down frequency and a short useful life. Further, a power V plow does not clean the plowed surface as thoroughly as a straight blade angle-plow. Moreover, when the power V plow is maneuvered into its containment position with the open part of the V facing forward, the effective width of the plow is narrowed, thus greatly reducing the amount of snow being relocated.
[0010] Therefore, a new snow management device is needed for quickly and efficiently containing and relocating large quantities of snow that also allows for the same vehicle to quickly transform between a pusher box vehicle and an angle blade vehicle without requiring the operator to leave the driver's compartment. Moreover, a device is needed that is effective, allows for efficient transport of large amounts of snow, is easy to use, is structurally sound, simple, and which overcomes the problems experienced in past methods and devices aimed at snow removal. The present invention meets these needs.
SUMMARY OF THE INVENTION
[0011] The present invention relates generally to a snow pusher device that can be coupled to the plow blade of a work vehicle. A snow pusher according to the present invention involves a simple attachment to a straight blade snow plow which temporarily converts the plow into a pusher box for the purpose of containing the snow against the plow without lateral spillage. The invention generally concerns a two-sided apparatus that is capable of attachment to the plow.
[0012] The invention is made up of a snow plow pusher box comprising a pair of panels located at the ends of snow plow blade of a work vehicle, a support assembly containing at least one horizontal beam member joining the pair of panels together, a pair of brackets attached to the snow plow blade, and a pair of cam hooks which are affixed to the support assembly and releasably attached to said pair of brackets when in use.
[0013] The invention will be used primarily in the context of loaders, (front end loaders, trucks, tractors, and skid steer loaders). Attachment of the snow pusher to the plow does not require the operator to exit the vehicle. The snow pusher allows the operator to quickly and safely switch from plowing to pushing and visa versa many times during a given operation. This versatility increases the productivity and profitability of the snow removal process. The snow pusher is compact in size and easily transported from site to site.
[0014] The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment, especially when considered in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of the snow pusher of the present invention attached to a work vehicle;
[0016] FIG. 2 is a perspective view of the main body of the snow pusher;
[0017] FIG. 3 is a rear perspective view of the main body of the snow pusher;
[0018] FIG. 4 is a side perspective view of the snow pusher where the plow blade and pusher are fully engaged;
[0019] FIG. 5 is a side perspective view of the main body of the snow pusher unattached to the brackets on the plow;
[0020] FIG. 6 is a side perspective view of the snow pusher with the brackets aligned for engagement with the hooks of the snow pusher;
[0021] FIG. 7 is a side perspective view of the snow pusher where the brackets on the plow blade are fully engaged with the hooks of the snow pusher; and
[0022] FIG. 8 is a side perspective view of an engaged hook and bracket assembly of the snow pusher.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The present invention generally includes a snow plow pusher 10 which is attached to a straight plow blade 12 of a work vehicle 14 . Suitable work vehicles with mounted plows may include but are not limited to skid steer vehicles, front end loaders, trucks, tractors, etc. The plow blades 12 to which the assembly attaches may include a variety of different blades made by different manufacturers. Suitable blades typically do however make use of a trip edge mechanism 16 located along the bottom blade surface for safety. Such a device will bend backwards against a spring mechanism if met by an obstruction on the surface being plowed.
[0024] The snow pusher is largely made up of a main body 18 which is attached to the plow blade 12 by engagement of a pair of its J cam hooks 20 and a pair of brackets 22 . Where brackets 22 are bolted to the snowplow blade 12 . When the arrangement is attached as shown in FIG. 1 , the snow plow work vehicle will be capable of moving large amounts of snow greater distances that a typical plow blade due to the unique features of the plow vehicle that results.
[0025] As seen in FIG. 2 , the main body 18 of the snow pusher is largely made up of two plate-like side panels 24 joined together by a plurality of horizontal bars and cross members. The panels 24 may be made of metal, polymers, plastic, or aluminum. The panels 24 have flat surfaces which are generally perpendicular with respect to the horizontal plane of the ground. The two panels 24 are displaced from one another in a corresponding parallel manner such that they are similarly oriented and aligned. Panels 24 are located on either side of a plow blade 12 when in use. The surface of panels 24 are therefore able to deflect and contain plowed snow that might escape from either end of the blade. The panels 24 can be seen to have a perimeter of angled edges 26 to maximize effectiveness in plowing through and containing snow. The angled edges 26 also are contoured to generally reflect the shape of the plow to assist in reducing excess snow build up. The panels 24 are also elevated slightly from the ground by a pair of skid plates 28 positioned below and to the outer side of the panels 24 . The plates 28 are made of replaceable material intended to wear during normal use. Using such material helps accommodate the uneven surfaces which are being plowed. Also found on the outside surfaces of the plates 28 are outer plate members 30 . Outer plate members 30 are generally flat horizontal bars joined to the sides of the plates 28 . The plates 28 and the outer plate members 30 are attached to the panels 24 via bolts 32 which pass through outer plate members 30 , the skid plates 28 and panels 24 . Various other well known methods of attaching the plates to the panels are contemplated by this invention as well.
[0026] Formed within the inside surface of both panels 24 is a seal member 34 . These members 34 are made of a strip of flexible material that sits against the flat inside edge of panel 24 in perpendicular relation. The flexible material curves from the top of the panel 24 to the bottom edge of the panel. Seal member 34 protrudes a short distance inward from either plate end toward the center of the device. See FIG. 3 . The seal's flexible material is attached to the horizontal beams between the panels 24 as well as to an angle bracket 38 at the bottom of the panel 24 . The flexible material of seal member 34 simulates the contour of the moldboard of the snowplow blade to which it attaches. This seal member 34 closes the gap between the side panels 24 and each end of the snow plow blade 12 . Accordingly, a seal member 34 will not allow snow to pass through a gap between the plow blade 12 and side panel 24 . Alternatively, a seal member could also be used which was not flexible, but was formed to prevent the passage of snow between the plow blade 12 and side panel 24 .
[0027] As seen in FIG. 4 , the two side panels 24 are connected by two beams 40 and 42 . These beams are positioned in a perpendicular orientation with respect to the side panels 24 to join these similarly aligned plates. Upper beam 40 extends between the tops of the plates 24 and the second lower beam 42 extends between locations found midway down the face of the plates 24 . The beams 40 and 42 may be made of metal or other suitable material and are welded to the plates 24 at both ends. Alternatively, the plates 24 may be rigidly joined to the beams 40 and 42 with bolts or other attachment devices (not shown) for easy disassembly for replacement of a bent or damaged side plate 24 .
[0028] While only two horizontal brace members are disclosed in this embodiment of the present invention, a design with a greater or lesser number of horizontal support beams is also contemplated. Cushion material 44 is mounted on the rear facing side of the lower beam 42 to provide padding between the mold board making up the face of the plow blade 12 and the lower beam 42 . See FIG. 3 . This cushion 44 is useful as the lower beam 42 generally takes the brunt of the pushing force and directs it into the curvature of the mold board of the plow.
[0029] Six diagonal brace members provide further support for the body member of the snow pusher. Four of these are side brace members 46 . Each of these members extends from locations on beams 40 and 42 which are inset a short distance from one of the four ends of the respective beams. The second end of these side brace members 46 is joined to a location near the front edge of the respective adjacent side panel members 24 . These four diagonal side brace members 46 thereby form structural supports for reinforcing the rigidity of the pusher. Two additional diagonal braces 48 extend from the lower beam 42 to the upper beam 40 to attach with and support these members. These diagonal brace members 48 may also be referred to as cross members. These cross members are not straight, but rather are bent or contoured to accommodate the shape of the plow blade and pusher. Also, a design utilizing a greater or lesser number of diagonal support beams than disclosed is also contemplated without departing from the scope of the invention.
[0030] A pair of J cam hooks 20 are also integrally connected to the top beam 40 . Each of these J cam hooks 20 projects rearwardly from the top beam 40 . The resulting hooks extending toward the plow 12 attached to work vehicle 14 that engages the snow pusher. The side surfaces of the J cam hooks 20 are positioned parallel with side panels 24 , and the top surfaces are angled up towards the rear in relation to the ground. Additionally, the lower sloping surface 52 of each cam hook has an opening 54 in which a bracket may be placed to join the plow and pusher. Also, integrated into the J cam hook 20 is the cam stop 64 which is the stop mechanism to prevent detaching of the pusher while in use. See FIG. 8 . This type of arrangement allows for easy alignment when connecting the snow pusher body 18 and plow blade 12 . The upper beam 40 and attached J cam hooks 20 keep the apparatus in position on the plow when the snow pusher is in use. Therefore, the J cam hooks, forces exerted by work vehicle movement, and gravity are the means by which the snow pusher is kept in position during normal operation.
[0031] Corresponding to the pair of j cam hooks 20 are a pair of brackets 22 which are mounted to the top of the back surface of the plow blade 12 . These brackets 22 are bolted to the plow blade such that they are located in equal spaced apart relation with respect to the center of the blade. The brackets 22 are formed such that they have a curved base plate 58 having a radius bend simulating the curvature of the moldboard of the plow to which it is attached. From that base extend two curved vertical plate members 60 that reach a height slightly above the top of the plow blade 12 . Joining each of the pairs of vertical plate members 60 is a horizontal cam bar 66 and a shaft or pipe 62 . It is these shafts 62 to which the J cam hooks 20 are joined and that enable pivotal latching by this invention.
[0032] Alternatively, it is also contemplated by this invention to use vertical plate members 60 which are not attached to the curved base plate 58 , but rather are integrally formed directly with the plow blade. Forming the vertical plate members 60 with the plow could be done by welding or during manufacture of the plow blade. Attachment of the vertical plate members 60 in this way would eliminate the need to bolt a curved base plate 58 to the plow. Moreover, it is also within the scope of the present invention to use bracket and hook members attached in an opposite configuration to the one shown in the figures. For example, the hook members may be rigidly attached to the blade of the plow and the bracket members may be rigidly attached to the support assembly. Such modifications would allow for a similar manner of releasable attachment and do not depart from the teaching of this invention.
[0033] Further, although only a pair of J-cam hooks 20 and a pair of corresponding brackets 22 is shown in this embodiment, using additional hooks and brackets for support is also contemplated by the present invention. For example, using three or more J-cam hooks 20 and corresponding brackets 22 may be necessary in designs with particularly large plow attachments or for designs seeking to be more integrally connected to the plow blade.
[0034] The method by which the J cam hooks 20 and plow blade 12 connect with the brackets 22 can be seen in FIGS. 5-7 . Initially the plow blade 12 and mounted brackets 22 are separate from the J cam hooks 20 and the main body of the pusher 18 . First, an operator tips forward the plow blade 12 of his work vehicle 14 such that the blade face is roughly parallel to the plane of the ground, as seen in FIG. 5 . Next, the operator moves the work vehicle and plow forward to align the brackets 22 with the openings 54 in J cam hooks 20 , as seen in FIG. 6 . Next, the operator rotates the plow blade 12 back into a plowing position where the plow blade is roughly perpendicular with the ground, as seen in FIG. 7 .
[0035] As disclosed, the bracket members 22 generally are joined in such a way that they are hooked and then rotated until the cam bar 66 of the bracket meets the cam stop 64 (i.e. brace member) of the hook. See FIG. 8 . This configuration prevents the snow pusher from becoming disconnected unless the operator reverse rotates, or tilts the plow to the ground. If an operator were to conduct such a reverse rotation maneuver, the cam bar 66 of the bracket 22 would be drawn away from the cam stop of the hook allowing the shaft 62 of the bracket 22 to be removed from the J cam hook 20 and thereby disconnect the snow pusher body 18 from the snow plow 12 .
[0036] Therefore, operation of the snow plow pusher device to clean an area containing a road and intersecting driveways is as follows. First, the work vehicle utilizes the plow blade 12 of his or her vehicle to back drag snow from the various driveways onto the main road. This is done with a work vehicle 14 using a plow blade 12 with the bracket members 22 attached to its rear surface. No substantial interference to normal plow operation is caused by brackets 22 . Next, an operator loads the body 18 of the snow pusher device onto the plow blade 12 by driving up to the main body 18 of the pusher, rotating the plow blade such that its face is roughly parallel to the plane of the ground, and driving the vehicle forward until the pipes 62 of the brackets 22 mounted on the plow align with the openings 54 in the J cam hooks 20 .
[0037] Next, the plow blade 12 is rotated such that the blade is roughly perpendicular to the ground in a normal plowing configuration, and such that the main pusher body 18 is securely attached to the snow plow blade. The operator next drives the vehicle down the main road where the snow has accumulated. Because of the attachment of the pusher member a large amount of snow is able to be pushed down the road to a desired location very quickly and with relatively few passes. Further, because the plow blade retains the ability to angle itself with the pusher member attached, greater versatility and effectiveness of use is retained with the new device. And furthermore, with the pusher member attached, the trip edge mechanism 16 on the plow blade retains its full range of motion, thus retaining the safety feature for which the trip edge was intended. When areas along the road and driveway need touch up work or additional plowing the main pusher body 18 can easily and quickly be removed. The operator may do this by rotating the plow blade forward until the blade is roughly horizontal and the pusher attachment drops out of the J cam member 20 . The attachment can be left in any convenient location and the work vehicle can leave to perform work with the plow blade on its own. This configuration and attachment method allows the quick and repeated conversion of a snow plow into a snow pusher box and visa versa. Clearing snow from a location in this way results in an area where snow has been rapidly removed and transported in an efficient manner without requiring the operator to leave the cab of his or her work vehicle.
[0038] Those skilled in the art will appreciate that the snow pusher of the present invention may be manufactured in a variety of shapes and sizes to accommodate various sizes and types of work vehicles, plow blades, and work vehicle attachments. The invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself.
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A snow pusher attachment for use in conjunction with a straight blade angle-type snow plow mounted to a work vehicle. This pusher allows a work vehicle to capture, contain, and relocate large amounts of snow very quickly and efficiently. The attachment consists of side panels, connected by horizontal members between. This pusher attachment is secured to the snow plow by bracket assemblies, attached to the upper edge of the snow plow that engage hooks on the upper, rear portion of the pusher attachment. The attachment does not require the operator to exit the work vehicle to secure or release it from the snowplow. Accordingly, the attachment allows the quick and repeated conversion of a snow plow into a snow pusher box and visa versa.
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This application is a continuation of PCT/SE99/00138, filed on Jan 29, 1997.
The invention relates to data communication networks. In particular it relates to packet-switching networks and to the aspect of such networks interworking.
Definitions of some used terms and abbreviations
(STALLNDGS, William, Data and Computer Communications; Macmillan Publishing Company; 1991; and DE PRYCKER, Martin, Asynchronous Transfer Mode: Solution for broadband ISDN; Ellis Horwood series in computer communications and networking; 1991; both herein incorporated by reference)
ISDN: Integrated Services Digital Network;
N-ISDN: Narrowband-ISDN;
SS7: Signalling System Number 7 is a layered set of protocols that is used for control communication internal to a digital network, e.g. an N-ISDN, and provides facilities for establishing, maintaining and terminating connections. It comprises in total four levels;
N-ISLTD: N-ISDN User Part and the fourth level of SS7. It provides for the control signallin needed in an N-ISDN to deal with N-ISDN subscriber calls and related functions;
MTP: Message Transfer Part, lower three levels of SS7, provides a reliable but connectionless service for routing messages through the SS7 network, whereby
MTP 1 is the Signalling data link and the first level of SS7;
MTP 2 is the Signalling link and the second level of SS7. This level is specified in the ITU-T Recommendation Q.703 (03/93) and is herein incorporated by reference. According to the ITU-T Recommendation Q.703 (03/93) the signalling link functions, together with a signalling data link as bearer, provide a signalling link for reliable transfer of signalling messages between two directly connected signalling points. Signalling messages delivered by superior hierarchical levels are transferred over the signalling link in variable length signal units. A signal unit is constituted of a variable length signalling information field which carries the information generated by a user Part and a number of fixed length fields which carry information required for message transfer control. In the case of link stanus signal units LSSU, the signalling information field and the service information octet is replaced by a status field which is generated by the signalling link terminal. There are three types of signal unit, i.e. the message signal units MSU, link status signal units LSSU and fill-in signal units FISU. The signalling link functions comprise signal unit delimitation, signal unit alignment, error detection, error correction, intitial alignment, signalling link error monitoring and flow control. All these functions are coordinated by the link state control;
MTP 3 is the Sionallin, network and the third level of SS7
HDLC: HDLC uses synchronous transmission. All transmissions are in frames, and a single frame format suffices for all types of data and control exchanges. The frame has the following fields: Flag, Address; Control; Information; Frame check sequence (FCS); and Flag. Bit stuffing is a procedure which is used for providing data transparency.
B-ISDN: Broadband-ISDN is a service or system requiring transmission channels of supporting rates greater than the primary rates;
B-ISUP: B-ISDN User part;
ATM: Asychronous Transfer Mode (protocol) is a transfer mode solution for implementing a B-ISDN, comprising three layers defined as the physical layer PHY which mainly transports information;
the ATM layer which mainly performs switching/routing and multiplexing; and
the ATM adaptation layer (AAL) which is mainly responsible for adapting service information to the ATM stream;
ST: Signalling terminal;
ET: Exchange terminal;
IWF/IWU: Interworking function/Interworking unit;
NNI: Network to Network interface;
Node: to which stations attach, is the boundery of a communication network, e.g. a B-ISDN network, and the node is capable of transferring data between pairs of attached stations.
BACKGROUND
Both information and parameters are sent from and received by an N-ISDN using the SS7 protocol and are furthermore transmitted in a HDLC (High Level Data Link Control) based frame format, e.g. HDLC or LAP-D. The SS7 and the HDLC based frame format are well known in the art. A B-ISDN, however, sends and receives information and parameters using an ATM protocol which is a specific packet oriented transfer mode based on fixed length cells. The ATM protocol is well known in the art. The difficulty in sending data from one type of network to another resides in the use of different protocols and data formats, frames or cells, required for these protocols.
Special interworking units/functions IWU/IWF have been developed for solving the problem of interworking between N-ISDN and B-ISDN. The interworking is performed either by an Interworking Unit, IWU which is a unit separate from the B-ISDN or an Interworking Function, IWF which is an integral part of the B-ISDN. IWU/DV are specified in the ITU-T Recommendation I.580 from 03.93: “General Arrangements for Interworking between B-ISDN and 64 kbits/s based ISDN”. Accordingly a standard NNI is the interface between the 64 kbits/s ISDN, i.e. the N-ISDN. and the IWU/IWF and between the B-ISDN and the IWU/IWF. EP-A-0 581 087 discloses an N-ISDN and a B-ISDN interworking by means of an IWU. The advantage of IWU/IWF is that they are standardised. However, they need a large processing capacity. They are furthermore highly dependent on market adaptations. This entails considerable costs.
SUMMARY
It is an object of the invention to provide an interworking function which needs less processing capacity.
It is a further object of the invention to provide an interworking function which is less dependent on the market adaptations.
It is yet another object of the invention to provide an interworking function which is low in cost.
These and other objects and advantages are obtained according to the invention as disclosed in independent claim 1 and claim 11 . Preferred embodiments of the invention are given in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be explained in greater detail, referring to the drawings in which
FIG. 1 is a schematic view of networks interworking according to the prior art;
FIG. 2 is a schematic view of networks interworking according to an embodiment of the invention;
FIG. 3 is a schematic drawing of the interworking function according to an embodiment of the invention;
FIG. 4 is a flow diagram illustrating the split MTP 2 layer according to an embodiment of the invention;
FIG. 5 is a schematic drawing illustrating the functions of the split MTP 2 layer according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 is a schematic view of a B-ISDN 10 and an N-ISDN 20 interworking according to the prior art.
FIG. 2 is a schematic view of networks signalling interworking according to an embodiment of the invention. An ATM-based network 10 , e.g a B-ISDN, and a SS7-based network 20 , e.g. N-ISDN, are interworking by means of an interworking unit 60 comprised in the B-ISDN, for ensuring that a standard NNI is the only interface between the N-ISDN and the B-ISDN.
FIGS. 3 a and 3 b show two schematic drawings of a B-ISDN 10 and an N-ISDN 20 interworking. In FIG. 3 a a B-ISDI 10 can be seen comprising an exchange terminal ET 90 coupled to an ATM-based switch core 70 which is coupled to a signalling link terminal ST 100 . A signalling link terminal refers to the means for performing all of the functions defined at level 2 regardless of their implementation. When interworking with a B-ISDN 10 , the N-ISDN 20 is coupled to the exchange terminal ET 90 of the B-ISDN 10 . A means for achieving the objects of the invention is to provide the B-ISDN 10 with a means for interworking for supporting N-ISDN subscriber calls and related functions within the B-ISDN 10 . FIG. 3 b describes more specifically the means for interworking. Therein can be seen that the second MTP level of the SS7 80 , i.e. MTP2, is split into two sublevels, MTP 2 lower 92 and MRP2higher 103 . The MTP 2 lower 92 is preferably situated in the exchange terminal ET 90 and the MTP 2 higher 103 103 in the signalling terminal ST 100 . The functions of the MTP 2 are thereby split between the MTP 2 lower 92 and the MTP 2 higher 103 .
When an application X of the N-ISDN 20 has a message to an application Y of the N-ISLP supported within the B-ISDN 10 , it transfers those data to the N-ISUP 81 of the SS7 80 used in the N-ISDN 20 . Parameters containing the required information for the N-ISUP protocol are appended to those data and is passed as a unit together with the data to the MTP 3 . This process continues down through MTP 2 which generates a unit called frame using e.g. a HDLC based protocol. The frame is then passed by the MTP 1 onto the transmission medium. When the frame is received by the B-ISDN 10 it ascends to the N 1 of the exchange terminal ET 90 . The MTP 1 91 strips off the outermost parameters, acts on the protocol information contained therein, and passes the remainder up to the next layer MTP 2 lower 92 . MTP 2 lower 92 strips off the outermost parameters, acts on parts of the protocol information contained therein in accordance with an embodiment of the invention, and passes the remainder to the AAL 93 . Parameters are appended to the data that contains the required information for the AAL 93 protocol. In substance one can say that the AAL 93 protocol is a protocol for packeting and segmenting data into cells on transmission and reassembling the data from cells on reception. The cells are then passed by the ATM layer 94 onto the transmission medium and switched by the ATM switch core 70 to be received by an ATM layer 101 . The ATM layer 101 strips off the outermost parameters, acts on the protocol information contained therein, and passes the remainder up to the AAL 102 . On reception, the AAL 102 reassembles the data from cells in accordance with its protocol and passes the data up to the MTP 2 higher 103 . MTP 2 higher 103 strips off the outermost parameters, acts on the remaining parts of the MTP 2 protocol information contained therein in accordance with an embodiment of the invention. and passes the remainder to the MTP 3 104 . The MTP 3 104 sizes off the outermost parameters, acts on the protocol information contained therein, and passes the remainder to the N-ISUP 105 . The process continues through N-ISUP 105 for transfering the message of applicantion X to applicantion Y. When applicantion Y has a message for applicantion X, the reverse process occurs.
In a preferred embodiment of the invention, the exchange terminal ET 90 comprised within the B-ISDN 10 , comprises the MTP 1 level 91 , the MTP 2 lower 92 , an ATM layer 93 and an ALL 92 , e. g. AAL5 which is the AAL for Variable Bit Rate VBR. The signalling terminal ST 100 comprises an ATM layer 101 , an ATM adaptation layer 102 , e.g. AAL5 101 , MTP 2 higher 103 , MTP 3 104 and N-ISUP 105 .
In FIG. 4 the main functions of MTP 2 are shown. In a broad outline: Signal unit delimitation and alignment provide the functions for bit stuffing, insertion and removal of flags and analysis thereof; Error detection provides the functions for analysing the check bit at the end of each signal unit; Error correction provides the function of retransmission; Intitial alignment provides the functions for indicating the alignment status using four different alignment status indications, i.e. status indication “O” for out of alignment (SIO), “N” for normal alignment status (SIN), “E” for emergency alignment status (SIE) and “OS” for out of service (SIOS), all indications being carried in the status field of the link status signal unit LSSU. The alignment procedure passes through a number of states during the initial alignment one of them being proving by which means the signalling link terminal validates the link's ability to carry signal units correctly by inspecting the signal units; Signalling link error monitoring provides two functions, one which is employed whilst a signalling link is in service and which provides one of the criteria for taking the link out of service, and one which is employed whilst a link is in the proving state of the initial alignment procedure. These are called the signal unit error rate monitor SUERM and the alignment error rate monitor AERM respectively; and lastly flow control for handling a level 2 congestion situation. All the above mentioned functions are coordinated by the link state control. The functions of the MTP 2 and the corresponding procedures are well known in the art. FIG. 4 furthermore shows how the different functions of MTP 2 are split upon two sublevels in accordance with an embodiment of the invention.
FIG. 5 shows the MTP 2 split into two sublevels, the two sublevels being separated by a dotted line. It can be seen that the functions of MTP 2 lower 92 relate in general to the handling of the HDLC based frame format and the functions of MTP 2 higher 103 in general to error correction, retransmission and flow control of the transferred data. In particular, bit stuffing, flag detection/insertion and handling of the check sum are performed in the MTP 2 lower 92 , whilst sequence number handling, retransmission and flow control are performed in the MTP 2 higher 103 .
More specifically, MTP 2 higher 103 comprises means for error control and correction 120 , 130 , 140 and means for flow control 130 , 150 , 160 , e.g. buffering means. Link control functions are split between the MTP 2 lower 92 and the MTP 2 higher 103 in that regarding alignment it is performed in the MTP 2 higher 103 except the proving part which is performed in the MTP 2 lower 92 . Status control is performed in the MTP 2 higher 103 except for the status detection which is performed in the MTP 2 lower 92 . Furthermore, the reliable exchange of message signalling unit MSU is not effected by the split of the M 2 . The sequence control in MTP 2 is located in the MTP 2 higher 103 and will function in the same way as without the split.
FIG. 5 shows the functions of the MTP 2 layer and how they are distributed between the MTP 2 lower 92 and the MTP 2 higher 103 . When transferring data from lower to higher layers. MTP 2 lower 92 receives data from MTP 1 , strips off the outermost parameters and acts on the protocol information contained therein. It removes the bit stuffing and detects the flags 108 . The check bits are tested and removed 110 . If errors are detected a signal is sent to the MTP 2 higher for error correction. When transferring data from higher to lower layers, the reverse process occurs 180 , 190 . Furthermore, there is in the MTP 2 lower 92 a signal unit error rate monitor SUERM for monitoring the status of the signalling link, e.g. the link status signal unit LSSU “in service”. Upon detection of excessive error rate, an internal error signal is generated for being transferred to the MTP 2 higher 103 . Moreover, there is an alignment error rate monitor AERM for monitoring the alignment of the signalling link, whereby only the proving state of the alignment monitoring is performed in the MTP 2 lower 92 . If a counter reaches the error threshold during the proving period, an internal error signal is generated for being transferred to the MTP 2 higher 103 . If the the MTP 2 receives a link status signal unit LSSU ocher than SIN/STE, then the proving part of the alignment monitoring is terminated and the LSSU is passed on to the MTP 2 higher 103 . The generated internal signals may be transferred in the control field. The error thresholds for the SUERM and AERM are parameters which are initialized at restart.
A preferred embodiment regarding error detection and link control may be implemented as following:
In the direction of transferring data from the N-ISDN 20 to the B-ISDN 10 , MTP 2 lower 92 filters fill in signal units FISU by firstly detecting them and if a FISU is equal to the preceding FISU, then it is discarded; otherwise it is passed through to the MTP 2 higher 103 . In addition, a FISU may regularly be passed to the MTP 2 higher 103 as an “I'm alive” signal. In the direction of transferring data from the B-ISDN 10 to the N-ISDN 20 , the fill in signal units FISU will be inserted. To do this the MTP 2 lower 92 must keep the sequence numbers from the previous fill in signal unit FISU and use it for the generation of the fill in signal units FISU. The result of the filtering is that only fill in signal units FISU with relevant/new information is passed through to the MTP 2 higher 103 .
The proving part of the alignment monitoring is handled by the MTP 2 lower 92 , initiated by the MTP 2 higher 103 . Proving signal units are generated by the MTP 2 lower 92 and the result of the proving is transferred to the MTP 2 higher 103 .
The alignment status indications, e.g. SIOS/SIO/SIN/SIE, carried by the link status signal unit LSSU are filtered in the MTP 2 lower 92 . When the MTP 2 lower 92 receives one of these link status signal units LSSU, it will repeat it until another one is received. This filtering is valid for both directions and will thus be unburdening the MTP 2 higher 103 .
Hence, the MTP 2 higher 103 will be unburdened from continuous fill in signal units FISU and continuous link status signal units LSSU. However, for security in case a Link signal is lost, fill in signal units FISU and link status signal units LSSU will regularly be transferred from the MTP 2 lower 92 to the MTP 2 higher 103 . MTP 2 higher 103 sends a signal to the MTP 2 lower 92 when proving of alignment should be initiated by the MTP 2 lower 92 . A counter sudervises the MTP 2 lower 92 when proving.
The MTP 2 higher 103 is informed by the MTP 2 lower 92 of excessive error rate during the signalling link error detection by an internal error signal.
The functions of the MTP 2 lower 92 can be implemented in a access processor of the exchange termination board 90 and the MTP 2 upper in a central processor, the signalling terminal ST 100 . N-ISUP termination and/or message mapping to the B-ISUP can be handled in the B-ISDN node. By N-ISUP termination in the B-ISDN node, real N-ISDN functionality can be provided within the B-ISDN.
The invention is also applicable whenever two CCSS 7 based networks are interworking, i.e. MTP 2 interworking with other layer 2 protocols.
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For providing an interworking function between an N-ISDN and a B-ISDN, the B-TSDN includes a second Signalling System 7 based data communication protocol including an MTP2 level. The functions are split on a first sublevel and a second sublevel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to an exercise apparatus comprising a fixed lower body exercise platform and a pair of pole-like exercising units operatively coupled with the exercise platform for movement by the user against a yielding resistance in any direction in conjunction with a lower body stepping exercise on the fixed lower body exercise platform to accommodate a wide range of motion of a user of the platform with respect to the platform.
2. Background Information
Step aerobics has become an increasingly popular mode of aerobic exercise. A small platform, or step, typically only few inches off the ground, is provided and the user performs the aerobic exercise with the assistance of the platform. Basically, the user performs various exercises by stepping on to and off of the platform in fairly rapid succession.
Aerobic platforms in use today are contacted only by the feet of the user. Further, platforms today provide only aerobic exercise and provide no resistance exercise. To incorporate resistance training into a step aerobic routine, the platform user must use hand and/or ankle weights of some type. Heretofore, platforms included no handles or rails to assist the user in maintaining balance while performing exercise, and included no apparatus to provide the user with upper body, i.e., arms, shoulders, and chest, exercise.
The present invention is based upon the recognition of a need in the aerobic platform exerciser art to provide an aerobic platform exerciser which has the built-in capability of integrating resistance exercising to the basic aerobic exercising capability of such exercisers.
SUMMARY OF THE INVENTION
An object of the present invention is to fulfill the need expressed above. In accordance with the principles of the present invention this objective is achieved by providing an exercising apparatus which includes a base structure comprising a fixed lower body exercise platform constructed and arranged to permit a user to perform lower body exercises by stepping onto and off of the fixed lower body exercise platform in any of a plurality of different directions with respect to the fixed lower body exercise platform. A pair of elongated upper body exercising units are provided which have upper ends constructed and arranged to be grasped by opposite hands of the user. And a pair of mounting structures are provided which are constructed and arranged to mount lower ends of the pair of elongated upper body exercising units on the base structure to enable the upper ends of the pair of elongated upper body exercising units to be moved by the user grasping the upper ends of the pair of elongated upper body exercising units and moving the pair of elongated upper body exercise units against a yielding resistance in any direction about centers generally coincident with respective lower ends of the pair of elongated upper body exercising units to accommodate movement of the user in different directions with respect to the fixed lower body exercise platform.
The mounting structure is constructed and arranged to enable the user to move one or both of the elongated upper body exercising units against the yielding resistance in conjunction with the user stepping onto or off of the fixed lower body exercise platform or while the user is standing on the fixed lower body exercise platform.
It has also been noted that a number of exercises to be performed in conjunction with a step aerobic platform have been developed which require that the user move in a wide range of directions with respect to the platform, i.e., from side to side, fore and aft, and diagonally across the platform. In accordance with the principles of the present invention, the accommodation of a wide range of movements is accomplished by providing the exercising apparatus describe above wherein the mounting structures include adjusting mechanisms constructed and arranged to enable adjustment of a lateral orientation of the centers associated with the pair of elongated upper body exercising units with respect to the base structure by pivoting the centers associated with the pair of elongated upper body exercising units about respective substantially parallel vertical axes into different operative positions in which the centers associated with the pair of upper body exercising units are disposed in different laterally spaced orientations with respect to the base structure to accommodate different movements of the user with respect to the fixed lower body exercise platform while the user is moving one or both elongated upper body exercising units in any direction against the yielding resistance about the associated centers in conjunction with the user stepping onto or off of the fixed lower body exercise platform or while the user is standing on the fixed lower body exercise platform.
These and other features of the present invention will become more apparent during the course of the following detailed description and appended claims. The invention may best be understood with reference to the accompanying drawings wherein an illustrative embodiment is shown.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a step aerobic platform having upper body exercisers according to the present invention mounted thereon, with the upper body exercisers configured in a closely-spaced orientation;
FIG. 2 is a perspective view of a step aerobic platform having upper body exercisers according to the present invention mounted thereon, with the upper body exercising units configured in a widely-spaced orientation;
FIG. 3 is an exploded perspective view of the upper body exercising apparatus of the present invention as mounted on a step aerobic platform;
FIG. 4 is a partial cross-sectional view of an upper portion of an exercise pole of an upper body exerciser according to the present invention;
FIG. 5 is a partial cross-sectional view of a lower portion of an exercise pole of an upper body exerciser according to the present invention;
FIG. 6 is a partial plan view of a step aerobic platform having upper body exercisers according to the present invention mounted thereon; and
FIG. 7 is a partial elevation, partially in cross-section, of a step aerobic platform having upper body exercisers according to the present invention mounted thereon.
DETAILED DESCRIPTION OF THE INVENTION
An exercise apparatus 20 having upper body exercising units mounted thereon according to the principles of the present invention is shown in FIGS. 1 and 2. In the illustrated embodiment, the upper body exercising units, which comprise exercising poles 24 and pivoting mounting mechanisms 26, are attached to a step aerobic platform 22. Each of the mounting mechanisms 26 is preferably constructed, in a manner to be described below, so as to be pivotable in the direction indicated by arrow A in FIG. 2 about a substantially vertical pivot axis 27. As can be seen in FIGS. 1 and 2, the pivot axes 27 for both the left and right mounting mechanisms are substantially parallel to one another.
As shown by a comparison of FIGS. 1 and 2, the pivotability of mounting mechanisms 26 permits adjustment of the exercise poles 24 into a position, as shown in FIG. 1, of close proximity to one another or a configuration, as shown in FIG. 2, wherein poles 24 are widely spaced from one another and from the exercise platform 22. It can be appreciated that with the apparatus configured as shown in FIG. 1, a user can perform lateral side-to-side movements with respect to the platform 22, without impediment from the poles 24, and the user can grasp and use one or both poles 24 for upper body exercise and/or balance while making the side-to-side movements. Similarly, with the apparatus configured as shown in FIG. 2, a user can perform fore-and-aft movements with respect to the platform 22, without impediment from the poles 24, and the user can grasp and use one or both poles 24 for upper body exercise and/or balance while making the fore-and-aft movements. Furthermore, exercise poles 24 can preferably be adjusted into any position between that shown in FIG. 1 and that shown in FIG. 2, and the adjusting mechanisms can be pivoted rearwardly so that the exercise poles 24 are disposed against the sides of the platform 22.
In the preferred embodiment of the present invention, platform 22 comprises a conventional step aerobic platform, preferably including a flat top surface 21, an angled surface 23 extending downwardly from the flat top surface 21, and an area 25, including portions of top surface 21 and angled surface 23, having laterally extending ridges, or the like, provided thereon to enhance traction on the platform.
Although the upper body exercising units of the present invention are illustrated and described with respect to mounting thereof on a step aerobic platform, it is to be understood that, in the broadest aspects contemplated of the present invention, the upper body exercising units described herein could as well be mounted on various other types of lower body exercising platforms, such as, for example, treadmills, stationary bicycles, cross-country ski machines, and stair stepping machines. The moveability of the upper body exercise units of the present invention is most beneficial when the units are incorporated with a lower body exercise device that permits or requires a wide range of motion by the user with respect to the device, such as a step aerobic platform.
Furthermore, although it is preferred that the poles be mounted to the platform so as to be laterally pivotable, in the broadest aspects contemplated of the invention, significant benefit and improvement over prior art exercise platforms can be realized by providing an exercise platform with exercise poles having no pivoting adjusting capability.
The construction and assembly of the exercise poles 24 and mounting mechanisms 26 will be described in further detail with reference to FIGS. 3-7.
As shown in FIG. 3, each exercise pole 24 comprises an inner elongated member, or tube, 28 preferably of hollow tubular construction, and an outer elongated member, or tube, 30 preferably of a hollow tubular construction that is sized so as to fit coaxially over the inner elongated member 28 with a gap 29 (see FIGS. 5 and 6) between an outer surface of inner elongated member 28 and an inner surface of outer elongated member 30. Inner elongated member 28 is preferably made of aluminum and outer elongated member 30 is preferably made of polyvinylchloride ("PVC").
As shown in FIGS. 3-5, exercise poles 24 include coupling structure for operatively coupling the inner and outer elongated members 28 and 30. This coupling structure includes a guide plug 36 and an annular bushing 34. Guide plug 36 is disc-shaped and is disposed at the top end of the inner elongated member 28 and includes a cylindrical portion that fits inside inner tube 28 and is preferably held in place by a set screw 37. (see FIG. 4) The outside diameter of the guide plug 36 is smaller than the inside diameter of the outer elongated member 30 so that the outer elongated member 30 can easily fit over guide plug 36 and so that an annular gap 39 is defined between the outer periphery of the guide plug 36 and the inner surface of the outer elongated member 30.
Bushing 34 is snugly but slidably disposed on the inner elongated member 28 at a position below the guide plug 36. The lower end of outer elongated member 30 is fixedly secured to the bushing 34, preferably by press-fitting bushing 34 into elongated member 30 or by providing mating exterior threads on the bushing 34 and interior threads on the lower end of the outer elongated member 30. Bushing 34 is preferably composed of plastic.
A foam grip 32 is preferably provided over the upper end of the outer elongated member 30.
With the inner elongated member 28 and outer elongated member 30 configured as described, it can be appreciated that outer elongated member 30 is able to move in an axial telescoping manner with respect to the inner elongated member 28. Guide plug 36 functions as a stop which prevents the outer elongated member 30 from being raised beyond the upper end of the inner elongated member 28 when bushing 34 contacts guide plug 36. Thus telescoping movement of outer elongated member 30 with respect to inner elongated member 28 is limited by guide plug 36.
Furthermore, guide plug 36 and bushing 34 define a variable volume air chamber within gap 29. The volume of the air chamber is greatest when outer tube 30 is at its lowest position with respect to inner tube 28, i.e., when bushing 34 is at its most spaced apart position from guide plug 36. Alternatively, the volume of the air chamber is smallest, i.e., zero, when the outer tube 30 is at its highest position with respect to inner tube 28, i.e., when bushing 34 comes into contact with guide plug 36.
When outer tube 30 is raised with respect to inner tube 28, the decreasing volume of the air chamber forces air out of the variable volume air chamber through annular gap 39, which functions as an air passage. Because of the small size of air passage 39, airflow therethrough is restricted. As mentioned above, bushing 34 preferably fits snugly over inner tube 28, and therefore, little if any air escapes from the variable volume air chamber through the interface of bushing 34 and inner tube 28. The restriction of the flow of air being forced out of the variable volume air chamber through air passage 39 effects a resistance to the rapid raising of the outer tube 30 with respect to the inner tube 28.
Similarly, when the outer tube 30 is lowered with respect to inner tube 28, the increasing volume of the air chamber draws air into the variable volume air chamber through the air passage 39. Again, the restriction of the flow of air being drawn into the variable volume air chamber through air passage 39 effects a resistance to the rapid lowering of the outer tube 30 with respect to the inner tube 28.
Resistance to rapid raising and lowering of the outer tubes 30 with respect to the inner tubes 28 enhances the aerobic exercise effect of rapid reciprocating movement of the exercise poles 24 by a user.
An insert 38 is attached to the lower end of the inner tube 28. Insert 38 is externally threaded so as to be threadable into the upper end of a coil spring 42. Insert 38 is preferably comprised of steel and is preferably secured to inner elongated member 28 by means of exterior threads that mate with interior threads formed in the lower end of inner tube 28. A sleeve 40, preferably comprised of foam, is preferably placed over coil spring 42 to cover and protect spring 42.
As shown in FIG. 3, a frame structure 100 is preferably disposed within the platform 22. Poles 24 are attached to frame 100 via mounting mechanisms 26 in a manner to be described in more detail below. Frame 100 includes two parallel, spaced apart longitudinal structural members 106 and 108 and a lateral structural member 102 extending therebetween. A second lateral structure member 104 extends across the ends of longitudinal structural members 106 and 108 and extends laterally beyond the width of the spaced longitudinal members 106 and 108. Structural members 102, 104, 106 and 108 are preferably composed of tubular steel and are preferably attached to one another by welding.
The structure 100 is secured beneath the platform 22. Slots 110 (see FIG. 3) provided in the end face of platform 22 accommodate longitudinal structural members 106 and 108. Structural frame 100 is preferably secured to platform 22 by mechanical fasteners, such as bolts or screws or the like.
As shown in FIGS. 3 and 7, cylindrical swivel mounts 50 are disposed on opposite ends of the lateral structural member 104. Swivel mounts 50 are preferably of a steel tubular construction and are preferably secured to lateral structural member 104 by welding. Circular plastic plugs 52 are preferably inserted into the lower end of the cylindrical swivel mount 50 so as to prevent the lower end of swivel mount 50 from scratching or scuffing a floor surface. A threaded lug 48 extends vertically upwardly from the center of the cylindrical swivel mount 50. Lug 48 preferably comprises an upwardly extending bolt welded to a washer 49 which is welded to the swivel mount 50.
Mounting mechanisms 26 are secured atop the cylindrical swivel mounts 50 so as to be pivotal with respect thereto. As shown in FIGS. 3, 6, and 7, each mounting mechanism 26 includes a cylindrical swivel guide 64, a pivoting arm 62, and a pole attachment tube 54, all preferably of tubular steel construction and secured to one another by welding. Pivoting arm 62 extends radially outwardly from the swivel guide 64, and pole attachment tube 54 is secured proximate an end of the pivoting arm 62 opposite from the swivel guide 64. Plastic caps 63 are preferably press-fitted into the ends of pivoting arm 62. Swivel guide 64 includes circular plugs 66 and 67 inserted into opposite axial ends thereof, each plug having a centrally located aperture extending therethrough for receiving the threaded lug 48 extending from the swivel mount 50. An adjusting knob 46 having an interiorly threaded bore, is threaded onto the upper end of the lug 48.
It can be appreciated that swivel guide 64 sits atop the swivel mount 50 and is able to rotate with respect thereto about the lug 48. Adjusting knob 46 can be tightened onto lug 48 so as to place the swivel guide 64 into a state of compression between the swivel mount 50 and the adjusting knob 46 to prevent pivoting of the mounting mechanism 26 and thus secure the mounting mechanism 26 in a desired orientation.
Swivel guide 64 could be secured in a desired orientation by other means as well. For example, a disc having circumferentially-spaced apertures could be provided above and/or below swivel guide 64. An aperture provided in pivoting arm 62 would permit pivoting arm 62 to be locked by placing a pin through aligned holes in pivoting arm 62 and the above described disc(s). The above-described adjusting knobs 46 are preferred, however, because they permit a continuous variety of pivoting arm orientations.
Arcuate surfaces 68 are preferably formed in the corners of the platform 22 so as to accommodate the cylindrical swivel mount 50 and the swivel guide 26.
The pole attachment tube 54 preferably extends downwardly below the pivoting arm 62 so that the bottom end of the pole attachment tube 54 is in contact with the floor at all times. Plastic caps 56 are preferably inserted into the bottom end of the pole attachment tube 54 so as to prevent scuffing or scratching of the floor surface.
As shown in FIGS. 3 and 5, annular threaded inserts 60 having an interiorly threaded aperture are secured to the tops of the pole attachment tubes 54 by means of bolts 58. Bolts 58 are threaded into threaded slugs 59, which are welded to attachment tubes 54. The outer surface of insert 60 is threaded so as to accommodate the lower end of coil spring 42. In this manner, poles 24 are operatively secured, or mounted, to the base structure via the mounting mechanisms 26 and are capable of oscillation, via the coil springs 42, in any direction about the points at which the springs 42 are attached to the base, i.e., at the top of pole attachment tubes 54, which comprise centers of movement of the poles 24. The coil springs 42 also provide yielding resistance to oscillating movement of the poles 24, thus enhancing the exercise effect of such movement. Of course, while a coil spring is preferred, it should be apparent that other resilient couplings, such as for example, lengths of rubber hose of sufficient stiffness, could be used to couple the lower ends of poles 24 to the mounting mechanisms is manner that permits oscillation of the poles in any direction.
Further, while in the preferred embodiment shown both the mounting function and the yieldable resistance providing function are performed by a single structure, namely, coil spring 42, it is within the contemplation of the invention in it broadest aspects to provide these functions by separate structures. One example might comprise a rigid mount fixing the pole to the base structure in a fixed, vertical orientation, with a coil spring provided at an intermediate location along the length of the pole to permit movement against yielding resistance about the intermediate point.
Furthermore, in embodiments having no lateral adjustment capability, the poles are operatively coupled, by means of springs or the like, directly to a fixed portion of the platform.
As mentioned above, the inner tubes 28 are preferably made of aluminum and the outer tubes 30 are preferably made of PVC. A user of the base lower body exercise device, especially a user of a step aerobic platform, can be expected to move through a wide range of positions and directions with respect to the base in the context of performing the lower body exercise thereon. Accordingly, it is desired that the exercise poles be able to accommodate this wide range of movement. Part of that accommodation is provided by the mounting of the poles to the platform which permits the poles to oscillate in any direction about their centers. In addition, the tubes, primarily the PVC outer tube 30 but also to some extent the aluminum inner tube 28, are able to flex elastically, thus further accommodating a wide range of movement by the user with respect to the base.
The embodiment describe above represents the preferred embodiment of the present upper body exercising apparatus. As an alternative to the configuration described above, the outer hollow tube of the exercise poles could be coupled, via a coil spring, to a base exercise device and the inner tube could be disposed so as to be capable of telescoping movement with respect to the outer tube. In this case, a guide plug would be fixed to the bottom end of the inner tube and a slidable bushing would be fixed to an upper end of the outer tube.
Also alternatively, the guide plug could be dimensioned so as to fit snugly between the inner and outer tubes and a gap could be provided between the bushing and the outer surface of the inner tube, which would then serve as the restricted air passage.
In either of the above-described alternative embodiments, the fundamental operation of the present invention is the same. Specifically, as a telescoping tube is moved axially upwardly with respect to a fixed tube, the volume of a variable volume air chamber defined between the two coaxial tubes decreases, and air is forced out of the chamber through a restricted air passage which effects a resistance to the upward axial movement. Conversely, as the telescoping tube is moved axially downwardly with respect to the fixed tube, the volume of a variable volume air chamber increases, and air is drawn into the chamber through the restricted air passage which effects a resistance to the downward axial movement.
It will be realized that the foregoing preferred specific embodiment of the present invention has been shown and described for the purposes of illustrating the functional and instructional principles of this invention and are subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
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An exercise apparatus including a base structure comprising a fixed lower body exercise platform and a pair of elongated upper body exercising units is disclosed. The units are mounted to the base structure by mounting structure that enables the units to be moved by a user against a yielding resistance in any direction with respect to a center in conjunction with the user stepping onto or off of the platform in any direction while performing an exercise thereon. The elongated upper body exercising units preferably include two telescoping exercise poles to be grasped by opposite hands of the user and capable of both oscillating and reciprocating upper body exercising motion. A variable volume air chamber is defined in an annular gap between coaxially arranged inner and outer members of the telescoping exercise poles and a restricted air passage communicates with the air chamber. Reciprocating motion of the telescoping pole causes the volume of the air chamber to alternately expand and contract and the restricted air passage restricts air flow into and out of the chamber to effect a resistance to the reciprocating motion. The poles are preferably mounted to the base structure by coupling each pole to a separate pivoting arm that is secured to the base structure so as to be pivotable about a vertical axis. Lateral orientation of the poles with respect to the base structure and each other can be varied by pivoting each pivoting arm to which each pole is attached and then securing each arm in a desired orientation.
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TECHNICAL FIELD
[0001] The present invention relates to a novel compound, and a β-secretase inhibitor and a preventive or therapeutic agent for a disease associated with β-secretase that utilize the same.
BACKGROUND ART
[0002] With the arrival of a rapidly aging society in recent years, senile dementia has become a serious medical and social problem and effective anti-dementia drugs are awaited anxiously. While Alzheimer's disease (AD) has been well studied, its pathogenesis remains unclear. Aricept, the only therapeutic agent for Alzheimer's disease that has been launched in Japan, is based on the inhibitory action on acetylcholinesterase. Although Aricept is very useful for symptomatic treatment, this drug is not a definitive treatment.
[0003] One causative substance that induces Alzheimer's disease is thought to be amyloid β protein, which is generated from amyloid precursor protein (APP) through the actions of enzymes called secretases. A compound that has an inhibitory action on these secretases is therefore a promising candidate of a therapeutic agent for Alzheimer's disease. Some compounds that have an inhibitory action on secretases are already known and patent applications for the compounds have been filed (Patent Literatures 1, 2, and 3).
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: Japanese Patent Laid-Open No. 2002-173448
Patent Literature 2: Japanese Patent Laid-Open No. 2004-149429
Patent Literature 3: WO 2004/076478
SUMMARY OF INVENTION
Technical Problem
[0007] Secretase-inhibiting substances can inhibit not only generation of amyloid β protein but also other reactions in the living body. As such substances may cause severe adverse reactions in patients, it is difficult to use the substances in treatment of Alzheimer's disease. An object of the present invention is to provide a highly safe measure to treat Alzheimer's disease using a secretase-inhibiting substance against such a technical background.
Solution to Problem
[0008] The present inventor has conducted an intense study to achieve the foregoing object. As a result, the inventor has found that a group of compounds having a 6-phenyl-hex-5-ene-2,4-dione structure as with curcumin contained in turmeric, one of curry spices, have a potent inhibitory action on β-secretase. The inventor has also found that, of the compounds having this structure, compounds that have an electron-withdrawing substituent at the second position of a phenyl group have a potent inhibitory action, and compounds that have a phenyl group substituted with a chlorine atom, a bromine atom, or a nitro group at the second position thereof or with a hydroxyl group at the fourth or fifth position thereof have a particularly potent inhibitory action.
[0009] The present invention has been accomplished based on the above-described findings.
[0010] Specifically, the present invention provides the following (1) to (10):
[0011] (1) A compound represented by the following general formula (I) or a salt thereof:
[0000]
[0000] wherein A represents an aryl group that is optionally substituted or a heteroaryl group that is optionally substituted, R 1 represents an electron-withdrawing group, R 2 , R 3 , R 4 , and R 5 are the same or different and each represent a hydrogen atom or a group with which a benzene ring can be substituted, and L represents CH 2 —CH 2 or CH═CH.
[0012] (2) The compound according to (1) or a salt thereof, wherein in the general formula (I), R 1 is a fluorine atom, a chlorine atom, a bromine atom, a nitro group, a trifluoromethyl group, a cyano group, an azide group, an alkoxycarbonyl group that is optionally substituted, a carboxyl group, an alkylaminocarbonyl group that is optionally substituted, a dialkylaminocarbonyl group that is optionally substituted, an alkylaminosulfonyl group that is optionally substituted, a dialkylaminosulfonyl group that is optionally substituted, an alkylsulfinyl group that is optionally substituted, an alkylsulfonyl group that is optionally substituted, an alkylsulfonyloxy group that is optionally substituted, an alkylcarbonyloxy group that is optionally substituted, a benzoyl group that is optionally substituted, a phenyl group that is optionally substituted, a naphthyl group that is optionally substituted, a triazolyl group that is optionally substituted, a tetrazolyl group that is optionally substituted, a styryl group that is optionally substituted, or a functional group equivalent thereto and R 2 , R 3 , R 4 , and R 5 are the same or different and are each a hydrogen atom, a hydroxyl group, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, a nitro group, a trifluoromethyl group, a methoxymethoxy group, an alkyl group that is optionally substituted, an alkoxy group that is optionally substituted, a phenyl group that is optionally substituted, a phenoxy group that is optionally substituted, a dialkylamino group that is optionally substituted, a pyridinylmethoxy group that is optionally substituted, a 2-dimethylaminoethoxy group that is optionally substituted, a benzyloxy group that is optionally substituted, a piperidin-1-yl group that is optionally substituted, a 1,4-diazepan-1-yl group that is optionally substituted, or a piperazin-1-yl group that is optionally substituted.
[0013] (3) The compound according to (1) or a salt thereof, wherein in the general formula (I), R 1 is a chlorine atom, a bromine atom, or a nitro group and R 2 , R 3 , R 4 , and R 5 are the same or different and are each a hydrogen atom, a hydroxyl group, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, a nitro group, a trifluoromethyl group, a methoxymethoxy group, an alkyl group that is optionally substituted, an alkoxy group that is optionally substituted, a phenyl group that is optionally substituted, a phenoxy group that is optionally substituted, a dialkylamino group that is optionally substituted, a pyridinylmethoxy group that is optionally substituted, a 7-dimethylnminoethoxy group that is optionally substituted, a benzyloxy group that is optionally substituted, a piperidin-1-yl group that is optionally substituted, a 1,4-diazepan-1-yl group that is optionally substituted, or a piperazin-1-yl group that is optionally substituted.
[0014] (4) The compound according to (1) or a salt thereof, wherein in the general formula (I), R 1 is a chlorine atom, a bromine atom, or a nitro group and R 2 , R 3 , R 4 , and R 5 are the same or different and are each a hydrogen atom or a hydroxyl group.
[0015] (5) The compound according to (1) or a salt thereof, wherein in the general formula (I), R 1 is a chlorine atom, a bromine atom, or a nitro group, one of R 3 and R 4 is a hydroxyl group and the other is a hydrogen atom, and R 2 and R 5 are each a hydrogen atom.
[0016] (6) The compound according to (1) or a salt thereof, wherein in the general formula (I), R 1 is a nitro group, R 2 , R 3 , and R 5 are each a hydrogen atom, and R 4 is a hydroxyl group.
[0017] (7) The compound according to any of (1) to (6) or a salt thereof, wherein in the general formula (I), L is CH═CH.
[0018] (8) The compound according to any of (1) to (7) or a salt thereof, wherein in the general formula (I), A is a phenyl group or an indolyl group that is optionally substituted with one or two or more substituents selected from the following substituent group a, the substituent group a consisting of an electron-withdrawing group, a hydroxyl group, an alkoxy group that is optionally substituted, and a dialkylamino group that is optionally substituted.
[0019] (9) A β-secretase inhibitor, comprising a compound according to any of (1) to (8) or a salt thereof as an active ingredient.
[0020] (10) A preventive or therapeutic agent for a disease associated with β-secretase, comprising a compound according to any of (1) to (8) or a salt thereof as an active ingredient.
ADVANTAGEOUS EFFECTS OF INVENTION
[0021] Because the compound represented by the general formula (I) (hereinafter referred to as “the compound of the present invention”) has a structure similar to that of curcumin contained in food, the compound inhibits β-secretase without affecting the human body adversely and is therefore considered to be useful in the treatment of Alzheimer's disease or the like. Furthermore, the compound of the present invention can be used not only for direct treatment of Alzheimer's disease but also for development of novel therapeutic agents for Alzheimer's disease or the like and assessment of the influence of β-secretase inhibition on the living body.
BRIEF DESCRIPTION OF DRAWINGS
[0022] FIG. 1 shows the results of determination of 50% inhibitory concentrations against β-secretase.
[0023] FIG. 2 shows the results of determination of the Aβ1-40 and Aβ1-42 production-suppressing actions of CU532 in rat nerve cells in the primary culture.
DESCRIPTION OF EMBODIMENTS
[0024] The present invention will be described below in detail.
[0025] In the present invention, examples of “alkyl” include alkyl having 1 to 20 carbon atoms, and alkyl having 1 to 8 carbon atoms is preferred.
[0026] In the present invention, examples of “alkoxy” include alkoxy having 1 to 20 carbon atoms, and alkoxy having 1 to 8 carbon atoms is preferred.
[0027] In the present invention, examples of “naphthyl group” include a 1-naphthyl group and a 2-naphthyl group.
[0028] In the present invention, examples of “indolyl group” include a 1H-indol-2-yl group, a 1H-indol-3-yl group, a 1H-indol-4-yl group, a 1H-indol-5-yl group, a 1H-indol-6-yl group, and a 1H-indol-7-yl group.
[0029] In the present invention, examples of “pyridinylmethoxy group” include a pyridin-2-ylmethoxy group and a pyridin-3-ylmethoxy group.
[0030] In the present invention, examples of “triazolyl group” include a 1H-1,2,4-triazol-1-yl group, a 1H-1,2,3-triazol-1-yl group, a 1H-1,2,3-triazol-4-yl group, and a 1H-1,2,3-triazol-5-yl group.
[0031] In the present invention, examples of “tetrazolyl group” include 1H-tetrazol-5-yl group.
[0032] In the present invention, examples of “functional group equivalent thereto” are as follows: examples of the functional group equivalent to a chloro atom include a thiocyanate group and 2,2-difluorovinyl group, examples of the functional group equivalent to a carboxyl group include an oxadiazolyl group, an isoxazolyl group, a hydroxamate group, a phosphate group, a sulfo group, and a sulfonamide group, examples of the functional group equivalent to an alkoxycarbonyl group that is optionally substituted include an oxazolyl group and a thiazolyl group, and examples of the functional group equivalent to a phenyl group that is optionally substituted include an ethynyl group and cyclohexenyl group.
[0033] In the present invention, substituents for “alkoxycarbonyl group that is optionally substituted,” “alkylaminocarbonyl group that is optionally substituted,” “dialkylaminocarbonyl group that is optionally substituted,” “alkylaminosulfonyl group that is optionally substituted,” “dialkylaminosulfonyl group that is optionally substituted,” “alkylsulfinyl group that is optionally substituted,” “alkylsulfonyl group that is optionally substituted,” “alkylsulfonyloxy group that is optionally substituted,” “alkylcarbonyloxy group that is optionally substituted,” “benzoyl group that is optionally substituted,” “phenyl group that is optionally substituted,” “naphthyl group that is optionally substituted,” “alkyl group that is optionally substituted,” “alkoxy group that is optionally substituted,” “phenoxy group that is optionally substituted,” “dialkylamino group that is optionally substituted,” “pyridinylmethoxy group that is optionally substituted,” “2-dimethylaminoethoxy group that is optionally substituted,” “benzyloxy group that is optionally substituted,” “triazolyl group that is optionally substituted,” “tetrazolyl group that is optionally substituted,” “styryl group that is optionally substituted,” “piperidin-1-yl group that is optionally substituted,” “1,4-diazepan-1-yl group that is optionally substituted,” and “piperazin-1-yl group that is optionally substituted” may be any substituents as long as the substituents are groups with which the groups described above can be substituted, and examples thereof include a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, a nitro group, a trifluoromethyl group, a hydroxyl group, an alkyl group, a cycloalkyl group, an alkoxy group, a phenyl group, a phenoxy group, an alkylamino group, a dialkylamino group, an ethoxycarbonyl group, a benzyl group, an ethoxycarbonylmethyl group, an isobutoxy group, a 4-tert-butoxycarbonyl group, and a heterocyclic ring. Two or more of these may be taken together to form a substituent.
[0034] In the general formula (I), R 1 is preferably a fluorine atom, a chlorine atom, a bromine atom, a nitro group, a trifluoromethyl group, a cyano group, an alkoxycarbonyl group that is optionally substituted, a carboxyl group, an alkylaminocarbonyl group that is optionally substituted, a dialkylaminocarbonyl group that is optionally substituted, an alkylaminosulfonyl group that is optionally substituted, a dialkylaminosulfonyl group that is optionally substituted, an alkylsulfinyl group that is optionally substituted, an alkylsulfonyl group that is optionally substituted, an alkylsulfonyloxy group that is optionally substituted, an alkylcarbonyloxy group that is optionally substituted, a benzoyl group that is optionally substituted, a phenyl group that is optionally substituted, a naphthyl group that is optionally substituted, a triazolyl group that is optionally substituted, a tetrazolyl group that is optionally substituted, a styryl group that is optionally substituted, or a functional group equivalent thereto, more preferably a chlorine atom, a bromine atom, or a nitro group, and further preferably a nitro group.
[0035] In the general formula (I), R 3 and R 4 preferably are the same or different and are each a hydrogen atom, a hydroxyl group, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, a nitro group, a trifluoromethyl group, a methoxymethoxy group, an alkyl group that is optionally substituted, an alkoxy group that is optionally substituted, a phenyl group that is optionally substituted, a phenoxy group that is optionally substituted, a dialkylamino group that is optionally substituted, a pyridinylmethoxy group that is optionally substituted, a 2-dimethylaminoethoxy group that is optionally substituted, a benzyloxy group that is optionally substituted, a piperidin-1-yl group that is optionally substituted, a 1,4-diazepan-1-yl group that is optionally substituted, or a piperazin-1-yl group that is optionally substituted, and more preferably are the same or different and are each a hydrogen atom or a hydroxyl group. Further preferably, one R 3 and R 4 is a hydroxyl group and the other is a hydrogen atom. Most preferably, R 3 is a hydrogen atom and R 4 is a hydroxyl group.
[0036] In the general formula (I), R 2 and R 5 preferably are the same or different and are each a hydrogen atom, a hydroxyl group, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, a nitro group, a trifluoromethyl group, a methoxymethoxy group, an alkyl group that is optionally substituted, an alkoxy group that is optionally substituted, a phenyl group that is optionally substituted, a phenoxy group that is optionally substituted, a dialkylamino group that is optionally substituted, a pyridinylmethoxy group that is optionally substituted, a 2-dimethylaminoethoxy group that is optionally substituted, a benzyloxy group that is optionally substituted, a piperidin-1-yl group that is optionally substituted, a 1,4-diazepan-1-yl group that is optionally substituted, or a piperazin-1-yl group that is optionally substituted, and more preferably are the same or different and are each a hydrogen atom or a hydroxyl group, and further preferably a hydrogen atom.
[0037] In the general formula (I), L is preferably CH═CH.
[0038] In the general formula (I), A is preferably a phenyl group that is optionally substituted with one or two or more substituents selected from the group consisting of an electron-withdrawing group, a hydroxyl group, an alkoxy group that is optionally substituted, and a dialkylamino group that is optionally substituted or an indolyl group, more preferably a phenyl group that is substituted with one or two or more substituents selected from the group consisting of a hydroxyl group, a methoxy group, and a chlorine atom, further preferably a 4-hydroxyphenyl group, a 4-hydroxy-3-methoxyphenyl group, a 3-hydroxy-4-methoxyphenyl group, a 4-hydroxy-2-methoxyphenyl group, or a 4-hydroxy-2-chlorophenyl group, and most preferably a 4-hydroxyphenyl group, a 4-hydroxy-2-methoxyphenyl group, or a 4-hydroxy-2-chlorophenyl group.
[0039] Representative examples of the compound represented by the general formula (I) include compounds described in Examples 1 to 129 provided below.
[0040] Instead of the compound of the present invention, salts of the compound of the present invention may also be used. Such salts are preferably pharmacologically acceptable salts and examples thereof include alkali metal salts (sodium salts, potassium salts), alkaline earth metal salts (calcium salts, magnesium salts), sulfates, hydrochlorides, and nitrates.
[0041] Of the compounds represented by the general formula (I), compounds wherein L is CH═CH (compounds represented by general formula [Ia]) gap can be produced by known methods (for example, a method described in National Publication of International Patent Application No. 11-502232). Specifically, these compounds can be produced by steps 1 and 2 described below.
[0000]
[0000] wherein A and R 1 to R 5 have the same meanings as defined above.
[0042] Step 1 is a step of reacting an aldehyde represented by general formula (II) with 2,4-pentanedione in the presence of a solvent and a catalyst to give a compound represented by general formula (III).
[0043] The solvent used is not particularly limited so long as the solvent does not inhibit the reaction and examples thereof include ethyl acetate, N,N-dimethylacetamide, N,N-dimethylformamide, N-methylpyrrolidinone, dimethyl sulfoxide, tetrahydrofuran, and acetonitrile. A solvent thereof may be used solely or two or more solvents thereof may be mixed at a suitable ratio and used as necessary.
[0044] The catalyst used is not particularly limited either and examples thereof include bases such as primary amines and secondary amines. More specific examples include n-butylamine, ethanolamine, piperidine, and morpholine.
[0045] Furthermore, a water scavenger may be added to scavenge water generated by the reaction. Examples of the water scavenger include alkyl borates, alkyl phosphates, and orthoesters. More specific examples include trimethyl orthoformate and tri-n-butyl borate.
[0046] The volume ratio of an aldehyde represented by the general formula (II) and 2,4-pentanedione is not particularly limited and is preferably 0.5 to 10 moles, more preferably 1 to 5 moles of the latter, to 1 mole of the former.
[0047] The reaction temperature is not particularly limited and is preferably 0° C. to 200° C., more preferably 50° C. to 100° C.
[0048] The reaction time is not particularly limited either and is preferably 0.5 to 48 hours, more preferably 1 to 24 hours.
[0049] The aldehyde represented by the general formula (II) that is used in step 1 is a commercially available product, a product synthesized from a commercially available product by a known method, or a product synthesized by a novel method described in the Examples. In addition, 2,4-pentanedione is a commercially available product.
[0050] Step 2 is a step of reacting a compound represented by the general formula (III) with a benzaldehyde derivative represented by general formula (IV) in the presence of a solvent and a catalyst to give a compound represented by the general formula (Ia).
[0051] The solvent used is not particularly limited as long as the solvent does not inhibit the reaction and examples thereof include ethyl acetate, N,N-dimethylacetamide, N,N-dimethylformamide, N-methylpyrrolidinone, dimethyl sulfoxide, tetrahydrofuran, and acetonitrile. A solvent thereof may be used solely or two or more solvents thereof may be mixed at a suitable ratio and used as necessary.
[0052] The catalyst used is not particularly limited either and examples thereof include bases such as primary amines and secondary amines. More specific examples include n-butylamine, ethanolamine, piperidine, and morpholine.
[0053] Furthermore, a water scavenger may be added to scavenge water generated by the reaction. Examples of the water scavenger include alkyl borates, alkyl phosphates, and orthoesters. More specific examples include trimethyl orthoformate and tri-n-butyl borate.
[0054] The volume ratio of a compound represented by the general formula (III) and a benzaldehyde derivative represented by the general formula (IV) is not particularly limited and is preferably 0.1 to 10 moles, more preferably 0.5 to 5 moles of the latter, to 1 mole of the former.
[0055] The reaction temperature is not particularly limited and is preferably 0° C. to 200° C., more preferably 50° C. to 100° C.
[0056] The reaction time is not particularly limited either and is preferably 0.5 to 48 hours, more preferably 1 to 24 hours.
[0057] The benzaldehyde derivative represented by the general formula (IV) that is used in step 2 is a commercially available product, a product synthesized from a commercially available product by a known method, or a product synthesized by a novel method described in the Examples.
[0058] When an aldehyde with a free hydroxyl group is low in reactivity in step 2, the reactivity may be improved by using an aldehyde with a protected hydroxyl group instead. The protecting group in this case is not particularly limited. If deprotection is performed at the same time as treatment with hydrochloric acid in the present step, a protecting group that is eliminated with an acid is preferred. Examples thereof include a methoxymethyl group and a t-butyldimethylsilyl group.
[0059] Of the compounds represented by the general formula (I), compounds in which L is CH 2 —C 2 (compounds represented by general formula (Ib)) can be produced by steps 3 and 4 described below.
[0000]
[0000] wherein A and le to R 5 have the same meanings as defined above.
[0060] Step 3 is a step of reducing the compound represented by the general formula (III) in the presence of a solvent and a catalyst to give a compound represented by general formula (V).
[0061] The solvent used is not particularly limited as long as the solvent does not inhibit the reaction and examples thereof include ester solvents such as ethyl acetate, alcohol solvents such as methanol, ethanol, and isopropanol, and ether solvents such as tetrahydrofuran, diethyl ethers, and dimethoxyethane. A solvent thereof may be used solely or two or more solvents thereof may be mixed at a suitable ratio and used as necessary.
[0062] The catalyst used is not particularly limited either and examples thereof include palladium catalysts such as palladium carbon and nickel catalysts such as Raney nickel and nickel diatomaceous earth.
[0063] The reaction temperature is not particularly limited and is preferably −40° C. to 200° C., more preferably 0° C. to 100° C.
[0064] The reaction time is not particularly limited either and is preferably 0.1 to 48 hours, more preferably 0.5 to 24 hours.
[0065] Step 4 is a step of reacting the compound represented by the general formula (V) with a benzaldehyde derivative represented by the general formula (IV) in the presence of a solvent and a catalyst to give a compound represented by the general formula (Ib). Step 4 can be implemented in the same manner as step 2.
[0066] The compound of the present invention has a β-secretase inhibiting activity and is therefore effective in preventing and treating diseases associated with β-secretase, such as Alzheimer's disease (familial Alzheimer's disease and sporadic Alzheimer's disease), senile dementia, Down's syndrome, Parkinson's disease, Creutzfelt-Jacob disease, amyotrophic lateral sclerosis, diabetic neuropathy, Huntington's disease, and multiple sclerosis. Of these neurogenic diseases, the compound of the present invention is particularly effective in preventing and treating Alzheimer's disease.
[0067] When the compound of the present invention is used as a preventive or therapeutic agent for Alzheimer's disease or the like, the compound can be mixed with a pharmaceutically acceptable carrier or diluent according to a known method to prepare a formulation. The dosage form is not particularly limited and examples thereof include a tablet, a powder, a granule, a capsule, a solution, an injection, a suppository, and a sustained-release agent. The administration method is not particularly limited either and the compound can be administered orally or parenterally (topical, rectal, or intravenous administration). The dosage varies depending on the administration target, administration method, disease type, and the like. For example, if the compound of the present invention is orally administered to adults as a therapeutic agent for Alzheimer's disease, then the compound can be administered in a single dose or divided into several doses per day so that the dose is 0.1 to 500 mg.
[0068] The compound of the present invention can be used in a method for treating a disease associated with β-secretase. Specific examples of the method include (A) described below.
[0000] (A) A method for treating diseases associated with β-secretase, comprising a step of administering a compound represented by the general formula (I) or a salt thereof to a patient with a disease associated with β-secretase.
[0069] The compound of the present invention can also be used in a method for inhibiting β-secretase.
[0070] Specific examples of the method include (B) and (C) described below.
[0000] (B) A method for inhibiting β-secretase, comprising a step administering a compound represented by the general formula (I) or a salt thereof to a human to inhibit β-secretase in the human body.
(C) A method for inhibiting β-secretase, comprising a step of bringing a compound represented by the general formula (I) or a salt thereof into contact with β-secretase.
EXAMPLES
[0071] The present invention will be described below in further detail with reference to Examples and the like. It is to be noted that synthesized compounds in the Examples are designated as compounds having a structure represented by the general formula (Ia) or (Ib) shown below and these are detected as compounds having structures represented by the general formula (Ia′) or (Ib′) shown below, respectively, in 1H NMR (heavy acetone solvent, room temperature). Therefore, compounds detected as compounds having not a structure represented by the general formula (Ia) or (Ib) but a structure represented by the general formula (Ia′) or (Ib′) in 1H NMR are also included in the synthesized compounds in the Examples. Furthermore, the melting point may be a value different from those shown in the Synthesis Examples depending on the crystalline system or the degree of mixture of impurities.
Example 1
Synthesis of (1E,6E)-1-(2-chloro-4-hydroxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU127)
[0072] 6-(4-Hydroxyphenyl)hex-5-ene-2,4-dione (17.5 mg, 85 μmol) and boron trioxide (11 mg, 0.16 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.4 mL of ethyl acetate. To the stirring mixture at 80° C. was added a solution of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol) and tri-n-butyl borate (25 μL, 93 μmol, sequentially. After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (10 μL, 0.10 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (1 mL) of 1N HCl and brine at room temperature, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized by saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound (13.2 mg, 45%) as a solid. 1 H NMR (δ, acetone-d 6 ): 6.01 (s, 1H), 6.69 (d, J=16 Hz, 1H), 6.74 (d, J=16 Hz, 1H), 6.87˜6.9 (m, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.98 (d, J=2.4 Hz, 1H), 7.58 (d, J=8.7 Hz, 2H), 7.63 (d, J=16 Hz, 1H), 7.78 (d, J=8.7 Hz, 1H), 7.97 (d, J=16 Hz, 1H), 9.0 (br s, OH).
[0073] Melting Point 131-138° C., MS (ESI+) m/z 343 (M+1), 365 (M+Na).
Example 2
Synthesis of (1E,6E)-1-(2-chloro-4-hydroxyphenyl)-7-(4-hydroxy-3-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU129) 6-(4-Hydroxy-3-methoxyphenyl)hex-5-ene-2,4-dione (20 mg, 85 μmol) and boron trioxide (11 mg, 0.16 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.4 mL of ethyl acetate. To the stirring mixture at 80° C. was added a solution of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol) and tri-n-butyl borate (25 μL, 93 μmol), sequentially. After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (10 μL, 0.10 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (1 mL) of 1N HCl and brine at room temperature, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized by saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound (8.0 mg, 25%) as a solid.
[0074] 1 H NMR (δ, acetone-d 6 ): 3.92 (s, 3H), 6.01 (s, 1H), 6.74 (d, J=16 Hz, 1H), 6.74 (d, J=16 Hz, 1H), 6.89 (d, J=8.2 Hz, 1H), 6.90 (dd, J=2.4, 8.8 Hz, 1H), 6.98 (d, J=2.4 Hz, 1H), 7.19 (dd, J=1.9, 8.2 Hz, 1H), 7.36 (d, J=1.9 Hz, 1H), 7.63 (d, J=16 Hz, 1H), 7.79 (d, J=8.8 Hz, 1H), 7.97 (d, J=16 Hz, 1H).
[0075] Melting Point 185-192° C., MS (ESI+) m/z 373 (M+1).
Example 3
Synthesis of (1E,6E)-1-(2-chloro-4-hydroxyphenyl)-7-(3-hydroxy-4-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU130)
[0076] 6-(3-Hydroxy-4-methoxyphenyl)hex-5-ene-2,4-dione (20 mg, 85 μmol) and boron trioxide (11 mg, 0.16 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.4 mL of ethyl acetate. To the stirring mixture at 80° C. was added a solution of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol) and tri-n-butyl borate (25 μL, 93 μmol), sequentially. After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (10 μL, 0.10 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (1 mL) of 1N HCl and brine at room temperature, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized by saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound (7.4 mg, 23%) as a solid.
[0077] 1 H NMR (δ, acetone-d 6 ): 3.90 (s, 3H), 6.03 (s, 1H), 6.70 (d, J=16 Hz, 1H), 6.76 (d, J=16 Hz, 1H), 6.89 (dd, J=2.4, 8.8 Hz, 1H), 6.98 (d, J=2.4 Hz, 1H), 7.01 (d, J=8.2 Hz, 1H), 7.15 (dd, J=1.9, 8.2 Hz, 1H), 7.21 (d, J=1.9 Hz, 1H), 7.59 (d, J=16 Hz, 1H), 7.80 (d, J=8.8 Hz, 1H), 7.98 (d, J=16 Hz, 1H).
[0078] Melting Point 120-130° C., MS (ESI+) m/z 373 (M+1).
Example 4
Synthesis of (1E,6E)-1-(5-hydroxy-2-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU131)
[0079] The title compound was synthesized using the same procedure employed for Example 1, but with 5-hydroxy-2-nitrobenzaldehyde (18 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (7.8 mg, 26%) having the following characteristics.
[0080] 1 H NMR (δ, acetone-d 6 ): 6.12 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.06 (dd, J=2.4, 8.8 Hz, 1H), 7.22 (d, J=2.4 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 8.08 (d, J=8.8 Hz, 1H), 8.11 (d, J=16 Hz, 1H).
[0081] Melting Point 187-194° C., MS (ESI+) m/z 354 (M+1), 376 (M+Na).
Example 5
Synthesis of (1E,6E)-1-(4-hydroxy-3-methoxyphenyl)-7-(5-hydroxy-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU132)
[0082] The title compound was synthesized using the same procedure employed for Example 2, but with 5-hydroxy-2-nitrobenzaldehyde (18 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (5.8 mg, 18%) having the following characteristics.
[0083] 1H NMR (δ, acetone-d 6 ): 3.93 (s, 3H), 6.10 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.78 (d, J=16 Hz, 1H), 6.89 (d, J=8.2 Hz, 1H), 7.06 (dd, J=2.4, 8.8 Hz, 1H), 7.25˜7.35 (m, 2H), 7.37 (d, J=1.9 Hz, 1H), 7.67 (d, J=16 Hz, 1H), 8.08 (d, J=8.8 Hz, 1H), 8.11 (d, J=16 Hz, 1H).
[0084] Melting Point 147-152° C., MS (ESI+) m/z 384 (M+1), 406 (M+Na).
Example 6
Synthesis of (1E,6E)-1-(3-hydroxy-4-methoxyphenyl)-7-(5-hydroxy-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU133)
[0085] The title compound was synthesized using the same procedure employed for Example 3, but with 5-hydroxy-2-nitrobenzaldehyde (18 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (11.4 mg, 35%) having the following characteristics.
[0086] 1 H NMR (δ, acetone-d 6 ): 3.90 (s, 3H), 6.12 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 7.01 (d, J=8.7 Hz, 1H), 7.05 (dd, J=2.4, 8.7 Hz, 1H), 7.17 (dd, J=1.9, 8.7 Hz, 1H), 7.21 (d, J=2.4 Hz, 1H), 7.22 (d, J=1.9 Hz, 1H), 7.63 (d, J=16 Hz, 1H), 8.07 (d, J=8.7 Hz, 1H), 8.11 (d, J=16 Hz, 1H).
[0087] Melting Point 107-111° C., MS (ESI+) m/z 384 (M+1), 406 (M+Na).
Example 7
Synthesis of (1E,6E)-1-(2,4-dichlorophenyl)-7-(4-hydroxy-3-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU144)
[0088] The title compound was synthesized using the same procedure employed for Example 2, but with 2,4-dichlorobenzaldehyde (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.2 mg, 19%) having the following characteristics.
[0089] 1 H NMR (δ, acetone-d 6 ): 3.92 (s, 3H), 6.09 (s, 1H), 6.77 (d, J=16 Hz, 1H), 6.89 (d, J=8.2 Hz, 1H), 6.93 (d, J=16 Hz, 1H), 7.20 (dd, J=˜2, 8.2 Hz, 1H), 7.36 (d, J=˜2 Hz, 1H), 7.45 (dd, J=2.4, 7.8 Hz, 1H), 7.61 (d, J=2.4 Hz, 1H), 7.67 (d, J=16 Hz, 1H), 7.91 (d, J=7.8 Hz, 1H), 7.92 (d, J=16 Hz, 1H), 8.2 (br s, OH).
[0090] Melting Point 124-130° C., MS (ESI+) m/z 391 (M+1), 413 (M+Na).
Example 8
Synthesis of (1E,6E)-1-(2,4-dichlorophenyl)-7-(3-hydroxy-4-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU145)
[0091] The Title Compound was Synthesized Using the Same Procedure Employed for Example 3, but with 2,4-dichlorobenzaldehyde (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (8.7 mg, 26%) having the following characteristics.
[0092] 1 H NMR (δ, acetone-d 6 ): 3.90 (s, 3H), 6.10 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.93 (d, J=16 Hz, 1H), 6.98 (d, J=8.2 Hz, 1H), 7.10 (dd, J=˜2, 8.2 Hz, 1H), 7.22 (d, J=˜2 Hz, 1H), 7.45 (dd, J=2.4, 7.8 Hz, 1H), 7.60 (d, J=2.4 Hz, 1H), 7.63 (d, J=16 Hz, 1H), 7.8 (br s, OH), 7.92 (d, J=7.8 Hz, 1H), 7.93 (d, J=16 Hz, 1H).
[0093] MS (ESI+) m/z 391 (M+1), 413 (M+Na).
Example 9
Synthesis of (1E,6E)-1-(2,4-dichlorophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU146)
[0094] The title compound was synthesized using the same procedure employed for Example 1, but with 2,4-dichlorobenzaldehyde (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.6 mg, 22%) having the following characteristics.
[0095] 1 H NMR (δ, acetone-d 6 ): 6.09 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.93 (d, J=16 Hz, 1H), 7.45 (dd, J=˜2, 8.7 Hz, 1H), 7.57 (d, J=8.7 Hz, 2H), 7.60 (d, J=˜2 Hz, 1H), 7.67 (d, J=16 Hz, 1H), 7.91 (d, J=8.7 Hz, 1H), 7.92 (d, J=16 Hz, 1H), 8.9 (br s, OH). MS (ESI+) m/z 361 (M+1).
Example 10
Synthesis of (1E,6E)-1-(2,5-dichlorophenyl)-7-(4-hydroxy-3-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU184)
[0096] The title compound was synthesized using the same procedure employed for Example 2, but with 2,5-dichlorobenzaldehyde (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (7.4 mg, 22%) having the following characteristics.
[0097] 1 H NMR (δ, acetone-d 6 ): 3.92 (s, 3H), 6.11 (s, 1H), 6.79 (d, J=16 Hz, 1H), 6.89 (d, J=8.2 Hz, 1H), 7.01 (d, J=16 Hz, 1H), 7.22 (dd, J=˜2, 8.2 Hz, 1H), 7.38 (d, J=˜2 Hz, 1H), 7.45 (dd, J=2.4, 8.7 Hz, 1H), 7.54 (d, J=8.7 Hz, 1H), 7.68 (d, J=16 Hz, 1H), 7.90 (d, J=16 Hz, 1H), 7.92 (d, J=2.4 Hz, 1H).
[0098] Melting Point 142-147° C., MS (ESI+) m/z 391 (M+1), 413 (M+Na).
Example 11
Synthesis of (1E,6E)-1-(2,5-dichlorophenyl)-7-(3-hydroxy-4-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU185)
[0099] The title compound was synthesized using the same procedure employed for Example 3, but with 2,5-dichlorobenzaldehyde (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.8 mg, 20%) having the following characteristics.
[0100] 1 H NMR (δ, acetone-d 6 ): 3.90 (s, 3H), 6.13 (s, 1H), 6.74 (d, J=16 Hz, 1H), 7.01 (d, J=8.2 Hz, 1H), 7.03 (d, J=16 Hz, 1H), 7.18 (dd, J=1.9, 8.2 Hz, 1H), 7.23 (d, J=1.9 Hz, 1H), 7.45 (dd, J=2.4, 8.7 Hz, 1H), 7.54 (d, J=8.7 Hz, 1H), 7.64 (d, J=16 Hz, 1H), 7.90 (d, J=16 Hz, 1H), 7.94 (d, J=2.4 Hz, 1H).
[0101] Melting Point 140-146° C., MS (ESI+) m/z 391 (M+1), 413 (M+Na).
Example 12
Synthesis of (1E,6E)-1-(4-dimethylamino-2-nitrophenyl)-7-(4-hydroxy-3-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU192)
[0102] The title compound was synthesized using the same procedure employed for Example 2, but with 4-dimethylamino-2-nitrobenzaldehyde (21 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.4 mg, 18%) having the following characteristics.
[0103] 1 H NMR (δ, acetone-d 6 ): 3.13 (s, 6H), 3.92 (s, 3H), 5.99 (s, 1H), 6.70 (d, J=16 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 6.88 (d, J=8.2 Hz, 1H), 7.05 (dd, J=2.9, 9.2 Hz, 1H), 7.16 (d, J=2.9 Hz, 1H), 7.18 (dd, J=˜2, 8.2 Hz, 1H), 7.34 (d, J=˜2 Hz, 1H), 7.61 (d, J=16 Hz, 1H), 7.81 (d, J=16 Hz, 1H), 7.82 (d, J=9.2 Hz, 1H), 8.1 (br s, OH).
[0104] Melting Point 203-210° C., MS (ESI+) m/z 411 (M+1).
Example 13
Synthesis of (1E,6E)-1-(4-dimethylamino-2-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU194)
[0105] The title compound was synthesized using the same procedure employed for Example 1, but with 4-dimethylamino-2-nitrobenzaldehyde (21 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (8.4 mg, 26%) having the following characteristics.
[0106] 1 H NMR (δ, acetone-d 6 ): 3.12 (s, 6H), 5.99 (s, 1H), 6.68 (d, J=16 Hz, 1H), 6.71 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 7.04 (dd, J=2.4, 8.7 Hz, 1H), 7.15 (d, J=2.4 Hz, 1H), 7.57 (d, J=8.7 Hz, 2H), 7.62 (d, J=16 Hz, 1H), 7.81 (d, J=16 Hz, 1H), 7.82 (d, J=8.7 Hz, 1H), 8.9 (br s, OH).
[0107] Melting Point 217-222° C., MS (ESI+) m/z 381 (M+1).
Example 14
Synthesis of (1E,6E)-1-(2-chloro-4-dimethylaminophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU195)
[0108] The title compound was synthesized using the same procedure employed for Example 1, but with 2-chloro-4-dimethylaminobenzaldehyde (20 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (3.8 mg, 12%) having the following characteristics.
[0109] 1 H NMR (δ, acetone-d 6 ): 3.06 (s, 6H), 5.96 (s, 1H), 6.65 (d, J=16 Hz, 1H), 6.67 (d, J=16 Hz, 1H), 6.73˜6.78 (m, 2H), 6.90 (d, J=8.7 Hz, 2H), 7.57 (d, J=8.7 Hz, 2H), 7.60 (d, J=16 Hz, 1H), 7.75 (d, J=9.7 Hz, 1H), 8.00 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0110] Melting Point decomposed at 112° C., MS (ESI+) m/z 370 (M+1), 392 (M+Na).
Example 15
Synthesis of (1E,6E)-1-(2-chloro-4-dimethylaminophenyl)-7-(4-hydroxy-3-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU196)
[0111] The title compound was synthesized using the same procedure employed for Example 2, but with 2-chloro-4-dimethylaminobenzaldehyde (20 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (4.4 mg, 13%) having the following characteristics.
[0112] 1 H NMR (δ, acetone-d 6 ): 3.06 (s, 6H), 3.92 (s, 3H), 5.95 (s, 1H), 6.64 (d, J=16 Hz, 1H), 6.71 (d, J=16 Hz, 1H), 6.73˜6.78 (m, 2H), 6.88 (d, J=8.2 Hz, 1H), 7.18 (dd, J=1.9, 8.2 Hz, 1H), 7.34 (d, J=1.9 Hz, 1H), 7.59 (d, J=16 Hz, 1H), 7.74 (d, J=9.7 Hz, 1H), 7.99 (d, J=16 Hz, 1H), 8.1 (br s, OH).
[0113] Melting Point 113-120° C., MS (ESI+) m/z 400 (M+1).
Example 16
Synthesis of (1E,6E)-1-(4-dimethylamino-2-nitrophenyl)-7-(3-hydroxy-4-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU197)
[0114] The title compound was synthesized using the same procedure employed for Example 3, but with 4-dimethylamino-2-nitrobenzaldehyde (21 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (7.0 mg, 20%) having the following characteristics.
[0115] 1 H NMR (δ, acetone-d 6 ): 3.13 (s, 6H), 3.89 (s, 3H), 6.01 (s, 1H), 6.69 (d, J=16 Hz, 1H), 6.72 (d, J=16 Hz, 1H), 7.00 (d, J=˜2, 8.7 Hz, 1H), 7.05 (dd, J=˜2, 8.7 Hz, 1H), 7.14 (dd, J=˜2, 8.7 Hz, 1H), 7.15 (d, J=˜2 Hz, 1H), 7.21 (d, J=˜2 Hz, 1H), 7.57 (d, J=16 Hz, 1H), 7.8 (br s, OH), 7.81 (d, J=16 Hz, 1H), 7.83 (d, J=8.7 Hz, 1H).
[0116] Melting Point 183-186° C., MS (ESI+) m/z 411 (M+1), 433 (M+Na).
Example 17
Synthesis of (1E,6E)-1-(2-chloro-4-dimethylaminophenyl)-7-(3-hydroxy-4-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU202)
[0117] The title compound was synthesized using the same procedure employed for Example 3, but with 2-chloro-4-dimethylaminobenzaldehyde (20 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (12.6 mg, 37%) having the following characteristics.
[0118] 1 H NMR (δ, acetone-d 6 ): 3.06 (s, 6H), 3.89 (s, 3H), 5.97 (s, 1H), 6.65 (d, J=16 Hz, 1H), 6.67 (d, J=16 Hz, 1H), 6.73˜6.78 (m, 2H), 6.99 (d, J=8.2 Hz, 1H), 7.14 (dd, J=2.4, 8.2 Hz, 1H), 7.20 (d, J=2.4 Hz, 1H), 7.55 (d, J=16 Hz, 1H), 7.74 (d, J=9.7 Hz, 1H), 7.8 (br s, 1H), 8.00 (d, J=16 Hz, 1H).
[0119] Melting Point 160-164° C., MS (ESI+) m/z 400 (M+1), 422 (M+Na).
Example 18
Synthesis of (1E,6E)-1-(2,5-dichlorophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU229)
[0120] The title compound was synthesized using the same procedure employed for Example 1, but with 2,5-dichlorobenzaldehyde (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (11.8 mg, 38%) having the following characteristics.
[0121] 1 H NMR (δ, acetone-d 6 ): 6.11 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.01 (d, J=16 Hz, 1H), 7.44 (dd, J=˜2, 8 Hz, 1H), 7.55 (d, J=8 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 7.90 (d, J=16 Hz, 1H), 7.92 (d, J=˜2 Hz, 1H).
[0122] MS (ESI+) m/z 361 (M+1).
Example 19
Synthesis of (1E,6E)-1,7-bis(2-chloro-4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU362)
[0123] Acetylacetone (10.3 μL, 100 μmol) and boron trioxide (25 mg, 0.40 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.45 mL of ethyl acetate. To the stirring solution at 80° C. were added 2-chloro-4-hydroxybenzaldehyde (39 mg, 0.25 mmol) and tri-n-butyl borate (57 μL, 0.21 mmol), successively. After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (22 μL, 0.22 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (3 mL) of 1N HCl and brine at room temperature, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized with saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound as a solid (13.8 mg, 37%) having the following characteristics.
[0124] 1 H NMR (δ, acetone-d 6 ): 6.04 (s, 1H), 6.77 (d, J=16 Hz, 2H), 6.89 (dd, J=2, 8.7 Hz, 2H), 6.98 (d, J=2 Hz, 2H), 7.79 (d, J=8.7 Hz, 2H), 7.99 (d, J=16 Hz, 2H).
[0125] Melting Point 248-254° C., MS (ESI+) m/z 377.0 (M+1).
Example 20
Synthesis of (1E,6E)-1,7-bis(5-hydroxy-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU381)
[0126] The title compound was synthesized using the same procedure employed for Example 19, but with 5-hydroxy-2-nitrobenzaldehyde (42 mg, 0.25 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (39 mg, 0.25 mmol). The product was obtained as a solid (7.8 mg, 20%) having the following characteristics.
[0127] 1 H NMR (δ, acetone-d 6 ): 6.24 (s, 1H), 6.78 (d, J=16 Hz, 2H), 7.07 (dd, J=2.4, 9.2 Hz, 2H), 7.23 (d, J=2 Hz, 2H), 8.09 (d, J=9.2 Hz, 2H), 8.17 (d, J=16 Hz, 2H).
[0128] Melting Point 253-262° C., MS (ESI+) m/z 399.1 (M+1), 421.1 (M+Na).
Example 21
Synthesis of (1E,6E)-1,7-bis(4-dimethylamino-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU411)
[0129] The title compound was synthesized using the same procedure employed for Example 19, but with 4-dimethylamino-2-nitrobenzaldehyde (49 mg, 0.25 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (39 mg, 0.25 mmol). The product was obtained as a solid (13.6 mg, 30%) having the following characteristics.
[0130] 1 H NMR (δ, acetone-d 6 ): 3.13 (s, 12H), 6.02 (s, 1H), 6.74 (d, J=16 Hz, 2H), 7.05 (dd, J=3, 9 Hz, 2H), 7.17 (d, J=3 Hz, 2H), 7.82 (d, J=16 Hz, 2H), 7.84 (d, J=9 Hz, 2H).
[0131] Melting Point 245-250° C., MS (ESI+) m/z 453.4 (M+1), 475.3 (M+Na).
Example 22
Synthesis of (1E,6E)-1,7-bis(2-chloro-4-dimethylaminophenyl)hepta-1,6-diene-3,5-dione(CU412)
[0132] The title compound was synthesized using the same procedure employed for Example 19, but with 2-chloro-4-dimethylaminobenzaldehyde (46 mg, 0.25 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (39 mg, 0.25 mmol). The product was obtained as a solid (18.8 mg, 44%) having the following characteristics.
[0133] 1 H NMR (δ, acetone-d 6 ): 3.06 (s, 12H), 5.94 (s, 1H), 6.66 (d, J=16 Hz, 2H), 6.7˜6.8 (m, 4H), 7.75 (d, J=9.7 Hz, 2H), 7.99 (d, J=16 Hz, 2H).
[0134] Melting Point 238-241° C., MS (ESI+) m/z 431.3 (M+1).
Example 23
Synthesis of (1E,6E)-1-(5-chloro-2-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU465)
[0135] The title compound was synthesized using the same procedure employed for Example 1, but with 5-chloro-2-nitrobenzaldehyde (21 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (16.4 mg, 50%) having the following characteristics.
[0136] 1 H NMR (δ, acetone-d 6 ): 6.14 (s, 1H), 6.74 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.98 (d, J=16 Hz, 1H), 7.61 (d, J=8.7 Hz, 2H), 7.69 (dd, J=2.4, 8.7 Hz, 1H), 7.69 (d, J=16 Hz, 1H), 7.94 (d, J=16 Hz, 1H), 7.99 (d, J=2.4 Hz, 1H), 8.12 (d, J=8.7 Hz, 1H).
[0137] Melting Point 241-250° C., MS (ESI+) m/z 372.4 (M+1).
Example 24
Synthesis of (1E,6E)-1-(5-bromo-2-fluorophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU466)
[0138] The title compound was synthesized using the same procedure employed for Example 1, but with 5-bromo-2-fluorobenzaldehyde (24 μL, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (11.4 mg, 33%) having the following characteristics.
[0139] 1 H NMR (δ, acetone-d 6 ): 6.11 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.02 (d, J=16 Hz, 1H), 7.22 (dd, J=8.7, 10.6 Hz, 1H), 7.58˜7.63 (m, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.66 (d, J=16 Hz, 1H), 7.68 (d, J=16 Hz, 1H), 7.99 (dd, J=2.4, 6.8 Hz, 1H).
[0140] Melting Point 177-203° C., MS (ESI+) m/z 389.3 (M+1).
Example 25
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-(2-trifluoromethylphenyl)hepta-1,6-diene-3,5-dione(CU467)
[0141] The title compound was synthesized using the same procedure employed for Example 1, but with 2-trifluoromethylbenzaldehyde (20 μL, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (14.8 mg, 47%) having the following characteristics.
[0142] 1 H NMR (δ, acetone-d 6 ): 6.10 (s, 1H), 6.74 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.93 (d, J=16 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.62 (d, J=16 Hz, 1H), 7.68 (d, J=16 Hz, 1H), 7.73 (t, J=8 Hz, 1H), 7.81 (d, J=7.7 Hz, 1H), 7.96 (m, 1H), 8.02 (d, J=8.2 Hz, 1H).
[0143] Melting Point 181-185° C., MS (ESI+) m/z 361.4 (M+1).
Example 26
Synthesis of (1E,6E)-1-(2-chloro-5-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU470)
[0144] The title compound was synthesized using the same procedure employed for Example 1, but with 2-chloro-5-nitrobenzaldehyde (21 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (14.6 mg, 45%) having the following characteristics.
[0145] 1 H NMR (δ, acetone-d 6 ): 6.20 (s, 1H), 6.75 (d, J=16 Hz, 1H), 6.92 (d, J=8.7 Hz, 2H), 7.19 (d, J=16 Hz, 1H), 7.61 (d, J=8.7 Hz, 2H), 7.71 (d, J=16 Hz, 1H), 7.82 (d, J=8.7 Hz, 1H), 7.95 (d, J=16 Hz, 1H), 8.24 (dd, J=2.9, 8.7 Hz, 1H), 8.68 (d, J=2.9 Hz, 1H).
[0146] MS (ESI+) m/z 371.9 (M+1).
Example 27
Synthesis of (1E,6E)-1-(4-bromo-2-fluorophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU471)
[0147] The title compound was synthesized using the same procedure employed for Example 1, but with 4-bromo-2-fluorobenzaldehyde (23 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (9.0 mg, 26%) having the following characteristics.
[0148] 1 H NMR (δ, acetone-d 6 ): 6.10 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.96 (d, J=16 Hz, 1H), 7.46˜7.54 (m, 2H), 7.59 (d, J=8.7 Hz, 2H), 7.67 (d, J=16 Hz, 1H), 7.67 (d, J=16 Hz, 1H), 7.77 (dd, J=8, 9 Hz, 1H).
[0149] Melting Point 223-232° C., MS (ESI+) m/z 389.2 (M+1).
Example 28
Synthesis of (1E,6E)-1-(biphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU472)
[0150] The title compound was synthesized using the same procedure employed for Example 1, but with 2-phenylbenzaldehyde (20 μL, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.6 mg, 20%) having the following characteristics.
[0151] 1 H NMR (δ, acetone-d 6 ): 5.99 (s, 1H), 6.68 (d, J=16 Hz, 1H), 6.82 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 7.34˜7.53 (m, 8H), 7.58 (d, J=8.7 Hz, 2H), 7.62 (d, J=16 Hz, 1H), 7.66 (d, J=16 Hz, 1H), 7.77 (dd, J=1.5, 7˜8 Hz, 1H).
[0152] Melting Point 180-188° C., MS (ESI+) m/z 369.3 (M+1), 391.3 (M+Na).
Example 29
Synthesis of (1E,6E)-1-(2-fluoro-5-trifluoromethylphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU473)
[0153] The title compound was synthesized using the same procedure employed for Example 1, but with 2-fluoro-5-trifluoromethylbenzaldehyde (22 μL, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (2.6 mg, 8%) having the following characteristics.
[0154] 1 H NMR (δ, acetone-d 6 ): 6.14 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.92 (d, J=8.7 Hz, 2H), 7.12 (d, J=16 Hz, 1H), 7.48 (dd, J=9, 10 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.69 (d, J=16 Hz, 1H), 7.74 (d, J=16 Hz, 1H), 7.81 (m, 1H), 8.19 (dd, J=7˜8 Hz, 1H).
[0155] Melting Point 168-174° C., MS (ESI+) m/z 379.3 (M+1).
Example 30
Synthesis of (1E,6E)-1-(5-benzyloxy-2-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU475)
[0156] (1) Synthesis of 5-benzyloxy-2-nitrobenzaldehyde
[0157] To a suspension of 5-hydroxy-2-nitrobenzaldehyde (300 mg, 1.80 mmol), potassium carbonate (498 mg, 3.60 mmol), and tetrabutylammonium iodide (66 mg, 0.18 mmol) in 1.8 mL of dry N,N-dimethylformamide was added benzyl bromide (0.32 mL, 2.7 mmol) at 0° C. After being stirred at room temperature until the starting material disappeared (5 h), the reaction mixture was filtered to remove inorganic salts. The filtrate was diluted with diethyl ether, and the solution was washed with water, saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=90/10 to 75/25) to obtain the title compound as a slightly yellow solid (405 mg, 87%).
[0000] (2) Synthesis of (1E,6E)-1-(5-benzyloxy-2-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU475)
[0158] The title compound was synthesized using the same procedure employed for Example 1, but with 5-benzyloxy-2-nitrobenzaldehyde (29 mg, 11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (17.8 mg, 46%) having the following characteristics.
[0159] 1 H NMR (δ, acetone-d 6 ): 5.35 (s, 2H), 6.10 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.84 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.25 (dd, J=2.9, 9.2 Hz, 1H), 7.35˜7.48 (m, 4H), 7.55 (d, J=8.2 Hz, 2H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 8.10 (d, J=16 Hz, 1H), 8.14 (d, J=9.2 Hz, 1H).
[0160] Melting Point 168-172° C., MS (ESI+) m/z 466.1 (M+Na).
Example 31
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-(2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU477)
[0161] The title compound was synthesized using the same procedure employed for Example 1, but with 2-nitrobenzaldehyde (17 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (5.4 mg, 18%) having the following characteristics.
[0162] MS (ESI+) m/z 338.3 (M+1).
Example 32
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(methoxycarbonyl)phenyl]hepta-1,6-diene-3,5-dione(CU478)
[0163] The title compound was synthesized using the same procedure employed for Example 1, but with methyl 2-formylbenzoate (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (12.4 mg, 40%) having the following characteristics.
[0164] 1 H NMR (δ, acetone-d 6 ): 3.92 (s, 3H), 6.08 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.75 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.52 (dd, J=7, 7.7 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.64 (dd, J=7, 7.7 Hz, 1H), 7.66 (d, J=16 Hz, 1H), 7.86 (d, J=7.7 Hz, 1H), 7.95 (d, J=7.7 Hz, 1H), 8.42 (d, J=16 Hz, 1H).
[0165] Melting Point 145-150° C., MS (ESI+) m/z 351.5 (M+1), 373.4 (M+Na).
Example 33
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-(5-methoxy-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU481)
[0166] (1) Synthesis of 5-methoxy-2-nitrobenzaldehyde
[0167] To a solution of 5-hydroxy-2-nitrobenzaldehyde (300 mg, 1.80 mmol) in 3.6 mL of dry N,N-dimethylformamide was added sodium hydride (94 mg, 55%, 2.1 mmol) under nitrogen at 0° C. After the reaction mixture was stirred at room temperature for 30 min, methyl iodide (0.17 mL, 2.7 mmol) was added with additional stirring for 30 min. After the reaction mixture was quenched with saturated NH 4 Cl aqueous solution at 0° C., the solution was extracted with ether. The extract was washed with saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=80/20 to 70/30) to obtain the title compound as a slightly yellow powder (298 mg, 91%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-(5-methoxy-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU481)
[0168] The title compound was synthesized using the same procedure employed for Example 1, but with 5-methoxy-2-nitrobenzaldehyde (21 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (10.4 mg, 32%) having the following characteristics.
[0169] 1 H NMR (δ, acetone-d 6 ): 4.01 (s, 3H), 6.10 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.84 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.17 (dd, J=2.9, 9.2 Hz, 1H), 7.36 (d, J=3 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 8.10 (d, J=16 Hz, 1H), 8.14 (d, J=9.2 Hz, 1H).
[0170] Melting Point 151-155° C., MS (ESI+) m/z 368.5 (M+1), 390.5 (M+Na).
Example 34
Synthesis of (1E,6E)-1-(2-bromophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU486)
[0171] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromobenzaldehyde (21 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (22.2 mg, 68%) having the following characteristics.
[0172] 1 H NMR (δ, acetone-d 6 ): 6.09 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.87 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.33 (ddd, J=˜2, 7.3, 7˜8 Hz, 1H), 7.45 (dd, J=7.3, 7.7 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.67 (d, J=16 Hz, 1H), 7.70 (dd, J=˜2, 7.3 Hz, 1H), 7.88 (dd, J=˜2, 7.7 Hz, 1H), 7.98 (d, J=16 Hz, 1H).
[0173] Melting Point 155-159° C., MS (ESI+) m/z 371.4 (M+1).
Example 35
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[5-(4-methoxybenzyloxy)-2-nitrophenyl]hepta-1,6-diene-3,5-dione(CU490)
[0174] (1) Synthesis of 5-(4-methoxybenzyloxy)-2-nitrobenzaldehyde
[0175] The title compound was synthesized using the same procedure employed for Example 30 (1), but with 4-methoxybenzyl chloride instead of benzyl bromide (silica gel column chromatography: hexane/ethyl acetate=90/10 to 70/30). The product was obtained as a slightly yellow powder (462 mg, 89%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[5-(4-methoxybenzyloxy)-2-nitrophenyl]hepta-1,6-diene-3,5-dione(CU490)
[0176] The title compound was synthesized using the same procedure employed for Example 1, but with 5-(4-methoxybenzyloxy)-2-nitrobenzaldehyde (33 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (13.6 mg, 33%) having the following characteristics.
[0177] 1 H NMR (δ, acetone-d 6 ): 3.82 (s, 3H), 5.26 (s, 2H), 6.10 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.84 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.99 (d, J=8.7 Hz, 2H), 7.23 (dd, J=2.9, 8.7 Hz, 1H), 7.44 (d, J=2.9 Hz, 1H), 7.46 (d, J=8.7 Hz, 2H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 8.10 (d, J=16 Hz, 1H), 8.13 (d, J=8.7 Hz, 1H).
[0178] MS (ESI+) m/z 496.5 (M+Na).
Example 36
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-nitro-5-(pyridin-3-ylmethoxy)phenyl]hepta-1,6-diene-3,5-dione(CU491)
[0179] (1) Synthesis of 2-nitro-5-(pyridin-3-ylmethoxy)benzaldehyde
[0180] The title compound was synthesized using the same procedure employed for Example 30 (1), but with 3-(chloromethyl)pyridine hydrochloride instead of benzyl bromide (silica gel column chromatography: hexane/ethyl acetate=60/40 to 30/70). The product was obtained as a slightly yellow powder (49 mg, 11%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-nitro-5-(pyridin-3-ylmethoxy)phenyl]hepta-1,6-diene-3,5-dione(CU491)
[0181] The title compound was synthesized using the same procedure employed for Example 1, but with 2-nitro-5-(pyridin-3-ylmethoxy)benzaldehyde (30 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (4.8 mg, 12%) having the following characteristics.
[0182] 1 H NMR (δ, acetone-d 6 ): 5.42 (s, 2H), 6.10 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.86 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.29 (dd, J=2.9, 9.2 Hz, 1H), 7.45 (dd, J=5.4, 7.7 Hz, 1H), 7.51 (d, J=3 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 7.95 (br d, J=8.2 Hz, 1H), 8.10 (d, J=16 Hz, 1H), 8.16 (d, J=9.2 Hz, 1H), 8.60 (dd, J=˜2, 5 Hz, 1H), 8.76 (d, J=˜2 Hz, 1H).
[0183] MS (ESI+) m/z 445.6 (M+1).
Example 37
Synthesis of (1E,6E)-1-[5-(2-chloro-6-fluorobenzyloxy)-2-nitrophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU492)
[0184] (1) Synthesis of 5-(2-chloro-6-fluorobenzyloxy)-2-nitrobenzaldehyde
[0185] The title compound was synthesized using the same procedure employed for Example 30 (1), but with 2-chloro-6-fluorobenzyl chloride instead of benzyl bromide (silica gel column chromatography: hexane/ethyl acetate=90/10 to 70/30). The product was obtained as a slightly yellow powder (487 mg, 87%).
[0000] (2) Synthesis of (1E,6E)-1-[5-(2-chloro-6-fluorobenzyloxy)-2-nitrophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU492)
[0186] The title compound was synthesized using the same procedure employed for Example 1, but with 5-(2-chloro-6-fluorobenzyloxy)-2-nitrobenzaldehyde (35 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (11.2 mg, 26%) having the following characteristics.
[0187] 1 H NMR (δ, acetone-d 6 ): 5.47 (d, J=1.5 Hz, 1H), 6.11 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.91 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.29 (dd, J=9, 10 Hz, 1H), 7.30 (dd, J=2.9, 9.2 Hz, 1H), 7.43 (d, J=8.2 Hz, 1H), (m, 1H), 7.53 (d, J=2.9 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 8.11 (d, J=16 Hz, 1H), 8.17 (d, J=9.2 Hz, 1H).
[0188] Melting Point 180-183° C., MS (ESI+) m/z 496.5 (M+1), 518.5 (M+Na).
Example 38
Synthesis of (1E,6E)-1-[5-(2,4-dichlorobenzyloxy)-2-nitrophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU493)
[0189] (1) Synthesis of 5-(2,4-dichlorobenzyloxy)-2-nitrobenzaldehyde
[0190] The title compound was synthesized using the same procedure employed for Example 30 (1), but with 2,4-dichlorobenzyl chloride instead of benzyl bromide (purified by recrystallization (hexane/ethyl acetate) instead of silica gel column chromatography). The product was obtained as a slightly yellow powder (289 mg, 49%).
[0000] (2) Synthesis of (1E,6E)-1-[5-(2,4-dichlorobenzyloxy)-2-nitrophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU493)
[0191] The title compound was synthesized using the same procedure employed for Example 1, but with 5-(2,4-dichlorobenzyloxy)-2-nitrobenzaldehyde (37 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (18.4 mg, 41%) having the following characteristics.
[0192] 1 H NMR (δ, acetone-d 6 ): 5.42 (s, 1H), 6.10 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.87 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.29 (dd, J=2.4, 9.2 Hz, 1H), 7.48 (dd, J=1.9, 8.2 Hz, 1H), 7.52 (d, J=2.4 Hz, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.61 (d, J=1.9 Hz, 1H), 7.68 (d, J=16 Hz, 1H), 7.72 (d, J=8.2 Hz, 1H), 8.10 (d, J=16 Hz, 1H), 8.16 (d, J=9.2 Hz, 1H).
[0193] Melting Point 157-161° C., MS (ESI+) m/z 512.3 (M+1), 534.4 (M+Na).
Example 39
Synthesis of (1E,6E)-1-[5-(4-tert-butylbenzyloxy)-2-nitrophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU494)
[0194] (1) Synthesis of 5-(4-tert-butylbenzyloxy)-2-nitrobenzaldehyde
[0195] The title compound was synthesized using the same procedure employed for Example 30 (1), but with 4-tert-butylbenzyl chloride instead of benzyl bromide (silica gel column chromatography: hexane/ethyl acetate=90/10). The product was obtained as a slightly yellow oil (476 mg, 84%).
[0000] (2) Synthesis of (1E,6E)-1-[5-(4-tert-butylbenzyloxy)-2-nitrophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU494)
[0196] The title compound was synthesized using the same procedure employed for Example 1, but with 5-(4-tert-butylbenzyloxy)-2-nitrobenzaldehyde (36 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (26.0 mg, 59%) having the following characteristics.
[0197] 1 H NMR (δ, acetone-d 6 ): 1.33 (s, 9H), 5.31 (s, 1H), 6.10 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.84 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.24 (dd, J=2.4, 9.2 Hz, 1H), 7.44˜7.5 (m, 5H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 8.11 (d, J=16 Hz, 1H), 8.14 (d, J=9.2 Hz, 1H).
[0198] MS (ESI+) m/z 500.6 (M+1), 522.6 (M+Na).
Example 40
Synthesis of (E)-1-(2-chloro-4-hydroxyphenyl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU522)
[0199] (1) Synthesis of 6-(4-hydroxyphenyl)hexane-2,4-dione
[0200] To a solution of 6-(4-hydroxyphenyl)hex-5-ene-2,4-dione (1.00 g, 4.90 mmol) in 50 mL of ethyl acetate was added palladium 5% on carbon (200 mg) under nitrogen. After the vessel was purged with hydrogen, the reaction mixture was stirred under 1 atm of hydrogen at room temperature for 12 h. After the vessel was purged with nitrogen, the reaction mixture was filtered to remove palladium 5% on carbon. The filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=70/30 to 60/40) to obtain the title compound as a colorless oil (802 mg, 80%) having the following characteristics.
[0201] 1 H NMR (δ, acetone-d 6 ): 2.00 (s, 3H×0.7), 2.14 (s, 3H×0.3), 2.56 (t, J=7.7 Hz, 2H×0.7), 2.74˜2.84 (m, 2H+2H×0.3), 3.65 (2H×0.3), 5.64 (s, 1H×0.7), 6.73 (d, J=8.7 Hz, 2H×0.3), 6.74 (d, J=8.7 Hz, 2H×0.7), 7.03 (d, J=8.7 Hz, 2H×0.3), 7.05 (d, =8.7 Hz, 2H×0.7), 8.1 (br s, 1H, OH).
[0202] MS (ESI+) m/z 207.3 (M+1).
[0000] (2) Synthesis of (E)-1-(2-chloro-4-hydroxyphenyl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU522)
[0203] 6-(4-Hydroxyphenyl)hexane-2,4-dione (18 mg, 87 μmol) and boron trioxide (22 mg, 0.32 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.4 mL of ethyl acetate. To the stirring solution at 80° C. were added 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 umol) and tri-n-butyl borate (50 μL, 0.19 mmol). After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (19 μL, 0.19 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (1 mL) of 1N HCl and brine, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized by saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound as a solid (9.2 mg, 34%) having the following characteristics.
[0204] 1 H NMR (δ, acetone-d 6 ): 2.70 (t, J=8 Hz, 2H), 2.86 (t, J=8 Hz, 2H), 5.82 (s, 1H), 6.61 (d, J=16 Hz, 1H), 6.75 (d, J=8.7 Hz, 2H), 6.87 (d, J=2.4, 8.7 Hz, 1H), 6.96 (d, J=2.4 Hz, 1H), 7.07 (d, J=8.7 Hz, 2H), 7.74 (d, J=8.7 Hz, 1H), 7.89 (d, J=16 Hz, 1H).
[0205] MS (ESI+) m/z 345.4 (M+1), 367.4 (M+Na).
Example 41
Synthesis of (E)-1-(4-dimethylamino-2-nitrophenyl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU523)
[0206] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 4-dimethylamino-2-nitrobenzaldehyde (15 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (12.2 mg, 41%) having the following characteristics.
[0207] 1 H NMR (δ, acetone-d 6 ): 2.68 (t, J=8 Hz, 2H), 2.86 (t, J=8 Hz, 2H), 3.12 (s, 6H), 5.81 (s, 1H), 6.58 (d, J=16 Hz, 1H), 6.74 (d, J=8.7 Hz, 2H), 7.04 (d, J=2.4, 9.2 Hz, 1H), 7.07 (d, J=8.7 Hz, 2H), 7.15 (d, J=2.4 Hz, 1H), 7.75 (d, J=16 Hz, 1H), 7.79 (d, J=9.2 Hz, 1H), 8.1 (br s, 1H, OH).
[0208] Melting Point 136-142° C., MS (ESI+) m/z 383.5 (M+1), 405.4 (M+Na).
Example 42
Synthesis of (E)-1-(2-chloro-4-dimethylaminophenyl)-7-(4-hydroxyphenyl)hept-1-ent-3,5-dione(CU524)
[0209] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 2-chloro-4-dimethylaminobenzaldehyde (14 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (15.6 mg, 54%) having the following characteristics.
[0210] 1 H NMR (δ, acetone-d 6 ): 2.66 (t, J=8 Hz, 2H), 2.86 (t, J=8 Hz, 2H), 3.05 (s, 6H), 5.77 (s, 1H), 6.52 (d, J=16 Hz, 1H), 6.7˜6.76 (m, 4H), 7.07 (d, J=8.7 Hz, 2H), 7.70 (d, J=9.7 Hz, 1H), 7.93 (d, J=16 Hz, 1H), 8.1 (br s, 1H, OH).
[0211] Melting Point 120-129° C., MS (ESI+) m/z 372.5 (M+1).
Example 43
Synthesis of (E)-1-(biphenyl-2-yl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU525)
[0212] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 2-phenylbenzaldehyde (15 μL, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (13.8 mg, 48%) having the following characteristics.
[0213] 1 H NMR (δ, acetone-d 6 ): 2.68 (t, J=8 Hz, 2H), 2.84 (t, J=8 Hz, 2H), 5.81 (s, 1H), 6.68 (d, J=16 Hz, 1H), 6.74 (d, J=8.7 Hz, 2H), 7.06 (d, J=8.7 Hz, 2H), 7.32˜7.52 (m, 8H), 7.59 (d, J=16 Hz, 1H), 7.86 (dd, J=1.5, 7.3 Hz, 1H), 8.1 (br s, 1H, OH).
[0214] MS (ESI+) m/z 371.5 (M+1), 393.5 (M+Na).
Example 44
Synthesis of (1E,6E)-1-(4-hydroxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU526)
[0215] (1) Synthesis of 4-hydroxybiphenyl-2-carboxyaldehyde
[0216] To a suspension of 2-bromo-5-hydroxybenzaldehyde (300 mg, 1.49 mmol), sodium carbonate (190 mg, 1.79 mmol), and phenylboronic acid (272 mg, 2.23 mmol) in 3.0 mL of N,N-dimethylformamide/water (2:1) was added palladium acetate (17 mg, 76 μmol) under nitrogen. After being stirred at room temperature overnight, the reaction mixture was filtered. The filtrate was diluted with diethyl ether, and the solution was washed with brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=80/20 to 70/30) to obtain the title compound as a slightly yellow powder (242 mg, 82%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU526)
[0217] The title compound was synthesized using the same procedure employed for Example 1, but with 4-hydroxybiphenyl-2-carboxyaldehyde (23 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (15.8 mg, 47%) having the following characteristics.
[0218] 1 H NMR (δ, acetone-d 6 ): 5.98 (s, 1H), 6.67 (d, J=16 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 6.99 (dd, J=2.4, 8.2 Hz, 1H), 7.24 (d, J=8.2 Hz, 1H), 7.28˜7.34 (m, 3H), 7.39 (dd, J=7, 8 Hz, 1H), 7.46 (dd, J=7, 8 Hz, 2H), 7.57 (d, J=8.7 Hz, 2H), 7.61 (d, J=16 Hz, 1H), 7.62 (d, J=16 Hz, 1H).
[0219] Melting Point 179-186° C., MS (ESI+) m/z 385.4 (M+1), 407.4 (M+Na).
Example 45
Synthesis of (1E,6E)-1-(4-benzyloxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU527)
[0220] (1) Synthesis of 4-benzyloxybiphenyl-2-carboxyaldehyde
[0221] To a suspension of 4-hydroxybiphenyl-2-carboxyaldehyde (80 mg, 0.40 mmol), potassium carbonate (111 mg, 0.80 mmol), and tetrabutylammonium iodide (15 mg, 0.04 mmol) in 0.8 mL of dry N,N-dimethylformamide was added benzyl bromide (72 μL, 0.60 mmol) at 0° C. After being stirred at room temperature overnight, the reaction mixture was diluted with diethyl ether. The solution was washed with water, saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=95/5 to 80/20) to obtain the title compound as a white crystal (112 mg, 77%).
[0000] (2) Synthesis of (1E,6E)-1-(4-benzyloxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU527)
[0222] The title compound was synthesized using the same procedure employed for Example 1, but with 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (22.6 mg, 54%) having the following characteristics.
[0223] 1 H NMR (δ, acetone-d 6 ): 5.26 (s, 2H), 5.97 (s, 1H), 6.67 (d, J=16 Hz, 1H), 6.85 (d, J=16 Hz, 111), 6.90 (d, J=8.7 Hz, 2H), 7.16 (dd, J=2.4, 8.7 Hz, 1H), 7.3˜7.5 (m, 8H), 7.44 (d, J=8.7 Hz, 1H), 7.51˜7.59 (m, 3H), 7.55 (d, J=8.7 Hz, 2H), 7.62 (d, J=16 Hz, 1H), 7.64 (d, J=16 Hz, 1H).
[0224] Melting Point 172-178° C., MS (ESI+) m/z 475.5 (M+1), 497.4 (M+Na).
Example 46
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(naphthalen-1-yl)phenyl]hepta-1,6-diene-3,5-dione(CU528)
[0225] (1) Synthesis of 2-(naphthalen-1-yl)benzaldehyde
[0226] To a suspension of 2-bromobenzaldehyde (200 μL, 1.71 mmol), sodium carbonate (218 mg, 2.06 mmol), and 1-naphthaleneboronic acid (353 mg, 2.05 mmol) in 3.4 mL of N,N-dimethylformamide/water (2:1) was added palladium acetate (20 mg, 89 μmol) under nitrogen. After being stirred at room temperature overnight, the reaction mixture was filtered. The filtrate was diluted with diethyl ether, and the solution was washed with saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=90/10 to 80/20) to obtain the title compound as a white solid (346 mg, 87%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(naphthalen-1-yl)phenyl]hepta-1,6-diene-3,5-dione(CU528)
[0227] The title compound was synthesized using the same procedure employed for Example 1, but with 2-(naphthalen-1-yl)benzaldehyde (27 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (17.0 mg, 46%) having the following characteristics.
[0228] 1 H NMR (δ, acetone-d 6 ): 5.86 (s, 1H), 6.60 (d, J=16 Hz, 1H), 6.79 (d, J=16 Hz, 1H), 6.88 (d, J=8.7 Hz, 2H), 7.26 (d, J=16 Hz, 1H), 7.36˜7.46 (m, 4H), 7.5˜7.6 (m, 6H), 7.62 (dd, J=7, 9 Hz, 1H), 8.0˜8.05 (m, 3H).
[0229] Melting Point 95-101° C., MS (ESI+) m/z 419.4 (M+1), 441.4 (M+Na).
Example 47
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(naphthalen-2-yl)phenyl]hepta-1,6-diene-3,5-dione(CU529)
[0230] (1) Synthesis of 2-(naphthalen-2-yl)benzaldehyde
[0231] The title compound was synthesized using the same procedure employed for Example 46 (1), but with 2-naphthaleneboronic acid instead of 1-naphthaleneboronic acid. The product was obtained as a colorless oil (192 mg, 48%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(naphthalen-2-yl)phenyl]hepta-1,6-diene-3,5-dione(CU529)
[0232] The title compound was synthesized using the same procedure employed for Example 1, but with 2-(naphthalen-2-yl)benzaldehyde (27 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (15.8 mg, 43%) having the following characteristics.
[0233] 1 H NMR (δ, acetone-d 6 ): 5.99 (s, 1H), 6.65 (d, J=16 Hz, 1H), 6.85 (d, J=16 Hz, 1H), 6.89 (d, J=8.7 Hz, 2H), 7.46˜7.62 (m, 9H), 7.71 (d, J=16 Hz, 1H), 7.89 (s, 1H), 7.95 (d, J=7.2 Hz, 1H), 7.96˜8.02 (m, 2H), 8.03 (d, J=8.2 Hz, 1H).
[0234] Melting Point 105-114° C., MS (ESI+) m/z 441.4 (M+Na).
Example 48
Synthesis of (E)-1-(5-hydroxy-2-nitrophenyl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU530)
[0235] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 5-hydroxy-2-nitrobenzaldehyde (13 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (6.0 mg, 22%) having the following characteristics.
[0236] 1 H NMR (δ, acetone-d 6 ): 2.74 (t, J=8 Hz, 2H), 2.87 (t, J=8 Hz, 2H), 5.91 (s, 1H), 6.60 (d, J=16 Hz, 1H), 6.75 (d, J=8.7 Hz, 2H), 7.03 (dd, J=2, 8.7 Hz, 1H), 7.08 (d, J=8.7 Hz, 2H), 7.17 (d, J=2 Hz, 1H), 8.04 (d, J=16 Hz, 1H), 8.06 (d, J=8.7 Hz, 1H).
[0237] Melting Point 62-70° C., MS (ESI+) m/z 356.4 (M+1), 378.4 (M+Na).
Example 49
Synthesis of (1E,6E)-1-(5-benzyloxy-2-bromophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU531)
[0238] (1) Synthesis of 5-benzyloxy-2-bromobenzaldehyde
[0239] To a suspension of 2-bromo-5-hydroxybenzaldehyde (100 mg, 0.50 mmol), potassium carbonate (138 mg, 1.00 mmol), and tetrabutylammonium iodide (18 mg, 0.05 mmol) in 1.0 mL of dry N,N-dimethylformamide was added benzyl bromide (89 μL, 0.74 mmol) at 0° C. After being stirred at room temperature overnight, the reaction mixture was diluted with diethyl ether. The solution was washed with water, saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=95/5 to 80/20) to obtain the title compound as a colorless oil (140 mg, 97%).
[0000] (2) Synthesis of (1E,6E)-1-(5-benzyloxy-2-bromophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU531)
[0240] The title compound was synthesized using the same procedure employed for Example 1, but with 5-benzyloxy-2-bromobenzaldehyde (33 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (4.2 mg, 10%) having the following characteristics.
[0241] MS (ESI+) m/z 377.4 (M+1).
Example 50
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU532)
[0242] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol, prepared according to the procedure described in Synthetic Communications, (2007), 37, 579) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (25.6 mg, 75%) having the following characteristics.
[0243] 1 H NMR (δ, acetone-d 6 ): 6.08 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.77 (d, J=16 Hz, 1H), 6.86 (d, J=8.7 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.31 (br s, 1H), 7.49 (d, J=8.7 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.67 (d, J=16 Hz, 1H), 7.90 (d, J=16 Hz, 1H).
[0244] Melting Point 182-186° C., MS (ESI+) m/z 387.4 (M+1).
Example 51
Synthesis of (1E,6E)-1-[5-hydroxy-2-(naphthalen-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU538)
[0245] (1) Synthesis of 5-hydroxy-2-(naphthalen-1-yl)benzaldehyde
[0246] To a suspension of 2-bromo-5-hydroxybenzaldehyde (300 mg, 1.49 mmol), sodium carbonate (190 mg, 1.79 mmol), and 1-naphthaleneboronic acid (384 mg, 2.23 mmol) in 3.0 mL of N,N-dimethylformamide/water (2:1) was added palladium acetate (18 mg, 80 μmol) under nitrogen. After being stirred at room temperature overnight, the reaction mixture was filtered. The filtrate was diluted with ethyl acetate, and the solution was washed with saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=85/15 to 75/25) to obtain the title compound as a white solid (274 mg, 74%).
[0000] (2) Synthesis of (1E,6E)-1-[5-hydroxy-2-(naphthalen-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU538)
[0247] The title compound was synthesized using the same procedure employed for Example 1, but with 5-hydroxy-2-(naphthalen-1-yl)benzaldehyde (28 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (26.2 mg, 69%) having the following characteristics.
[0248] 1 H NMR (δ, acetone-d 6 ): 5.85 (s, 1H), 6.59 (d, J=16 Hz, 1H), 6.69 (d, J=16 Hz, 1H), 6.88 (d, J=8.7 Hz, 2H), 7.06 (d, J=2.4, 8.2 Hz, 1H), 7.20 (d, J=8.2 Hz, 1H), 7.21 (d, J=16 Hz, 1H), 7.35 (d, J=6.8 Hz, 1H), 7.4˜7.61 (m, 8H), 7.98 (d, J=8.2 Hz, 1H), 7.99 (d, J=8.2 Hz, 1H), 8.8 (br s, 1H, OH).
[0249] Melting Point 215-221° C., MS (ESI+) m/z 435.4 (M+1), 457.4 (M+Na).
Example 52
Synthesis of (1E,6E)-1-(2-bromo-4-hydroxy-5-methoxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU539)
[0250] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-4-hydroxy-5-methoxybenzaldehyde (26 mg, 0.11 mmol, prepared according to the procedure described in J. Org. Chem., (2002), 67, 6493) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (24.2 mg, 66%) having the following characteristics.
[0251] 1 H NMR (δ, acetone-d 6 ): 3.94 (s, 3H), 5.99 (s, 1H), 6.68 (d, J=16 Hz, 1H), 6.79 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.13 (s, 1H), 7.48 (s, 1H), 7.57 (d, J=8.7 Hz, 2H), 7.63 (d, J=16 Hz, 1H), 7.93 (d, J=16 Hz, 1H).
[0252] Melting Point 237-242° C., MS (ESI+) m/z 417.3 (M+1), 439.3 (M+Na).
Example 53
Synthesis of (E)-1-(4-hydroxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU541)
[0253] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 4-hydroxybiphenyl-2-carboxyaldehyde (16 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (15.0 mg, 50%) having the following characteristics.
[0254] 1 H NMR (δ, acetone-d 6 ): 2.68 (t, J=8 Hz, 2H), 2.84 (t, J=8 Hz, 2H), 5.81 (s, 1H), 6.59 (d, J=16 Hz, 1H), 6.74 (d, J=8.2 Hz, 2H), 6.98 (dd, J=2.9, 8.2 Hz, 1H), 7.06 (d, J=8.2 Hz, 2H), 7.23 (d, J=8.2 Hz, 1H), 7.28 (d, J=2.9 Hz, 1H), 7.29 (d, J=7 Hz, 2H), 7.38 (t, J=7 Hz, 1H), 7.45 (dd, J=7, 7 Hz, 2H), 7.55 (d, J=16 Hz, 1H).
[0255] Melting Point 148-158° C., MS (ESI+) m/z 387.4 (M+1), 409.4 (M+Na).
Example 54
Synthesis of (E)-1-[5-hydroxy-2-(naphthalen-1-yl)phenyl]-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU542)
[0256] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 5-hydroxy-2-(naphthalen-1-yl)benzaldehyde (20 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (17.2 mg, 51%) having the following characteristics.
[0257] 1 H NMR (δ, acetone-d 6 ): 2.60 (t, J=8 Hz, 2H), 2.77 (t, J=8 Hz, 2H), 5.68 (s, 1H), 6.56 (d, J=16 Hz, 1H), 6.72 (d, J=8.2 Hz, 2H), 7.01 (d, J=8.2 Hz, 2H), 7.04 (dd, J=2.4, 8.2 Hz, 1H), 7.14 (d, J=16 Hz, 1H), 7.19 (d, J=8.2 Hz, 1H), 7.34 (d, J=6.8 Hz, 1H), 7.40 (d, J=2.4 Hz, 1H), 7.4˜7.54 (m, 3H), 7.58 (dd, J=7.2, 8.2 Hz, 1H), 7.97 (d, J=8.2 Hz, 1H), 7.98 (d, J=8.2 Hz, 1H).
[0258] Melting Point 138-142° C., MS (ESI+) m/z 437.4 (M+1), 459.5 (M+Na).
Example 55
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxy-4-methoxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU543)
[0259] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-5-hydroxy-4-methoxybenzaldehyde (26 mg, 0.11 mmol, prepared according to the procedure described in Zhejiang Daxue Xuebao, Gongxueban, (2006), 40, 520) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (13.2 mg, 36%) having the following characteristics.
[0260] 1 H NMR (δ, acetone-d 6 ): 3.93 (s, 3H), 6.04 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.72 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.21 (s, 1H), 7.35 (s, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.64 (d, J=16 Hz, 1H), 7.90 (d, J=16 Hz, 1H).
[0261] Melting Point 224-229° C., MS (ESI+) m/z 417.3 (M+1).
Example 56
Synthesis of (1E,6E)-1-(2,4-dibromo-5-hydroxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU544)
[0262] The title compound was synthesized using the same procedure employed for Example 1, but with 2,4-dibromo-5-hydroxybenzaldehyde (32 mg, 0.11 mmol, prepared according to the procedure described in Tetrahedron: Asymmetry, (2002), 13, 2261) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (17.2 mg, 42%) having the following characteristics.
[0263] 1 H NMR (δ, acetone-d 6 ): 6.07 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.75 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.44 (s, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.67 (d, J=16 Hz, 1H), 7.82 (s, 1H), 7.82 (d, J=16 Hz, 1H).
[0264] Melting Point 255-259° C., MS (ESI+) m/z 465.2 (M+1).
Example 57
Synthesis of (E)-1-(5-benzyloxy-2-nitrophenyl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU548)
[0265] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 5-benzyloxy-2-nitrobenzaldehyde (20 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (6.8 mg, 20%) having the following characteristics.
[0266] 1 H NMR (δ, acetone-d 6 ): 2.74 (t, J=8 Hz, 2H), 2.87 (t, J=8 Hz, 2H), 5.34 (s, 2H), 5.90 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.75 (d, J=8.7 Hz, 2H), 7.07 (d, J=8.7 Hz, 2H), 7.24 (dd, J=2.9, 9.2 Hz, 1H), 7.36˜7.46 (m, 3H), 7.44 (d, J=2.9 Hz, 1H), 7.52 (d, J=7.2 Hz, 2H), 8.04 (d, J=16 Hz, 1H), 8.13 (d, J=9.2 Hz, 1H).
[0267] MS (ESI+) m/z 446.5 (M+1), 468.5 (M+Na).
Example 58
Synthesis of (E)-1-(2-bromo-5-hydroxyphenyl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU549)
[0268] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 2-bromo-5-hydroxybenzaldehyde (16 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (8.0 mg, 26%) having the following characteristics.
[0269] 1 H NMR (δ, acetone-d 6 ): 2.73 (t, J=8 Hz, 2H), 2.87 (t, J=8 Hz, 2H), 5.89 (s, 1H), 6.65 (d, J=16 Hz, 1H), 6.75 (d, J=8.7 Hz, 2H), 6.84 (dd, J=2.9, 8.7 Hz, 1H), 7.08 (d, J=8.7 Hz, 2H), 7.26 (d, J=2.9 Hz, 1H), 7.48 (d, J=8.7 Hz, 1H), 7.83 (d, J=16 Hz, 1H).
[0270] Melting Point 161-165° C., MS (ESI+) m/z 389.2 (M+1), 411.2 (M+Na).
Example 59
Synthesis of (1E,6E)-1-[2-chloro-4-(2-dimethylaminoethoxy)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU551)
[0271] (1) Synthesis of 2-chloro-4-(2-dimethylaminoethoxy)benzaldehyde
[0272] A suspension of 2-chloro-4-hydroxybenzaldehyde (234 mg, 1.49 mmol), (2-chloroethyl)dimethylamine hydrochloride (536 mg, 3.72 mmol), potassium carbonate (514 mg, 3.72 mmol), and tetrabutylammonium iodide (55 mg, 0.15 mmol) in 4.0 mL of acetonitrile was stirred at 115° C. overnight in a sealed tube. After the reaction mixture was diluted with water, the solution was extracted with ethyl acetate. The extract was washed with brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (chloroform/methanol=99/1 to 94/6) to obtain the title compound as a brown oil (137 mg, 40%).
[0000] (2) Synthesis of (1E,6E)-1-[2-chloro-4-(2-dimethylaminoethoxy)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione (CU551)
[0273] The title compound was synthesized using the same procedure employed for Example 1, but with 2-chloro-4-(2-dimethylaminoethoxy)benzaldehyde (25 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (4.2 mg, 12%) having the following characteristics.
[0274] 1 H NMR (δ, acetone-d 6 ): 2.26 (s, 6H), 2.69 (t, J=5.8 Hz, 2H), 4.18 (t, J=5.8 Hz, 2H), 6.04 (s, 1H), 6.70 (d, J=16 Hz, 1H), 6.79 (d, J=16 Hz, 1H), 6.88 (d, J=8.7 Hz, 2H), 6.99 (dd, J=2.4, 8.7 Hz, 1H), 7.10 (d, J=2.4 Hz, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.64 (d, J=16 Hz, 1H), 7.85 (d, J=8.7 Hz, 1H), 7.97 (d, J=16 Hz, 1H), 8.0 (s, 1H).
[0275] Melting Point 170-173° C., MS (ESI+) m/z 414 (M+1).
Example 60
Synthesis of (1E,6E)-1-[2-bromo-5-(2-dimethylaminoethoxy)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU552)
[0276] (1) Synthesis of 2-bromo-5-(2-dimethylaminoethoxy)benzaldehyde
[0277] The title compound was synthesized using the same procedure employed for Example 59 (1), but with 2-bromo-5-hydroxybenzaldehyde (300 mg, 1.49 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (234 mg, 1.49 mmol). The product was obtained as a brown oil (45 mg, 11%).
[0000] (2) Synthesis of (1E,6E)-1-[2-bromo-5-(2-dimethylaminoethoxy)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU552)
[0278] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-5-(2-dimethylaminoethoxy)benzaldehyde (30 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (3.0 mg, 7%) having the following characteristics.
[0279] 1 H NMR (δ, acetone-d 6 ): 2.27 (s, 6H), 2.70 (t, J=5.8 Hz, 2H), 4.16 (t, J=5.8 Hz, 2H), 6.08 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.92 (d, J=16 Hz, 1H), 6.96 (dd, J=2.9, 9 Hz, 1H), 7.44 (d, J=2.9 Hz, 1H), 7.57 (d, J=9 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.67 (d, J=16 Hz, 1H), 7.91 (d, J=16 Hz, 1H).
[0280] Melting Point 163-167° C., MS (ESI+) m/z 458 (M+1).
Example 61
Synthesis of (E)-1-[2-chloro-4-(2-dimethylaminoethoxy)phenyl]-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU553)
[0281] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 2-chloro-4-(2-dimethylaminoethoxy)benzaldehyde (18 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (4.6 mg, 13%) having the following characteristics.
[0282] 1 H NMR (δ, acetone-d 6 ): 2.26 (s, 6H), 2.69 (t, J=5.8 Hz, 2H), 2.71 (t, J=7.7 Hz, 2H), 2.86 (t, J=7.7 Hz, 2H), 4.17 (t, J=5.8 Hz, 2H), 5.84 (s, 1H), 6.66 (d, J=16 Hz, 1H), 6.74 (d, J=8.7 Hz, 2H), 6.98 (dd, J=2.4, 8.7 Hz, 1H), 7.07 (d, J=8.7 Hz, 2H), 7.08 (d, J=2.4 Hz, 1H), 7.81 (d, J=8.7 Hz, 1H), 7.90 (d, J=16 Hz, 1H).
[0283] MS (ESI+) m/z 416 (M+1).
Example 62
Synthesis of (1E,6E)-1-(4-fluoro-2-trifluoromethylphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU554)
[0284] The title compound was synthesized using the same procedure employed for Example 1, but with 4-fluoro-2-trifluoromethylbenzaldehyde (21 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.8 mg, 20%) having the following characteristics.
[0285] 1 H NMR (δ, acetone-d 6 ): 6.09 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.91 (d, J=16 Hz, 1H), 7.5˜7.6 (m, 2H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 7.89 (dd, J=1.9, 16 Hz, 1H), 8.10 (dd, J=5.3, 8.7 Hz, 1H), 8.9 (br s, OH).
[0286] Melting Point 164-170° C., MS (ESI+) m/z 479 (M+1).
Example 63
Synthesis of (1E,6E)-1-(4-dimethylamino-2-trifluoromethylphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU555)
[0287] (1) Synthesis of 4-dimethylamino-2-trifluoromethylbenzaldehyde
[0288] A suspension of 4-fluoro-2-trifluoromethylbenzaldehyde (500 mg, 2.60 mmol), dimethylamine (5.5 mol/L in ethanol, 0.95 mL, 5.2 mmol), potassium carbonate (360 mg, 2.6 mmol) in 5.2 mL of N,N-dimethylformamide was stirred at 110° C. overnight in a sealed tube. After the reaction mixture was diluted with water, the solution was extracted with ether. The extract was washed with brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=85/15 to 75/25) to obtain the title compound as a pale yellow powder (393 mg, 70%).
[0000] (2) Synthesis of (1E,6E)-1-(4-dimethylamino-2-trifluoromethylphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU555)
[0289] The title compound was synthesized using the same procedure employed for Example 1, but with 4-dimethylamino-2-trifluoromethylbenzaldehyde (24 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (16.0 mg, 45%) having the following characteristics.
[0290] 1 H NMR (δ, acetone-d 6 ): 3.12 (s, 6H), 5.98 (s, 1H), 6.68 (d, J=16 Hz, 1H), 6.72 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 6.99 (d, J=8 Hz, 1H), 7.00 (s, 1H), 7.58 (d, J=8.7 Hz, 2H), 7.62 (d, J=16 Hz, 1H), 7.91 (d, J=8 Hz, 1H), 7.93 (dd, J=˜2, 16 Hz, 1H).
[0291] Melting Point 195-199° C., MS (ESI+) m/z 404 (M+1).
Example 64
Synthesis of (E)-1-(4-dimethylamino-2-trifluoromethylphenyl)-7-(4-hydroxyphenyl)hept-1-ene-3,5-dione(CU556)
[0292] The title compound was synthesized using the same procedure employed for Example 40 (2), but with 4-dimethylamino-2-trifluoromethylbenzaldehyde (17 mg, 78 μmol) instead of 2-chloro-4-hydroxybenzaldehyde (12 mg, 78 μmol). The product was obtained as a solid (20.3 mg, 64%) having the following characteristics.
[0293] 1 NMR (δ, acetone-d 6 ): 2.68 (t, J=7.2 Hz, 2H), 2.7˜2.9 (m, 2H), 3.10 (s, 6H), 5.79 (s, 1H), 6.59 (d, J=16 Hz, 1H), 6.74 (d, J=8.7 Hz, 2H), 6.98 (d, J=8 Hz, 1H), 6.99 (s, 1H), 7.07 (d, J=8.7 Hz, 2H), 7.85 (dd, J=˜2, 16 Hz, 1H), 7.86 (d, J=8 Hz, 1H), 8.1 (br s, OH).
[0294] Melting Point 110-114° C., MS (ESI+) m/z 406 (M+1).
Example 65
Synthesis of (1E,6E)-1-(4-benzyloxybiphenyl-2-yl)-7-(4-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU559)
[0295] (1) Synthesis of 6-(4-hydroxy-2-methoxyphenyl)hex-5-ene-2,4-dione
[0296] Ethyl acetate (7 mL), 2,4-pentanedione (9.6 mL, 94 mmol) and boron trioxide (5.9 g, 85 mmol) was placed in a 200 mL reaction vessel with a reflux condenser. To the stirring mixture at 85° C. was added dropwise a solution of 4-hydroxy-2-methoxybenzaldehyde (2.16 g, 14.2 mmol) and trimethyl orthoformate (1.6 mL, 14 mmol) in 14 mL of ethyl acetate. After the reaction mixture was stirred for 30 min at 95° C., n-butylamine (7.0 mL, 71 mmol) was added dropwise with additional stirring for 2 h. The reaction mixture was cooled to 50° C. before addition of 3N HCl (33 mL). After being stirred at 50° C. for 30 min, the mixture was filtered to remove solids. The filtrate was diluted with ethyl acetate, washed with brine twise, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=95/5 to 75/25) followed by recrystallization (hexane/ethyl acetate) to obtain the title compound as a pale yellow crystal (1.07 g, 33%).
[0297] 1H NMR (δ, acetone-d 6 ): 2.09 (s, 3H), 3.87 (s, 3H), 5.73 (s, 1H), 6.49 (d, J=8.7 Hz, 1H), 6.53 (s, 1H), 6.58 (d, J=16 Hz, 1H), 7.51 (d, J=8.7 Hz, 1H), 7.84 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0298] Melting Point 139-142° C., MS (ESI+) m/z 235.1 (M+1).
[0000] (2) Synthesis of (1E,6E)-1-(4-benzyloxybiphenyl-2-yl)-7-(4-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU559)
[0299] 6-(4-Hydroxy-2-methoxyphenyl)hex-5-ene-2,4-dione (20 mg, 85 μmol) and boron trioxide (11 mg, 0.16 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.4 mL of ethyl acetate. To the stirring mixture at 80° C. was added a solution of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol) and tri-n-butyl borate (25 μL, 93 μmol), sequentially. After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (10 μL, 0.10 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (1 mL) of 1N HCl and brine at room temperature, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized by saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound (16.8 mg, 39%) as a solid.
[0300] 1H NMR (δ, acetone-d 6 ): 3.89 (s, 3H), 5.26 (s, 2H), 5.94 (s, 1H), 6.51 (dd, J=2.4, 8.2 Hz, 1H), 6.54 (d, J=2.4 Hz, 1H), 6.71 (d, J=16 Hz, 1H), 6.85 (d, J=16 Hz, 1H), 7.16 (dd, J=2.4, 8.2 Hz, 1H), 7.4˜7.7 (m, 13H), 7.62 (d, J=16 Hz, 1H), 7.93 (d, J=16 Hz, 1H).
[0301] Melting Point 175-180° C., MS (ESI+) m/z 505 (M+1).
Example 66
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(4-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU561)
[0302] The title compound was synthesized using the same procedure employed for Example 65 (2), but with 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol) instead of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol). The product was obtained as a solid (11.6 mg, 33%) having the following characteristics.
[0303] 1 H NMR (δ, acetone-d 6 ): 3.90 (s, 3H), 6.04 (s, 1H), 6.52 (dd, J=2.4, 8.7 Hz, 1H), 6.55 (d, J=2.4 Hz, 1H), 6.77 (d, J=16 Hz, 1H), 6.78 (d, J=16 Hz, 1H), 6.86 (dd, J=2.9, 8.7 Hz, 1H), 7.30 (d, J=2.9 Hz, 1H), 7.49 (d, J=8.7 Hz, 1H), 7.57 (d, J=8.7 Hz, 1H), 7.89 (d, J=16 Hz, 1H), 7.97 (d, J=16 Hz, 1H).
[0304] Melting Point 92-98° C., MS (ESI+) m/z 417 (M+1).
Example 67
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU562)
[0305] (1) Synthesis of 6-(1H-indol-6-yl)hex-5-ene-2,4-dione
[0306] Ethyl acetate (7 mL), 2,4-pentanedione (9.35 mL, 90.9 mmol) and boron trioxide (5.76 g, 82.7 mmol) was placed in a 200 mL reaction vessel with a reflux condenser. To the stirring mixture at 85° C. was added dropwise a solution of 1H-indole-6-carboxaldehyde (2.00 g, 13.8 mmol) and trimethyl orthoformate (1.6 mL, 14 mmol) in 14 mL of ethyl acetate. After the reaction mixture was stirred for 30 min at 95° C., n-butylamine (6.8 mL, 69 mmol) was added dropwise with additional stirring for 2 h. The reaction mixture was cooled to 50° C. before addition of 3N HCl (32 mL). After being stirred at 50° C. for 30 min, the mixture was filtered to remove solids. The filtrate was diluted with ethyl acetate, washed with brine twise, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=95/5 to 75/25) followed by recrystallization (hexane/ethyl acetate) to obtain the title compound as a pale yellow crystal (0.92 g, 29%).
[0307] 1H NMR (δ, acetone-d 6 ): 2.12 (s, 3H), 5.82 (s, 1H), 6.52 (d, J=˜2 Hz, 1H), 6.67 (d, J=16 Hz, 1H), 7.40 (d, J=8.2 Hz, 1H), 7.45 (d, J=˜2 Hz, 1H), 7.60 (d, J=8.2 Hz, 1H), 7.70 (s, 1H), 7.72 (d, J=16 Hz, 1H), 10.5 (br s, NH).
[0308] Melting Point 138-142° C., MS (ESI+) m/z 228.3 (M+1).
[0000] (2) Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU562)
[0309] 6-(1H-Indol-6-yl)hex-5-ene-2,4-dione (19.4 mg, 85 μmol) and boron trioxide (11 mg, 0.16 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.4 mL of ethyl acetate. To the stirring mixture at 80° C. was added a solution of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol) and tri-n-butyl borate (25 μL, 93 μmol), sequentially. After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (10 μL, 0.10 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (1 mL) of 1N HCl and brine at room temperature, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized by saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound (7.0 mg, 19%) as a solid.
[0310] 1H NMR (δ, acetone-d 6 ): 6.13 (s, 1H), 6.53 (d, J=˜2 Hz, 1H), 6.79 (d, J=16 Hz, 1H), 6.86 (d, J=16 Hz, 1H), 6.86 (dd, J=2.9, 8.7 Hz, 1H), 7.31 (d, J=2.9 Hz, 1H), 7.46 (d, J=8.2 Hz, 1H), 7.48 (d, J=˜2 Hz, 1H), 7.50 (d, J=8.7 Hz, 1H), 7.63 (d, J=8.2 Hz, 1H), 7.76 (s, 1H), 7.85 (d, J=16 Hz, 1H), 7.91 (d, J=16 Hz, 1H), 8.8 (br s, OH), 10.5 (s, NH).
[0311] Melting Point 196-200° C., MS (ESI+) m/z 410 (M+1), 432 (M+Na).
Example 68
Synthesis of (1E,6E)-1-(4-benzyloxybiphenyl-2-yl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU566)
[0312] The title compound was synthesized using the same procedure employed for Example 67 (2), but with 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol) instead of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol). The product was obtained as a solid (8.8 mg, 20%) having the following characteristics.
[0313] 1H NMR (δ, acetone-d 6 ): 5.28 (s, 2H), 6.02 (s, 1H), 6.52 (d, J=˜2 Hz, 1H), 6.81 (d, J=16 Hz, 1H), 6.86 (d, J=16 Hz, 1H), 7.17 (dd, J=2.4, 8.7 Hz, 1H), 7.3˜7.6 (m, 13H), 7.62 (d, J=8 Hz, 1H), 7.63 (s, 1H), 7.64 (d, J=16 Hz, 1H), 7.74 (s, 1H), 7.79 (d, J=16 Hz, 1H).
[0314] Melting Point 178-183° C., MS (ESI+) m/z 498 (M+1), 520 (M+Na).
Example 69
Synthesis of (1E,6E)-1-(1H-indol-6-yl)-7-(2-trifluoromethylphenyl)hepta-1,6-diene-3,5-dione(CU571)
[0315] The title compound was synthesized using the same procedure employed for Example 67 (2), but with 2-trifluoromethylbenzaldehyde (20 μL, 0.11 mmol) instead of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol). The product was obtained as a solid (2.5 mg, 7%) having the following characteristics.
[0316] 1H NMR (δ, acetone-d 6 ): 6.15 (s, 1H), 6.53 (br s, 1H), 6.87 (d, J=16 Hz, 1H), 6.95 (d, J=16 Hz, 1H), 7.47 (d, J=8.2 Hz, 1H), 7.48 (br s, 1H), 7.62 (m, 1H), 7.63 (d, J=8.2 Hz, 1H), 7.77 (s, 1H), 7.74 (dd, J=7.7, 7.7 Hz, 1H), 7.82 (d, J=7.7 Hz, 1H), 7.86 (d, J=16 Hz, 1H), 7.97 (dd, J=˜2, 16 Hz, 1H), 8.04 (d, J=7.7 Hz, 1H), 10.5 (br s, NH).
[0317] Melting Point 178-182° C., MS (ESI+) m/z 373 (M+1), 395 (M+Na).
Example 70
Synthesis of (1E,6E)-1-(4-hydroxy-2-methoxyphenyl)-7-(2-trifluoromethylphenyl)hepta-1,6-diene-3,5-dione(CU574)
[0318] The title compound was synthesized using the same procedure employed for Example 65 (2), but with 2-trifluoromethylbenzaldehyde (20 μL, 0.11 mmol) instead of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol). The product was obtained as a solid (5.4 mg, 16%) having the following characteristics.
[0319] 1H NMR (δ, acetone-d 6 ): 3.90 (s, 3H), 6.06 (s, 1H), 6.52 (dd, J=2.4, 8.7 Hz, 1H), 6.55 (d, J=2.4 Hz, 1H), 6.78 (d, J=16 Hz, 1H), 6.93 (d, J=16 Hz, 1H), 7.58 (d, J=8.7 Hz, 1H), 7.61 (dd, J=7.7, 7.7 Hz, 1H), 7.73 (dd, J=7.7, 7.7 Hz, 1H), 7.81 (d, J=7.7 Hz, 1H), 7.95 (dd, J=˜2, 16 Hz, 1H), 7.99 (d, J=16 Hz, 1H), 8.03 (d, J=7.7 Hz, 1H).
[0320] Melting Point 176-180° C., MS (ESI+) m/z 391 (M+1), 413 (M+Na).
Example 71
Synthesis of (1E,6E)-1-(2-chloro-4-dimethylaminophenyl)-7-(4-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU581)
[0321] The title compound was synthesized using the same procedure employed for Example 65 (2), but with 2-chloro-4-dimethylaminobenzaldehyde (20 mg, 0.11 mmol) instead of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol). The product was obtained as a solid (13.0 mg, 38%) having the following characteristics.
[0322] 1H NMR (δ, acetone-d 6 ): 3.05 (s, 6H), 3.89 (s, 3H), 5.92 (s, 1H), 6.51 (dd, J=2.4, 8.7 Hz, 1H), 6.54 (d, J=2.4 Hz, 1H), 6.65 (d, J=16 Hz, 1H), 6.71 (d, J=16 Hz, 1H), 6.72˜6.78 (m, 2H), 7.55 (d, J=8.7 Hz, 1H), 7.74 (d, J=9.7 Hz, 1H), 7.91 (d, J=16 Hz, 1H), 7.99 (d, J=16 Hz, 1H).
[0323] Melting Point 187-192° C., MS (ESI+) m/z 400 (M+1).
Example 72
Synthesis of
[0324] (1E,6E)-1-(4-hydroxybiphenyl-2-yl)-7-(4-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU582)
[0325] The title compound was synthesized using the same procedure employed for Example 65 (2), but with 4-hydroxybiphenyl-2-carboxyaldehyde (23 mg, 0.11 mmol) instead of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol). The product was obtained as a solid (21.4 mg, 60%) having the following characteristics.
[0326] 1H NMR (δ, acetone-d 6 ): 3.89 (s, 3H), 5.92 (s, 1H), 6.51 (d, J=2.4, 8.7 Hz, 1H), 6.54 (d, J=2.4 Hz, 1H), 6.71 (d, J=16 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 6.98 (dd, J=2.4, 8.2 Hz, 1H), 7.24 (d, J=8.2 Hz, 1H), 7.28˜7.35 (m, 3H), 7.35˜7.5 (m, 3H), 7.55 (d, J=8.7 Hz, 1H), 7.61 (d, J=16 Hz, 1H), 7.93 (d, J=16 Hz, 1H).
[0327] Melting Point 108-114° C., MS (ESI+) m/z 415 (M+1), 437 (M+Na).
Example 73
Synthesis of (1E,6E)-1-(2-chloro-4-dimethylaminophenyl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU584)
[0328] The title compound was synthesized using the same procedure employed for Example 67 (2), but with 2-chloro-4-dimethylaminobenzaldehyde (20 mg, 0.11 mmol) instead of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol). The product was obtained as a solid (6.2 mg, 18%) having the following characteristics.
[0329] 1H NMR (δ, acetone-d 6 ): 3.06 (s, 6H), 6.00 (s, 1H), 6.52 (br s, 1H), 6.67 (d, J=16 Hz, 1H), 6.72˜6.78 (m, 2H), 6.81 (d, J=16 Hz, 1H), 7.44 (d, J=8.2 Hz, 1H), 7.46 (d, J=˜2 Hz, 1H), 7.62 (d, J=8.2 Hz, 1H), 7.73 (s, 1H), 7.75 (m, 1H), 7.78 (d, J=16 Hz, 1H), 8.01 (d, J=16 Hz, 1H), 10.5 (br s, NH).
[0330] Melting Point 180-185° C., MS (ESI+) m/z 393 (M+1).
Example 74
Synthesis of (1E,6E)-1-(4-hydroxy-2-methoxyphenyl)-7-(5-hydroxy-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU585)
[0331] The title compound was synthesized using the same procedure employed for Example 65 (2), but with 5-hydroxy-2-nitrobenzaldehyde (18 mg, 0.11 mmol) instead of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol). The product was obtained as a solid (9.6 mg, 29%) having the following characteristics.
[0332] 1H NMR (δ, acetone-d 6 ): 3.90 (s, 3H), 6.06 (s, 1H), 6.52 (d, J=2.4, 8.7 Hz, 1H), 6.55 (d, J=2.4 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 6.77 (d, J=16 Hz, 1H), 7.05 (dd, J=2.4, 9.2 Hz, 1H), 7.22 (d, J=2.4 Hz, 1H), 7.57 (d, J=8.7 Hz, 1H), 7.98 (d, J=16 Hz, 1H), 8.07 (d, J=9.2 Hz, 1H), 7.93 (d, J=16 Hz, 1H).
[0333] Melting Point 119-123° C., MS (ESI+) m/z 384 (M+1), 406 (M+Na).
Example 75
Synthesis of (1E,6E)-1-(5-benzyloxy-2-nitrophenyl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU588)
[0334] The title compound was synthesized using the same procedure employed for Example 67 (2), but with 5-benzyloxy-2-nitrobenzaldehyde (29 mg, 0.11 mmol) instead of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol). The product was obtained as a solid (3.1 mg, 8%) having the following characteristics.
[0335] 1H NMR (δ, acetone-d 6 ): 5.36 (s, 2H), 6.14 (s, 1H), 6.53 (d, J=2.4 Hz, 1H), 6.86 (d, J=16 Hz, 1H), 6.87 (d, J=16 Hz, 1H), 7.26 (dd, J=2.4, 8.7 Hz, 1H), 7.35˜7.5 (m, 6H), 7.54 (d, J=7.7 Hz, 2H), 7.63 (d, J=8.7 Hz, 1H), 7.77 (s, 1H), 7.86 (d, J=16 Hz, 1H), 8.11 (d, J=16 Hz, 1H), 8.15 (d, J=8.7 Hz, 1H), 10.5 (br s, NH).
[0336] Melting Point 181-186° C., MS (ESI+) m/z 467 (M+1), 489 (M+Na).
Example 76
Synthesis of (1E,6E)-1-(4-dimethylamino-2-nitrophenyl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU592)
[0337] The title compound was synthesized using the same procedure employed for Example 67 (2), but with 4-dimethylamino-2-nitrobenzaldehyde (21 mg, 0.11 mmol) instead of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol). The product was obtained as a solid (5.4 mg, 15%) having the following characteristics.
[0338] 1H NMR (δ, acetone-d 6 ): 3.13 (s, 6H), 6.04 (s, 1H), 6.52 (d, J=2.4 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 6.82 (d, J=16 Hz, 1H), 7.05 (dd, J=2.4, 9.2 Hz, 1H), 7.16 (d, J=2.4 Hz, 1H), 7.44 (dd, J=˜2, 9.2 Hz, 1H), 7.47 (m, 1H), 7.62 (d, J=9.2 Hz, 1H), 7.74 (s, 1H), 7.80 (d, J=16 Hz, 1H), 7.82 (d, J=16 Hz, 1H), 7.84 (d, J=9.2 Hz, 1H), 10.5 (br s, NH).
[0339] Melting Point 196-201° C., MS (ESI+) m/z 404 (M+1), 426 (M+Na).
Example 77
Synthesis of (1E,6E)-1-(5-benzyloxy-2-nitrophenyl)-7-(4-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU594)
[0340] The title compound was synthesized using the same procedure employed for Example 65 (2), but with 5-benzyloxy-2-nitrobenzaldehyde (29 mg, 0.11 mmol) instead of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol). The product was obtained as a solid (18.4 mg, 46%) having the following characteristics.
[0341] 1H NMR (δ, acetone-d 6 ): 3.90 (s, 1H), 5.35 (s, 2H), 6.05 (s, 1H), 6.51 (dd, J=2.4, 8.7 Hz, 1H), 6.55 (d, J=2.4 Hz, 1H), 6.77 (d, J=16 Hz, 1H), 6.84 (d, J=16 Hz, 1H), 7.24 (dd, J=2.4, 9.2 Hz, 1H), 7.35˜7.5 (m, 4H), 7.54 (d, J=6.8 Hz, 2H), 7.57 (d, J=8.7 Hz, 1H), 7.98 (d, J=16 Hz, 1H), 8.09 (d, J=16 Hz, 1H), 8.13 (d, J=9.2 Hz, 1H).
[0342] Melting Point 183-186° C., MS (ESI+) m/z 474 (M+1), 496 (M+Na).
Example 78
Synthesis of (1E,6E)-1-(5-hydroxy-2-nitrophenyl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU596)
[0343] The title compound was synthesized using the same procedure employed for Example 67 (2), but with 5-hydroxy-2-nitrobenzaldehyde (18 mg, 0.11 mmol) instead of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol). The product was obtained as a solid (4.6 mg, 14%) having the following characteristics.
[0344] 1H NMR (δ, acetone-d 6 ): 6.15 (s, 1H), 6.53 (d, J=2.9 Hz, 1H), 6.74 (d, J=16 Hz, 1H), 6.86 (d, J=16 Hz, 1H), 7.06 (dd, J=2.4, 8.7 Hz, 1H), 7.23 (d, J=2.4 Hz, 1H), 7.46 (dd, J=˜2, 8.7 Hz, 1H), 7.47 (m, 1H), 7.63 (d, J=8.7 Hz, 1H), 7.76 (s, 1H), 7.85 (d, J=16 Hz, 1H), 8.08 (d, J=8.7 Hz, 1H), 8.11 (d, J=16 Hz, 1H), 10.5 (br s, NH).
[0345] Melting Point 204-207° C., MS (ESI+) m/z 377 (M+1), 399 (M+Na).
Example 79
Synthesis of (1E,6E)-1-(2-chloro-4-hydroxyphenyl)-7-(4-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU600)
[0346] The title compound was synthesized using the same procedure employed for Example 65 (2), but with 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol) instead of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol). The product was obtained as a solid (10.4 mg, 33%) having the following characteristics.
[0347] 1H NMR (δ, acetone-d 6 ): 3.90 (s, 3H), 5.97 (s, 1H), 6.51 (dd, J=2.4, 8.7 Hz, 1H), 6.55 (d, J=2.4 Hz, 1H), 6.74 (d, J=16 Hz, 1H), 6.75 (d, J=16 Hz, 1H), 6.89 (dd, J=2.4, 8.7 Hz, 1H), 6.98 (d, J=2.4 Hz, 1H), 7.56 (d, J=8.7 Hz, 1H), 7.79 (d, J=8.7 Hz, 1H), 7.94 (d, J=16 Hz, 1H), 7.96 (d, J=16 Hz, 1H).
[0348] Melting Point 206-211° C., MS (ESI+) m/z 373 (M+1), 395 (M+Na).
Example 80
Synthesis of (1E,6E)-1-(2-chloro-4-hydroxyphenyl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU601)
[0349] The title compound was synthesized using the same procedure employed for Example 67 (2), but with 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol) instead of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol). The product was obtained as a solid (7.8 mg, 24%) having the following characteristics.
[0350] 1H NMR (δ, acetone-d 6 ): 6.06 (s, 1H), 6.53 (d, J=1.9 Hz, 1H), 6.76 (d, J=16 Hz, 1H), 6.83 (d, J=16 Hz, 1H), 6.90 (dd, J=2.4, 8.7 Hz, 1H), 6.99 (d, J=2.4 Hz, 1H), 7.44 (dd, J=˜2, 8.7 Hz, 1H), 7.47 (m, 1H), 7.62 (d, J=8.7 Hz, 1H), 7.75 (br s, 1H), 7.80 (d, J=8.7 Hz, 1H), 7.82 (d, J=16 Hz, 1H), 7.98 (d, J=16 Hz, 1H), 10.5 (br s, NH).
[0351] Melting Point 182-186° C., MS (ESI+) m/z 366 (M+1), 388 (M+Na).
Example 81
Synthesis of (1E,6E)-1-(4-dimethylamino-2-nitrophenyl)-7-(4-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU603)
[0352] The title compound was synthesized using the same procedure employed for Example 65 (2), but with 4-dimethylamino-2-nitrobenzaldehyde (21 mg, 0.11 mmol) instead of 4-benzyloxybiphenyl-2-carboxyaldehyde (33 mg, 0.11 mmol). The product was obtained as a solid (4.2 mg, 12%) having the following characteristics.
[0353] 1H NMR (δ, acetone-d 6 ): 3.13 (s, 6H), 3.89 (s, 3H), 5.96 (s, 1H), 6.51 (d, J=2.4, 8.7 Hz, 1H), 6.55 (d, J=2.4 Hz, 1H), 6.72 (d, J=16 Hz, 1H), 6.73 (d, =16 Hz, 1H), 7.05 (d, J=2.9, 8.7 Hz, 1H), 7.16 (d, J=2.9 Hz, 1H), 7.55 (d, J=8.7 Hz, 1H), 7.79 (d, J=16 Hz, 1H), 7.83 (d, J=8.7 Hz, 1H), 7.93 (d, J=16 Hz, 1H).
[0354] Melting Point 223-226° C., MS (ESI+) m/z 411 (M+1), 433 (M+Na).
Example 82
Synthesis of (1E,6E)-1-(4-hydroxybiphenyl-2-yl)-7-(1H-indol-6-yl)hepta-1,6-diene-3,5-dione(CU604)
[0355] The title compound was synthesized using the same procedure employed for Example 67 (2), but with 4-hydroxybiphenyl-2-carboxyaldehyde (23 mg, 0.11 mmol) instead of 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol). The product was obtained as a solid (12.0 mg, 33%) having the following characteristics.
[0356] 1H NMR (δ, acetone-d 6 ): 6.02 (s, 1H), 6.53 (d, J=˜2 Hz, 1H), 6.74 (d, J=16 Hz, 1H), 6.81 (d, J=16 Hz, 1H), 7.00 (dd, J=2.4, 8.2 Hz, 1H), 7.25 (d, J=8.2 Hz, 1H), 7.3˜7.35 (m, 3H), 7.35˜7.5 (m, 5H), 7.62 (d, J=8.2 Hz, 1H), 7.63 (d, J=16 Hz, 1H), 7.74 (br s, 1H), 7.79 (d, J=16 Hz, 1H), 10.5 (br s, NH).
[0357] Melting Point 185-191° C., MS (ESI+) m/z 408 (M+1), 430 (M+Na).
Example 83
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(5-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU608)
[0358] (1) Synthesis of 6-(2-bromo-5-hydroxyphenyl)hex-5-ene-2,4-dione
[0359] Ethyl acetate (3.1 mL), 2,4-pentanedione (4.25 mL, 41.4 mmol) and boron trioxide (2.6 g, 38 mmol) was placed in a 200 mL reaction vessel with a reflux condenser. To the stirring mixture at 85° C. was added dropwise a solution of 2-bromo-5-hydroxybenzaldehyde (1.26 g, 6.27 mmol) and trimethyl orthoformate (0.70 mL, 6.4 mmol) in 6 mL of ethyl acetate. After the reaction mixture was stirred for 30 min at 95° C., n-butylamine (3.1 mL, 31 mmol) was added dropwise with additional stirring for 2 h. The reaction mixture was cooled to 50° C. before addition of 3N HCl (15 mL). After being stirred at 50° C. for 30 min, the mixture was filtered to remove solids. The filtrate was diluted with ethyl acetate, washed with brine twise, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=85/15 to 75/25) twise followed by recrystallization (hexane/ethyl acetate) to obtain the title compound as a yellow crystal (0.12 g, 7%).
[0360] 1H NMR (δ, acetone-d 6 ): 2.16 (s, 3H), 5.88 (s, 1H), 6.65 (d, J=16 Hz, 1H), 6.85 (dd, J=2.9, 8.7 Hz, 1H), 7.27 (d, J=2.9 Hz, 1H), 7.48 (d, J=8.7 Hz, 1H), 7.84 (d, J=16 Hz, 1H), 8.8 (br s, OH).
[0361] 13C NMR (δ, acetone-d 6 ): 26.4, 101.8, 114.1, 114.2, 119.0, 125.7, 134.1, 135.6, 137.0, 157.3, 175.5, 199.4.
[0362] Melting Point 185-188° C., MS (ESI+) m/z 283.1 (M+1).
[0000] (2) Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(5-hydroxy-2-methoxyphenyl)hepta-1,6-diene-3,5-dione(CU608)
[0363] 6-(2-Bromo-5-hydroxyphenyl)hex-5-ene-2,4-dione (15 mg, 53 μmol) and boron trioxide (11 mg, 0.16 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.4 mL of ethyl acetate. To the stirring mixture at 80° C. was added a solution of 5-hydroxy-2-methoxybenzaldehyde (10 mg, 0.07 mmol) and tri-n-butyl borate (25 mL, 93 μmol), sequentially. After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (10 μL, 0.10 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (1 mL) of 1N HCl and brine at room temperature, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized by saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound (2.2 mg, 10%) as a solid.
[0364] 1H NMR (δ, acetone-d 6 ): 3.86 (s, 3H), 6.12 (s, 1H), 6.81 (d, J=16 Hz, 1H), 6.84 (d, J=16 Hz, 1H), 6.85˜7.0 (m, 3H), 7.16 (d, J=˜2 Hz, 1H), 7.31 (d, J=2.4 Hz, 1H), 7.50 (d, J=8.7 Hz, 1H), 7.92 (d, J=16 Hz, 1H), 7.99 (d, J=16 Hz, 1H), 8.1 (br s, OH), 8.8 (br s, OH).
[0365] Melting Point 90-96° C., MS (ESI+) m/z 417 (M+1), 439 (M+Na).
Example 84
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(2-chloro-4-dimethylaminophenyl)hepta-1,6-diene-3,5-dione(CU609)
[0366] The title compound was synthesized using the same procedure employed for Example 83 (2), but with 2-chloro-4-dimethylaminobenzaldehyde (13 mg, 0.07 mmol) instead of 5-hydroxy-2-methoxybenzaldehyde (10 mg, 0.07 mmol). The product was obtained as a solid (1.7 mg, 7%) having the following characteristics.
[0367] 1H NMR (δ, acetone-d 6 ): 3.07 (s, 6H), 6.06 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.75˜6.8 (m, 2H), 6.78 (d, J=16 Hz, 1H), 6.86 (dd, J=2.9, 8.7 Hz, 1H), 7.30 (d, J=2.9 Hz, 1H), 7.49 (d, J=8.7 Hz, 1H), 7.77 (d, J=9.7 Hz, 1H), 7.90 (d, J=16 Hz, 1H), 8.06 (d, J=16 Hz, 1H), 8.8 (br s, OH).
[0368] Melting Point 209-214° C., MS (ESI+) m/z 448 (M+1).
Example 85
Synthesis of (1E,6E)-1-(2-chloro-4-hydroxyphenyl)-7-(5-hydroxy-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU611)
[0369] (1) Synthesis of 6-(2-chloro-4-hydroxyphenyl)hex-5-ene-2,4-dione
[0370] Ethyl acetate (0.8 mL), 2,4-pentanedione (1.03 mL, 10.0 mmol) and boron trioxide (0.63 g, 9.1 mmol) was placed in a 200 mL reaction vessel with a reflux condenser. To the stirring mixture at 85° C. was added dropwise a solution of 2-chloro-4-hydroxybenzaldehyde (238 mg, 1.52 mmol) and trimethyl orthoformate (0.17 mL, 1.5 mmol) in 3.0 mL of ethyl acetate. After the reaction mixture was stirred for 30 min at 95° C., n-butylamine (0.80 mL, 7.6 mmol) was added dropwise with additional stirring for 2 h. The reaction mixture was cooled to 50° C. before addition of 3N HCl (3.5 mL). After being stirred at 50° C. for 30 min, the mixture was filtered to remove solids. The filtrate was diluted with ethyl acetate, washed with brine twise, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=85/15 to 75/25) followed by recrystallization (hexane/ethyl acetate) to obtain the title compound as a yellow crystal (56 mg, 12%).
[0371] 1H NMR (δ, acetone-d 6 ): 2.13 (s, 3H), 5.82 (s, 1H), 6.62 (d, J=16 Hz, 1H), 6.88 (dd, J=2.4, 8.7 Hz, 1H), 6.97 (d, J=2.4 Hz, 1H), 7.75 (d, J=8.7 Hz, 1H), 7.90 (d, J=16 Hz, 1H).
[0372] Melting Point 125-129° C., MS (ESI+) m/z 239.3 (M+1).
[0000] (2) Synthesis of (1E,6E)-1-(2-chloro-4-hydroxyphenyl)-7-(5-hydroxy-2-nitrophenyl)hepta-1,6-diene-3,5-dione(CU611)
[0373] 6-(2-Chloro-4-hydroxyphenyl)hex-5-ene-2,4-dione (20.3 mg, 85 μmol) and boron trioxide (11 mg, 0.16 mmol) was placed in a 20 mL reaction vessel, and dissolved in 0.4 mL of ethyl acetate. To the stirring mixture at 80° C. was added a solution of 5-hydroxy-2-nitrobenzaldehyde (18 mg, 0.11 mmol) and tri-n-butyl borate (25 μL, 93 μmol), sequentially. After the reaction mixture was stirred for 2 h at the same temperature, n-butylamine (10 μL, 0.10 mmol) was added with additional stirring for 1 h. The reaction mixture was treated with a 1:1 solution (1 mL) of 1N HCl and brine at room temperature, and was stirred at 50° C. for 5 min to 1 h (if necessary, the reaction mixture was neutralized by saturated NaHCO 3 aqueous solution). The organic layer was purified directly by silica gel column chromatography (eluting with hexane/ethyl acetate or chloroform/methanol) to obtain the title compound (3.5 mg, 7%) as a solid.
[0374] 1H NMR (δ, acetone-d 6 ): 6.15 (s, 1H), 6.76 (d, J=16 Hz, 1H), 6.82 (d, J=16 Hz, 1H), 6.90 (dd, J=˜2, 8.7 Hz, 1H), 7.00 (d, J=˜2 Hz, 1H), 7.07 (dd, J=˜2, 9.2 Hz, 1H), 7.24 (d, J=˜2 Hz, 1H), 7.83 (d, J=8.7 Hz, 1H), 8.04 (d, J=16 Hz, 1H), 8.08 (d, J=9.2 Hz, 1H), 8.13 (d, J=16 Hz, 1H).
[0375] Melting Point 132-136° C., MS (ESI+) m/z 388 (M+1), 410 (M+Na).
Example 86
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(4-hydroxy-3-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU612)
[0376] The title compound was synthesized using the same procedure employed for Example 2, but with 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (2.4 mg, 7%) having the following characteristics.
[0377] 1H NMR (δ, acetone-d 6 ): 3.93 (s, 3H), 6.08 (s, 1H), 6.77 (d, J=16 Hz, 1H), 6.77 (d, J=16 Hz, 1H), 6.86 (dd, J=2.9, 8.7 Hz, 1H), 6.89 (d, J=8.2 Hz, 1H), 7.21 (dd, J=1.9, 8.2 Hz, 1H), 7.29 (d, J=2.9 Hz, 1H), 7.37 (d, J=1.9 Hz, 1H), 7.49 (d, J=8.7 Hz, 1H), 7.66 (d, J=16 Hz, 1H), 7.90 (d, J=16 Hz, 1H), 8.8 (br s, OH).
[0378] Melting Point 210-215° C., MS (ESI+) m/z 417 (M+1).
Example 87
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(3-hydroxy-4-methyoxyphenyl)hepta-1,6-diene-3,5-dione(CU613)
[0379] The title compound was synthesized using the same procedure employed for Example 3, but with 2-bromo-5-hydroxybenzaldehyde (23 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.6 mg, 19%) having the following characteristics.
[0380] 1H NMR (δ, acetone-d 6 ): 3.91 (s, 3H), 6.10 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.78 (d, J=16 Hz, 1H), 6.86 (dd, J=2.9, 8.7 Hz, 1H), 7.01 (d, J=8.2 Hz, 1H), 7.17 (dd, J=1.9, 8.2 Hz, 1H), 7.22 (d, J=1.9 Hz, 1H), 7.31 (d, J=2.9 Hz, 1H), 7.49 (d, J=8.7 Hz, 1H), 7.63 (d, J=16 Hz, 1H), 7.8 (br s, OH), 7.91 (d, J=16 Hz, 1H), 8.8 (br s, OH).
[0381] Melting Point 90-94° C., MS (ESI+) m/z 417 (M+1).
Example 88
Synthesis of (1E,6E)-1,7-bis(2-bromo-5-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU614)
[0382] The title compound was synthesized using the same procedure employed for Example 19, but with 2-bromo-5-hydroxybenzaldehyde (50 mg, 0.25 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (39 mg, 0.25 mmol). The product was obtained as a solid (8.0 mg, 17%) having the following characteristics.
[0383] 1H NMR (δ, acetone-d 6 ): 6.18 (s, 1H), 6.83 (d, J=16 Hz, 2H), 6.88 (dd, J=2.9, 8.7 Hz, 2H), 7.32 (d, J=2.9 Hz, 2H), 7.50 (d, J=8.7 Hz, 2H), 7.96 (d, J=16 Hz, 2H), 8.8 (br s, OH).
[0384] Melting Point 239-243° C., MS (ESI+) m/z 465 (M+1).
Example 89
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(2-trifluoromethylphenyl)hepta-1,6-diene-3,5-dione(CU615)
[0385] The title compound was synthesized using the same procedure employed for Example 83 (2), but with 2-trifluoromethyl benzaldehyde (9 μL, 0.07 mmol) instead of 5-hydroxy-2-methoxybenzaldehyde (10 mg, 0.07 mmol). The product was obtained as a solid (1.1 mg, 5%) having the following characteristics.
[0386] 1H NMR (δ, acetone-d 6 ): 6.20 (s, 1H), 6.85 (d, J=16 Hz, 1H), 6.88 (dd, J=2.9, 8.7 Hz, 1H), 7.00 (d, J=16 Hz, 1H), 7.33 (d, J=2.9 Hz, 1H), 7.51 (d, J=8.7 Hz, 1H), 7.64 (dd, J=7.7, 7.7 Hz, 1H), 7.75 (dd, J=7.7, 7.7 Hz, 1H), 7.83 (d, J=7.7 Hz, 1H), 7.97 (d, J=16 Hz, 1H), 8.02 (d, J=16 Hz, 1H), 8.05 (d, J=7.7 Hz, 1H), 8.8 (br s, OH).
[0387] Melting Point 66-70° C., MS (ESI+) m/z 439 (M+1).
Example 90
Synthesis of (1E,6E)-1-(2-bromo-5-hydroxyphenyl)-7-(4-hydroxybiphenyl-2-yl)hepta-1,6-diene-3,5-dione(CU616)
[0388] The title compound was synthesized using the same procedure employed for Example 83 (2), but with 4-hydroxybiphenyl-2-carboxyaldehyde (14 mg, 0.07 mmol) instead of 5-hydroxy-2-methoxybenzaldehyde (10 mg, 0.07 mmol) The product was obtained as a solid (3.1 mg, 13%) having the following characteristics.
[0389] 1H NMR (δ, acetone-d 6 ): 6.08 (s, 1H), 6.78 (d, J=16 Hz, 1H), 6.79 (d, J=16 Hz, 1H), 6.87 (dd, J=2.9, 8.7 Hz, 1H), 7.01 (dd, J=˜2, 8.2 Hz, 1H), 7.26 (d, J=8.2 Hz, 1H), 7.2˜7.5 (m, 7H), 7.49 (d, J=8.7 Hz, 1H), 7.68 (d, J=16 Hz, 1H), 7.91 (d, J=16 Hz, 1H), 8.6 (br s, OH), 8.8 (br s, OH).
[0390] Melting Point 101-104° C., MS (ESI+) m/z 463 (M+1), 485 (M+Na).
Example 91
Synthesis of (1E,6E)-1-(2-benzoyloxy-4-diethylaminophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU425)
[0391] (1) Synthesis of 2-benzoyloxy-4-diethylaminobenzaldehyde
[0392] To a solution of 4-diethylamino-2-hydroxybenzaldehyde (300 mg, 1.55 mmol), pyridine (0.19 mL, 2.3 mmol) in 1.6 mL of dry dichloromethane was added benzoyl chloride (216 μL, 1.84 mmol) at 0° C. After being stirred at room temperature overnight, the reaction mixture was diluted with ethyl acetate. The mixture was washed with 1N HCl, saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=90/10 to 80/20) to obtain the title compound as a white solid (432 mg, 94%).
[0000] (2) Synthesis of (1E,6E)-1-(2-benzoyloxy-4-diethylaminophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU425)
[0393] The title compound was synthesized using the same procedure employed for Example 1, but with 2-benzoyloxy-4-diethylaminobenzaldehyde (34 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (13.8 mg, 32%) having the following characteristics.
[0394] 1 H NMR (δ, acetone-d 6 ): 1.20 (t, J=7 Hz, 6H), 3.49 (q, J=7 Hz, 4H), 5.81 (s, 1H), 6.58 (d, J=16 Hz, 1H), 6.61 (d, J=16 Hz, 1H), 6.65 (d, J=2.4 Hz, 1H), 6.73 (dd, J=2.4, 9.2 Hz, 1H), 6.89 (d, J=8.7 Hz, 2H), 7.52 (d, J=16 Hz, 1H), 7.53 (d, J=8.7 Hz, 2H), 7.66 (dd, J=7, 8 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 7.72 (d, J=9.2 Hz, 1H), 7.78 (m, 1H), 8.25 (dd, J=1.5, 8.2 Hz, 2H).
[0395] Melting Point 212-215° C., MS (ESI+) m/z 484.4 (M+1), 506.3 (M+Na).
Example 92
Synthesis of (1E,6E)-1,7-bis(2-benzoyloxy-4-diethylaminophenyl)hepta-1,6-diene-3,5-dione(CU427)
[0396] The title compound was synthesized using the same procedure employed for Example 19, but with 2-benzoyloxy-4-diethylaminobenzaldehyde (74 mg, 0.25 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (39 mg, 0.25 mmol). The product was obtained as a solid (12.2 mg, 19%) having the following characteristics.
[0397] 1 H NMR (δ, acetone-d 6 ): 1.19 (t, J=7 Hz, 12H), 3.48 (q, J=7 Hz, 8H), 5.66 (s, 1H), 6.53 (d, J=16 Hz, 2H), 6.63 (d, J=2.4 Hz, 2H), 6.71 (dd, J=2.4, 9.2 Hz, 2H), 7.61 (d, J=16 Hz, 2H), 7.63 (dd, J=7, 8 Hz, 4H), 7.68 (d, J=9.2 Hz, 2H), 7.76 (t, J=7 Hz, 2H), 8.22 (dd, J=1.5, 8 Hz, 4H).
[0398] Melting Point 192-196° C., MS (ESI+) m/z 659.5 (M+1).
Example 93
Synthesis of (1E,6E)-1-[2-(hydroxycarbonyl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU476)
[0399] The title compound was synthesized using the same procedure employed for Example 1, but with 2-formylbenzoic acid (17 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (9.0 mg, 30%) having the following characteristics.
[0400] MS (ESI+) m/z 359.4 (M+Na).
Example 94
Synthesis of (1E,6E)-1-[2-(dimethylaminocarbonyl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU479)
[0401] (1) Synthesis of 2-formyl-N,N-dimethylbenzamide
[0402] To a solution of 2-formylbenzoic acid (500 mg, 3.33 mmol), N,N-diisopropylethylamine (0.58 mL, 3.3 mmol), and dimethylamine/ethanol solution (1.2 mL, 5.6 M, 6.7 mmol) in 3.3 mL of dichloromethane was added 1-ethyl-3-(3-dimethylaminopropyl)-3-ethylcarbodiimide monohydrochloride (1.28 g, 6.67 mmol) at 0° C. After being stirred at room temperature overnight, the reaction mixture was diluted with diethyl ether. The solution was washed with 1N HCl, saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo to obtain the title compound as a slightly yellow oil (113 mg, 19%).
[0000] (2) Synthesis of (1E,6E)-1-[2-(dimethylaminocarbonyl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU479)
[0403] The title compound was synthesized using the same procedure employed for Example 1, but with 2-formyl-N,N-dimethylbenzamide (20 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (15.0 mg, 47%) having the following characteristics.
[0404] 1 H NMR (δ, acetone-d 6 ): 2.81 (s, 3H), 3.11 (s, 3H), 6.03 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.85 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.31 (m, 1H), 7.47 (m, 2H), 7.59 (d, J=8.7 Hz, 2H), 7.61 (d, J=16 Hz, 1H), 7.65 (d, J=16 Hz, 1H), 7.87 (m, 1H).
[0405] Melting Point 210-218° C., MS (ESI+) m/z 364.4 (M+1).
Example 95
Synthesis of (1E,6E)-1-[2-(dimethylaminosulfonyl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU480)
[0406] (1) Synthesis of 2-formyl-N,N-dimethylbenzenesulfonamide
[0407] To a solution of 2-sulfobenzaldehyde sodium salt (2.0 g, 9.6 mmol) in 0.8 mL of dry N,N-dimethylformamide was added thionyl chloride (7.0 mL, 96 mmol) under nitrogen at 0° C. After being stirred at 100° C. for 3 min, the reaction mixture was diluted with diethyl ether and water at 0° C., successively. The separated organic layer was washed with water, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo to obtain crude 2-formylbenzenesulfonyl chloride (0.75 g).
[0408] To a solution of the above product, pyridine (0.57 mL, 7.0 mmol), and N,N-dimethylaminopyridine (21 mg, 0.17 mmol) in 3.5 mL of dry dichloromethane was added dimethylamine/ethanol solution (0.62 mL, 5.6 M, 3.5 mmol) at 0° C. After being stirred at room temperature overnight, the reaction mixture was diluted with ethyl acetate. The solution was washed with 1N HCl, saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified with silica gel column chromatography (hexane/ethyl acetate=80/20 to 50/50) to obtain the title compound as a colorless oil (280 mg, 2 steps 14%).
[0000] (2) Synthesis of (1E,6E)-1-[2-(dimethylaminosulfonyl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU480)
[0409] The title compound was synthesized using the same procedure employed for Example 1, but with 2-formyl-N,N-dimethylbenzenesulfonamide (24 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (12.4 mg, 35%) having the following characteristics.
[0410] 1 H NMR (δ, acetone-d 6 ): 2.77 (s, 6H), 6.09 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.81 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.60 (d, J=8.7 Hz, 2H), 7.62 (m, 1H), 7.67 (d, J=16 Hz, 1H), 7.73 (m, 1H), 7.98 (d, J=8 Hz, 1H), 7.98 (d, J=8 Hz, 1H), 8.57 (d, J=16 Hz, 1H).
[0411] Melting Point 86-90° C., MS (ESI+) m/z 400.4 (M+1), 422.4 (M+Na).
Example 96
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(methylsulfonyloxy)phenyl]hepta-1,6-diene-3,5-dione(CU483)
[0412] (1) Synthesis of 2-formylphenyl methanesulfonate
[0413] To a solution of 2-hydroxybenzaldehyde (0.30 mL, 2.8 mmol) and pyridine (0.91 mL, 11.2 mmol) in 5.6 mL of dichloromethane was added methanesulfonyl chloride (0.65 mL, 8.4 mmol) at 0° C. After being stirred at room temperature overnight, the reaction mixture was diluted with ethyl acetate. The solution was washed with 1N HCl, saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=75/25 to 50/50) to obtain the title compound as a white solid (553 mg, 98%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(methylsulfonyloxy)phenyl]hepta-1,6-diene-3,5-dione(CU483)
[0414] The title compound was synthesized using the same procedure employed for Example 1, but with 2-formylphenyl methanesulfonate (23 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (7.2 mg, 21%) having the following characteristics.
[0415] 1 H NMR (δ, acetone-d 6 ): 3.41 (s, 3H), 6.09 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.94 (d, J=16 Hz, 1H), 7.42˜7.56 (m, 3H), 7.59 (d, J=8.7 Hz, 2H), 7.67 (d, J=16 Hz, 1H), 7.90 (d, J=16 Hz, 1H), 7.94 (dd, J=˜2, 9 Hz, 1H).
[0416] Melting Point 163-167° C., MS (ESI+) m/z 387.4 (M+1), 409.3 (M+Na).
Example 97
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(methylsulfiny)phenyl]hepta-1,6-diene-3,5-dione(CU485)
[0417] (1) Synthesis of 2-(methylsulfinyl)benzaldehyde
[0418] To a solution of 2-(methylthio)benzaldehyde (500 mg, 3.28 mmol) in 6.6 mL of dichloromethane was added m-chlorobenzoic peracid (0.85 g, 4.9 mmol) at 0° C. After being stirred at room temperature for 1 h, the reaction mixture was diluted with ethyl acetate. The solution was washed with saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=50/50 to 15/85) to obtain the title compound as a white crystal (493 mg, 89%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[2-(methylsulfiny)phenyl]hepta-1,6-diene-3,5-dione(CU485)
[0419] The title compound was synthesized using the same procedure employed for Example 1, but with 2-(methylsulfinyl)benzaldehyde (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (5.6 mg, 18%) having the following characteristics.
[0420] 1 H NMR (δ, acetone-d 6 ): 2.69 (s, 3H), 6.10 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.91 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.60 (d, J=8.7 Hz, 2H), 7.61 (m, 1H), 7.68 (d, J=16 Hz, 1H), 7.69 (ddd, J=1.0, 7.7, 8 Hz, 1H), 7.83 (d, J=16 Hz, 1H), 7.89 (d, J=7.7 Hz, 1H), 8.01 (dd, J=1.0, 7.7 Hz, 1H).
[0421] MS (ESI+) m/z 355.4 (M+1), 377.3 (M+Na).
Example 98
Synthesis of (1E,6E)-1-(2-fluoro-5-hydroxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU621)
[0422] The title compound was synthesized using the same procedure employed for Example 1, but with 2-fluoro-5-hydroxybenzaldehyde (16 mg, 0.11 mmol, prepared according to the procedure described in J. Med. Chem., (1986), 29, 1982-1988) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (9.5 mg, 33%) having the following characteristics.
[0423] 1H NMR (δ, acetone-d 6 ): 6.08 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.84 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.87˜6.93 (m, 1H), 7.05 (dd, J=9, 10.5 Hz, 1H), 7.17 (dd, J=2.9, 6.3 Hz, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.66 (d, J=16 Hz, 1H), 7.68 (d, J=16 Hz, 1H), 8.7 (br s, OH).
[0424] Melting Point 205-209° C., MS (ESI+) m/z 327.4 (M+1).
Example 99
Synthesis of (1E,6E)-1-(2-fluorophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU622)
[0425] The title compound was synthesized using the same procedure employed for Example 1, but with 2-fluorobenzaldehyde (14 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (9.1 mg, 33%) having the following characteristics.
[0426] 1H NMR (δ, acetone-d 6 ): 6.09 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.93 (d, J=16 Hz, 1H), 7.22 (dd, J=8.2, 11 Hz, 1H), 7.27 (t, J=7.7 Hz, 1H), 7.46 (m, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.67 (d, J=16 Hz, 1H), 7.75 (d, J=16 Hz, 1H), 7.80 (dt, J=˜2, 7.7 Hz, 1H), 9.1 (br s, OH).
[0427] Melting Point 146-150° C., MS (ESI+) m/z 311.5 (M+1).
Example 100
Synthesis of
[0428] (1E,6E)-1-[2-(1H-1,2,4-triazol-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU623)
[0429] The title compound was synthesized using the same procedure employed for Example 1, but with 2-(1H-1,2,4-triazol-1-yl)benzaldehyde (19 mg, 0.11 mmol, prepared according to the procedure described in Aust. J. Chem., (1991), 44, 1097-1114) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.0 mg, 19%) having the following characteristics.
[0430] 1H NMR (δ, acetone-d 6 ): 6.02 (s, 1H), 6.69 (d, J=16 Hz, 1H), 6.85 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 7.46 (d, J=16 Hz, 1H), 7.58 (d, J=8.7 Hz, 2H), 7.5-7.63 (m, 3H), 7.64 (d, J=16 Hz, 1H), 8.02 (m, 1H), 8.19 (s, 1H), 8.70 (s, 1H).
[0431] Melting Point 186-192° C., MS (ESI+) m/z 360 (M+1).
Example 101
Synthesis of (1E,6E)-1-(2-chlorophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU624)
[0432] The title compound was synthesized using the same procedure employed for Example 1, but with 2-chlorobenzaldehyde (16 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (5.1 mg, 18%) having the following characteristics.
[0433] 1H NMR (δ, acetone-d 6 ): 6.10 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.91 (d, J=16 Hz, 1H), 6.92 (d, J=8.7 Hz, 2H), 7.42 (m, 2H), 7.52 (m, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 7.90 (m, 1H), 8.01 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0434] Melting Point 158-161° C., MS (ESI+) m/z 327.3 (M+1).
Example 102
Synthesis of (1E,6E)-1-[2-(4-ethoxycarbonyl-1H-1,2,3-triazol-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU625)
[0435] (1) Synthesis of ethyl 1-(2-formylphenyl)-1H-1,2,3-triazol-4-carboxylate and ethyl 1-(2-formylphenyl)-1H-1,2,3-triazol-5-carboxylate
[0436] To a solution of 2-azidobenzaldehyde (100 mg, 0.68 mmol) in 1.0 mL of dry N,N-dimethylformamide was added ethyl propiolate (0.14 mL, 1.4 mmol) at room temperature. After being stirred at 100° C. for 12 h, ethyl propiolate (0.14 mL, 1.4 mmol) was added again with additional stirring for 12 h. After cooling, the reaction mixture was diluted with a 5:1 solution (12 mL) of ethyl acetate and hexane. The solution was washed with water twice, brine, and dried over Na 2 SO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified with silica gel column chromatography (hexane/ethyl acetate=90/10 to 75/25) to obtain ethyl 1-(2-formylphenyl)-1H-1,2,3-triazol-4-carboxylate as a crystal (111 mg, 66%) and ethyl 1-(2-formylphenyl)-1H-1,2,3-triazol-5-carboxylate as a oil (28 mg, 17%).
[0000] (2) Synthesis of (1E,6E)-1-[2-(4-ethoxycarbonyl-1H-1,2,3-triazol-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-di ene-3,5-dione(CU625)
[0437] The title compound was synthesized using the same procedure employed for Example 1, but with ethyl 1-(2-formylphenyl)-1H-1,2,3-triazol-4-carboxylate (27 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (8.1 mg, 21%) having the following characteristics.
[0438] 1H NMR (δ, acetone-d 6 ): 1.38 (t, J=6.9 Hz, 3H), 4.41 (q, J=6.9 Hz, 2H), 6.03 (s, 1H), 6.69 (d, J=16 Hz, 1H), 6.90 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.30 (d, J=16 Hz, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.6-7.8 (m, 4H), 8.09 (d, J=6.9 Hz, 1H), 8.88 (s, 1H), 8.9 (br s, OH).
[0439] Melting Point 231-237° C., MS (ESI+) m/z 432.4 (M+1), 454.4 (M+Na).
Example 103
Synthesis of (1E,6E)-1-[2-(5-ethoxycarbonyl-1H-1,2,3-triazol-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU626)
[0440] The title compound was synthesized using the same procedure employed for Example 1, but with ethyl 1-(2-formylphenyl)-1H-1,2,3-triazol-5-carboxylate (27 mg, 0.11 mmol, synthesized in Example 102 (1)) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (2.7 mg, 7%) having the following characteristics.
[0441] 1H NMR (δ, acetone-d 6 ): 1.15 (t, J=6.9 Hz, 3H), 4.20 (q, J=6.9 Hz, 2H), 5.98 (s, 1H), 6.68 (d, J=16 Hz, 1H), 6.79 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 7.58 (d, J=8.7 Hz, 2H), 7.5-7.75 (m, 5H), 8.06 (d, J=7.6 Hz, 1H), 8.41 (s, 1H), 8.9 (br s, OH).
[0442] Melting Point 93-96° C., MS (ESI+) m/z 432.4 (M+1), 454.4 (M+Na).
Example 104
Synthesis of (1E,6E)-1-(4-fluorobiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU640)
[0443] The title compound was synthesized using the same procedure employed for Example 1, but with 4-fluorobiphenyl-2-carboxyaldehyde (22 mg, 0.11 mmol, prepared according to the procedure described in J. Am. Chem. Soc, (2007), 129, 5288-5295) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (14.5 mg, 43%) having the following characteristics.
[0444] 1H NMR (δ, acetone-d 6 ): 6.00 (s, 1H), 6.69 (d, J=16 Hz, 1H), 6.89 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 7.26 (dt, J=2.4, 8.2 Hz, 1H), 7.35 (d, J=6.8 Hz, 2H), 7.4-7.6 (m, 5H), 7.58 (d, J=8.7 Hz, 2H), 7.63 (d, J=16 Hz, 1H), 7.67 (dd, J=2.4, 10.6 Hz, 1H), 8.9 (br s, OH).
[0445] Melting Point 187-191° C., MS (ESI+) m/z 387.5 (M+1), 409.4 (M+Na).
Example 105
Synthesis of (1E,6E)-1-(4-chlorobiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU641)
[0446] (1) Synthesis of 4-chlorobiphenyl-2-carboxyaldehyde
[0447] To a solution of 2-bromo-5-chlorobenzaldehyde (438 mg, 2.00 mmol) in 20 mL of N,N-dimethylformamide was added phenylboronic acid (366 mg, 3.00 mmol), triphenylphosphine (262 mg, 1.00 mmol), 2M sodium carbonate aqueous solution (8.0 mL, 16 mmol), palladium acetate (75 mg, 0.33 mmol) under argon. After being stirred at room temperature overnight, the reaction mixture was filtered. The filtrate was diluted with diethyl ether, and the solution was washed with brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=99/1 to 90/10) to obtain the title compound (199 mg, 46%).
[0000] (2) Synthesis of (1E,6E)-1-(4-chlorobiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU641)
[0448] The title compound was synthesized using the same procedure employed for Example 1, but with 4-chlorobiphenyl-2-carboxyaldehyde (24 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (14.5 mg, 41%) having the following characteristics.
[0449] 1H NMR (δ, acetone-d 6 ): 6.02 (s, 1H), 6.69 (d, T=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.92 (d, J=16 Hz, 1H), 7.37 (m, 2H), 7.41 (d, J=8.2 Hz, 1H), 7.43-7.55 (m, 4H), 7.56 (d, J=16 Hz, 1H), 7.58 (d, J=8.7 Hz, 2H), 7.63 (d, J=16 Hz, 1H), 7.92 (d, J=1.9 Hz, 1H), 8.9 (br s, OH).
[0450] Melting Point 193-196° C., MS (ESI+) m/z 403.4 (M+1), 425.3 (M+Na).
Example 106
Synthesis of (1E,6E)-1-(4-hydroxy-2′-methylbiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU642)
[0451] (1) Synthesis of 4-hydroxy-2′-methylbiphenyl-2-carboxyaldehyde
[0452] To a solution of 2-bromo-5-hydroxybenzaldehyde (100 mg, 0.500 mmol) in 2.5 mL of N,N-dimethylformamide was added 2-methylphenylboronic acid (102 mg, 0.75 mmol), triphenylphosphine (39 mg, 0.15 mmol), 2M sodium carbonate aqueous solution (2.0 mL, 4.0 mmol), palladium acetate (12 mg, 50 μmol) under argon. After being stirred at 90° C. overnight, the reaction mixture was filtered. The filtrate was diluted with diethyl ether, and the solution was washed with brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=95/5 to 70/30) to obtain the title compound (87.9 mg, 83%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxy-2′-methylbiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU642)
[0453] The title compound was synthesized using the same procedure employed for Example 1, but with 4-hydroxy-2′-methylbiphenyl-2-carboxyaldehyde (23 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (20.5 mg, 59%) having the following characteristics.
[0454] 1H NMR (δ, acetone-d 6 ): 2.04 (s, 3H), 5.92 (s, 1H), 6.64 (d, J=16 Hz, 1H), 6.68 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 6.98 (dd, J=2.4, 8.2 Hz, 1H), 7.07 (d, J=8.2 Hz, 1H), 7.10 (br d, J=8 Hz, 1H), 7.23-7.4 (m, 5H), 7.56 (d, J=8.7 Hz, 2H), 7.60 (d, J=16 Hz, 1H), 8.8 (br s, OH).
[0455] Melting Point 173-177° C., MS (ESI+) m/z 399.4 (M+1), 421.4 (M+Na).
Example 107
Synthesis of (1E,6E)-1-(2′-ethoxy-4-hydroxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU643)
[0456] (1) Synthesis of 2′-ethoxy-4-hydroxybiphenyl-2-carboxyaldehyde
[0457] The title compound was synthesized using the same procedure employed for Example 106 (1), but with 2-ethoxyphenylboronic acid (124 mg, 0.75 mmol) instead of 2-methylphenylboronic acid (102 mg, 0.75 mmol), and the reaction temperature was room temperature. The product was obtained (118 mg, 97%).
[0000] (2) Synthesis of (1E,6E)-1-(2′-ethoxy-4-hydroxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU643)
[0458] The title compound was synthesized using the same procedure employed for Example 1, but with 2′-ethoxy-4-hydroxybiphenyl-2-carboxyaldehyde (27 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (6.8 mg, 18%) having the following characteristics.
[0459] 1H NMR (δ, acetone-d 6 ): 1.17 (t, J=6.8 Hz, 3H), 4.00 (m, 2H), 5.95 (s, 1H), 6.66 (d, J=16 Hz, 1H), 6.68 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 6.95 (dd, J=˜2, 8.2 Hz, 1H), 7.02 (br t, J=7.2 Hz, 1H), 7.08 (br d, J=8.2 Hz, 1H), 7.14 (br d, J=8.2 Hz, 2H), 7.31 (br d, J=Hz, 1H), 7.36 (m, 1H), 7.45 (d, J=16 Hz, 1H), 7.57 (d, J=8.7 Hz, 2H), 7.60 (d, J=16 Hz, 1H), 8.7 (br s, OH).
[0460] Melting Point 111-115° C., MS (ESI+) m/z 429.4 (M+1), 451.4 (M+Na).
Example 108
Synthesis of (1E,6E)-1-[2-(1-benzyl-1H-1,2,3-triazol-4-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU644)
[0461] (1) Synthesis of 2-(1-benzyl-1H-1,2,3-triazol-4-yl)benzaldehyde and 2-(1-benzyl-1H-1,2,3-triazol-5-yl)benzaldehyde
[0462] A solution of 2-ethynylbenzaldehyde (200 mg, 1.54 mmol) and benzyl azide (0.38 mL, 3.0 mmol) in 2.0 mL of N,N-dimethylformamide was stirred at 80° C. overnight. The reaction mixture was diluted with water, and the solution was extracted with a 5:1 solution (12 mL) of ethyl acetate and hexane. The extract was washed with water, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified with silica gel column chromatography (hexane/ethyl acetate=80/20 to 60/40) to obtain 2-(1-benzyl-1H-1,2,3-triazol-4-yl)benzaldehyde (259 mg, 65%) and 2-(1-benzyl-1H-1,2,3-triazol-5-yl)benzaldehyde (118 mg, 30%).
[0000] (2) Synthesis of (1E,6E)-1-[2-(1-benzyl-1H-1,2,3-triazol-4-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU644)
[0463] The title compound was synthesized using the same procedure employed for Example 1, but with 2-(1-benzyl-1H-1,2,3-triazol-4-yl)benzaldehyde (29 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (13.8 mg, 35%) having the following characteristics.
[0464] 1H NMR (δ, acetone-d 6 ): 5.75 (s, 2H), 6.04 (s, 1H), 6.70 (d, J=16 Hz, 1H), 6.79 (d, J=16 Hz, 1H), 6.92 (d, J=8.7 Hz, 2H), 7.31-7.50 (m, 7H), 7.59 (d, J=8.7 Hz, 2H), 7.65 (d, J=16 Hz, 1H), 7.74 (dd, J=˜2, 7.2 Hz, 1H), 7.86 (dd, J=˜2, 7.7 Hz, 1H), 8.14 (d, J=16 Hz, 1H), 8.23 (s, 1H), 8.9 (br s, OH).
[0465] Melting Point 103-109° C., MS (ESI+) m/z 450.5 (M+1), 472.4 (M+Na).
Example 109
Synthesis of (1E,6E)-1-[2-(1-benzyl-1H-1,2,3-triazol-5-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU645)
[0466] The title compound was synthesized using the same procedure employed for Example 1, but with 2-(1-benzyl-1H-1,2,3-triazol-5-yl)benzaldehyde (29 mg, 0.11 mmol, synthesized in Example 108 (1)) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (7.4 mg, 19%) having the following characteristics.
[0467] 1H NMR (δ, acetone-d 6 ): 5.45 (s, 2H), 5.92 (s, 1H), 6.67 (d, J=16 Hz, 1H), 6.68 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 6.95 (m, 2H), 7.15 (d, J=16 Hz, 1H), 7.16-7.22 (m, 3H), 7.29 (dd, J=˜2, 7.7 Hz, 1H), 7.48 (dt, J=˜2, 7.7 Hz, 1H), 7.57 (m, 1H), 7.58 (d, J=8.7 Hz, 2H), 7.63 (d, J=16 Hz, 1H), 7.75 (s, 1H), 7.91 (br d, J=7.7 Hz, 1H), 8.9 (br s, OH).
[0468] Melting Point 205-215° C., MS (ESI+) m/z 450.5 (M+1).
Example 110
Synthesis of (1E,6E)-1-[2-(1-ethoxycarbonylmethyl-1H-1,2,3-triazol-4-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU646)
[0469] (1) Synthesis of ethyl [4-(2-formylphenyl)-1H-1,2,3-triazol-1-yl]acetate and ethyl [5-(2-formylphenyl)-1H-1,2,3-triazol-1-yl]acetate
[0470] The title compounds were synthesized using the same procedure employed for Example 108 (1), but with ethyl azidoacetate (0.35 mL, 3.0 mmol) instead of benzyl azide (0.38 mL, 3.0 mmol). The products were obtained as ethyl [4-(2-formylphenyl)-1H-1,2,3-triazol-1-yl]acetate (226 mg, 56%) and ethyl [5-(2-formylphenyl)-1H-1,2,3-triazol-1-yl]acetate (83 mg, 21%).
[0000] (2) Synthesis of (1E,6E)-1-[2-(1-ethoxycarbonylmethyl-1H-1,2,3-triazol-4-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU646)
[0471] The title compound was synthesized using the same procedure employed for Example 1, but with ethyl [4-(2-formylphenyl)-1H-1,2,3-triazol-1-yl]acetate (28 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (15.8 mg, 40%) having the following characteristics.
[0472] 1H NMR (δ, acetone-d 6 ): 1.27 (t, J=7.2 Hz, 3H), 4.26 (q, J=7.2 Hz, 2H), 5.47 (s, 2H), 6.07 (s, 1H), 6.70 (d, J=16 Hz, 1H), 6.81 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.42-7.55 (m, 2H), 7.58 (d, J=8.7 Hz, 2H), 7.64 (d, J=16 Hz, 1H), 7.78 (d, J=7.2 Hz, 1H), 7.87 (d, J=7.7 Hz, 1H), 8.13 (d, J=16 Hz, 1H), 8.27 (s, 1H), 8.9 (br s, OH).
[0473] Melting Point 99-105° C., MS (ESI+) m/z 446.4 (M+1), 468.4 (M+Na).
Example 111
Synthesis of (1E,6E)-1-[2-(1-ethoxycarbonylmethyl-1H-1,2,3-triazol-5-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU647)
[0474] The title compound was synthesized using the same procedure employed for Example 1, but with ethyl [5-(2-formylphenyl)-1H-1,2,3-triazol-1-yl]acetate (28 mg, 0.11 mmol, synthesized in Example 110 (1)) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (9.2 mg, 23%) having the following characteristics.
[0475] 1H NMR (δ, acetone-d 6 ): 1.11 (t, J=7.2 Hz, 3H), 4.07 (q, J=7.2 Hz, 2H), 5.17 (s, 2H), 6.00 (s, 1H), 6.69 (d, J=16 Hz, 1H), 6.83 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.41 (d, J=16 Hz, 1H), 7.46 (dd, J=˜2, 8 Hz, 1H), 7.52-7.64 (m, 2H), 7.58 (d, J=8.7 Hz, 2H), 7.64 (d, J=16 Hz, 1H), 7.77 (s, 1H), 7.98 (br d, J=7.7 Hz, 1H), 8.9 (br s, OH).
[0476] Melting Point 169-174° C., MS (ESI+) m/z 446.5 (M+1), 468.4 (M+Na).
Example 112
Synthesis of (1E,6E)-1-[2-bromo-5-(methoxymethoxy)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU648)
[0477] (1) Synthesis of 2-bromo-5-(methoxymethoxy)benzaldehyde
[0478] The title compound was synthesized using the same procedure employed for Example 113 (1), but with 2-bromo-5-hydroxybenzaldehyde (3.62 g, 18.0 mmol) instead of 5-hydroxy-2-nitrobenzaldehyde (3.00 g, 18.0 mmol). The product was obtained (4.65 g, 90%).
[0000] (2) Synthesis of (1E,6E)-1-[2-bromo-5-(methoxymethoxy)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU648)
[0479] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-5-(methoxymethoxy)benzaldehyde (27 mg 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (4.4 mg, 12%) having the following characteristics.
[0480] 1H NMR (δ, acetone-d 6 ): 3.46 (s, 3H), 5.27 (s, 2H), 6.10 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.87 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.04 (dd, J=2.9, 9.2 Hz, 1H), 7.51 (d, J=2.9 Hz, 1H), 7.61 (d, J=8.7 Hz, 2H), 7.61 (d, J=9 Hz, 1H), 7.68 (d, J=16 Hz, 1H), 7.91 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0481] MS (ESI+) m/z 431 (M+1), 453 (M+Na).
Example 113
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[5-(methoxymethoxy)-2-nitrophenyl]hepta-1,6-diene-3,5-dione(CU649)
[0482] (1) Synthesis of 5-(methoxymethoxy)-2-nitrobenzaldehyde
[0483] To a solution of 5-hydroxy-2-nitrobenzaldehyde (3.00 g, 18.0 mmol) in 36 mL of dichloromethane was added N,N-diisopropylethylamine (9.2 mL, 54 mmol), 4-dimethylaminopyridine (0.22 g, 1.8 mmol), and chloromethyl methyl ether (2.7 mL, 36 mmol) at room temperature, successively. After being stirred at room temperature overnight, the reaction mixture was diluted with a 1:1 solution (200 mL) of ethyl acetate and hexane. The solution was washed with 1M HCl four times, saturated NaHCO 3 aqueous solution, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo to obtain the title compound as a white solid (3.71 g, 98%).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-[5-(methoxymethoxy)-2-nitrophenyl]hepta-1,6-diene-3,5-dione(CU649)
[0484] The title compound was synthesized using the same procedure employed for Example 1, but with 5-(methoxymethoxy)-2-nitrobenzaldehyde (23 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (9.4 mg, 27%) having the following characteristics.
[0485] 1H NMR (δ, acetone-d 6 ): 3.49 (s, 3H), 5.41 (s, 2H), 6.12 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.82 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.25 (br d, J=9.2 Hz, 1H), 7.45 (br s, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.68 (d, J=16 Hz, 1H), 8.08 (d, J=16 Hz, 1H), 8.13 (br d, J=9.2 Hz, 1H), 8.9 (br s, OH).
[0486] Melting Point 175-180° C., MS (ESI+) m/z 398 (M+1), 420 (M+Na).
Example 114
Synthesis of (1E,6E)-1-(2-azidophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU651)
[0487] The title compound was synthesized using the same procedure employed for Example 1, but with 2-azidobenzaldehyde (16 mg, 0.11 mmol, prepared according to the procedure described in J. Org. Chem., (1995), 60, 2254-2256) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (18.4 mg, 63%) having the following characteristics.
[0488] 1H NMR (δ, acetone-d 6 ): 6.06 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.89 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.24 (t, J=7.6 Hz, 1H), 7.36 (d, J=7.9 Hz, 1H), 7.51 (dt, J=˜2, 8 Hz, 1H), 7.59 (d, J=8.7 Hz, 2H), 7.66 (d, J=16 Hz, 1H), 7.81 (br d, J=8 Hz, 1H), 7.86 (d, J=16 Hz, 1H), 9.0 (br s, OH).
[0489] Melting Point 153-161° C., MS (ESI+) m/z 356.3 (M+Na).
Example 115
Synthesis of (1E,6E)-1-(2,3-dibromo-4-hydroxy-5-methoxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU652)
[0490] The title compound was synthesized using the same procedure employed for Example 1, but with 2,3-dibromo-4-hydroxy-5-methoxybenzaldehyde (34 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (23.2 mg, 53%) having the following characteristics.
[0491] 1H NMR (δ, acetone-d 6 ): 3.99 (s, 3H), 6.01 (s, 1H), 6.69 (d, J=16 Hz, 1H), 6.81 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.53 (s, 1H), 7.58 (d, J=8.7 Hz, 2H), 7.65 (d, J=16 Hz, 1H), 8.02 (d, J=16 Hz, 1H).
[0492] Melting Point 215-218° C., MS (ESI+) m/z 495.4 (M+1).
Example 116
Synthesis of (1E,6E)-1-(2-bromo-3-hydroxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU655)
[0493] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-3-hydroxybenzaldehyde (22 mg, 0.11 mmol, prepared according to the procedure described in Eur. J. Org. Chem., (2007), 5726-5733) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (15.0 mg, 44%) having the following characteristics.
[0494] 1H NMR (δ, acetone-d 6 ): 6.08 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.81 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.05 (dd, J=1.4, 7.7 Hz, 1H), 7.25 (t, J=7.7 Hz, 1H), 7.36 (dd, J=1.4, 7.7 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.67 (d, J=16 Hz, 1H), 8.04 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0495] MS (ESI+) m/z 387.2 (M+1), 409.2 (M+Na).
Example 117
Synthesis of (1E,6E)-1-[2-(1H-tetrazol-5-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU656)
[0496] (1) Synthesis of 2-(1H-tetrazol-5-yl)benzaldehyde
[0497] To a solution of 5-phenyl-1H-tetrazole (500 mg, 3.42 mmol) in 10 mL of dry tetrahydrofuran was added dropwise s-butyllithium (1.04 mol/L, 6.6 mL, 6.9 mmol) under nitrogen at −78° C. After the reaction mixture was stirred at the same temperature for 30 min, N,N-dimethylformamide (2 mL, 30 mmol) was added dropwise. After the reaction mixture was stirred at room temperature for 10 min, 1M HCl (10 mL) was added. The solution was allowed to warm up to room temperature, diluted with ethyl acetate, and extracted. The extract was washed with brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by recrystallization (hexane 2.5 mL, ethyl acetate 2.5 mL) to obtain the title compound (390 mg, 99%).
[0000] (2) Synthesis of (1E,6E)-1-[2-(1H-tetrazol-5-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU656)
[0498] The title compound was synthesized using the same procedure employed for Example 1, but with 2-(1H-tetrazol-5-yl)benzaldehyde (19 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (3.5 mg, 11%) having the following characteristics.
[0499] MS (ESI+) m/z 361.5 (M+1), 383.3 (M+Na).
Example 118
Synthesis of (1E,6E)-1-[2-(1-benzyl-1H-tetrazol-5-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU657)
[0500] (1) Synthesis of 2-(1-benzyl-1H-tetrazol-5-yl)benzaldehyde
[0501] To a solution of 2-(1H-tetrazol-5-yl)benzaldehyde (100 mg, 0.57 mmol, synthesized in Example 117 (1)) in a 3:1 solution (4 mL) of tetrahydrofuran and N,N-dimethylformamide was added potassium carbonate (0.12 g, 0.86 mmol), benzyl bromide (82 μL, 0.69 mmol) at room temperature, successively. After being stirred at room temperature overnight, the reaction mixture was diluted with a 5:2 solution (7 mL) of ethyl acetate and hexane. The solution was washed with water twise, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=100/0 to 80/20) to obtain the title compound (126 mg, 83%).
[0000] (2) Synthesis of (1E,6E)-1-[2-(1-benzyl-1H-tetrazol-5-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU657)
[0502] The title compound was synthesized using the same procedure employed for Example 1, but with 2-(1-benzyl-1H-tetrazol-5-yl)benzaldehyde (29 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (8.1 mg, 20%) having the following characteristics.
[0503] 1H NMR (δ, acetone-d 6 ): 6.03 (s, 2H), 6.07 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.85 (d, J=16 Hz, 1H), 6.92 (d, J=8.7 Hz, 2H), 7.35-7.63 (m, 9H), 7.66 (d, J=16 Hz, 1H), 7.96 (dd, J=˜2, 7.2 Hz, 1H), 8.03 (dd, J=˜2, 7 Hz, 1H), 8.46 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0504] MS (ESI+) m/z 451.4 (M+1), 473.6 (M+Na).
Example 119
Synthesis of (1E,6E)-1-[2-(1-ethoxycarbonylmethyl-1H-tetrazol-5-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU658)
[0505] (1) Synthesis of ethyl [5-(2-formylphenyl)-1H-tetrazol-1-yl]acetate
[0506] The title compound was synthesized using the same procedure employed for Example 118 (1), but with ethyl bromoacetate (83 μL, 0.75 mmol) instead of benzyl bromide (82 μL, 0.69 mmol). The product was obtained (95 mg, 64%)
[0000] (2) Synthesis of (1E,6E)-1-[2-(1-ethoxycarbonylmethyl-1H-tetrazol-5-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU658)
[0507] The title compound was synthesized using the same procedure employed for Example 1, but with ethyl [5-(2-formylphenyl)-1H-tetrazol-1-yl]acetate (29 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (4.5 mg, 11%) having the following characteristics.
[0508] 1H NMR (δ, acetone-d 6 ): 1.28 (t, J=7.2 Hz, 3H), 4.29 (q, J=7.2 Hz, 2H), 5.81 (s, 2H), 6.10 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.87 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.59 (d, J=8.7 Hz, 2H), 7.6-7.65 (m, 2H), 7.65 (d, J=16 Hz, 1H), 8.00 (br d, J=7.2 Hz, 1H), 8.04 (br d, J=7.7 Hz, 1H), 8.42 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0509] MS (ESI+) m/z 447.4 (M+1), 469.4 (M+Na).
Example 120
Synthesis of (1E,6E)-1-(2-bromo-4-hydroxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU671)
[0510] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-4-hydroxybenzaldehyde (22 mg, 0.11 mmol, prepared according to the procedure described in J. Organomet. Chem., (2003), 668, 101-122) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (7.2 mg, 21%) having the following characteristics.
[0511] 1H NMR (δ, acetone-d 6 ): 6.00 (s, 1H), 6.67 (d, J=16 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 7.05 (d, J=8.7 Hz, 1H), 7.52-7.60 (m, 4H), 7.62 (d, J=16 Hz, 1H), 7.88 (br s, 1H).
[0512] Melting Point 196-205° C., MS (ESI+) m/z 387.3 (M+1).
Example 121
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-(2-styrylphenyl)hepta-1,6-diene-3,5-dione(CU672)
[0513] The title compound was synthesized using the same procedure employed for Example 1, but with (E)-2-styrylbenzaldehyde (24 mg, 0.11 mmol, prepared according to the procedure described in Eur. J. Org. Chem., (2004), 3465-3476) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (7.6 mg, 22%) having the following characteristics.
[0514] 1H NMR (δ, acetone-d 6 ): 6.09 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.78 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.14 (d, J=16 Hz, 1H), 7.28-7.47 (m, 5H), 7.59 (d, J=8.7 Hz, 2H), 7.65 (d, J=16 Hz, 1H), 7.64-7.69 (m, 3H), 7.74 (t, J=8 Hz, 2H), 8.12 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0515] Melting Point 119-128° C., MS (ESI+) m/z 395.4 (M+1), 417.4 (M+Na).
Example 122
Synthesis of (1E,6E)-1-(4-hydroxy-2′-isobutoxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1084)
[0516] (1) Synthesis of 4-hydroxy-2′-isobutoxybiphenyl-2-carboxyaldehyde
[0517] The title compound was synthesized using the same procedure employed for Example 106 (1), but with 2-isobutoxyphenylboronic acid (146 mg, 0.75 mmol) instead of 2-methylphenylboronic acid (102 mg, 0.75 mmol), and the reaction temperature was 50° C. The product was obtained (136 mg, quant.).
[0000] (2) Synthesis of (1E,6E)-1-(4-hydroxy-2′-isobutoxybiphenyl-2-yl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1084)
[0518] The title compound was synthesized using the same procedure employed for Example 1, but with 4-hydroxy-2′-isobutoxybiphenyl-2-carboxyaldehyde (30 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (3.6 mg, 9%) having the following characteristics.
[0519] 1H NMR (δ, acetone-d 6 ): 0.82 (d, J=6.8 Hz, 6H), 1.84 (m, 1H), 3.72 (d, J=6.3 Hz, 2H), 5.93 (s, 1H), 6.66 (d, J=16 Hz, 1H), 6.68 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 6.96 (dd, J=2.5, 8.3 Hz, 1H), 7.02 (br t, J=7.4 Hz, 1H), 7.09 (br d, J=8.3 Hz, 1H), 7.10-7.15 (m, 2H), 7.33 (br d, J=2.5 Hz, 1H), 7.37 (m, 1H), 7.46 (d, J=16 Hz, 1H), 7.57 (d, J=8.7 Hz, 2H), 7.60 (d, J=16 Hz, 1H).
[0520] MS (ESI+) m/z 457 (M+1).
Example 123
Synthesis of (1E,6E)-1-[2-bromo-4-(piperidin-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1090)
[0521] (1) Synthesis of 2-bromo-4-(piperidin-1-yl)benzaldehyde
[0522] To a solution of 2-bromo-4-fluorobenzaldehyde (300 mg, 1.48 mmol) in 3.0 mL of N,N-dimethylformamidc was added potassium carbonate (204 mg, 1.48 mmol), piperidine (154 μL, 1.55 mmol) at room temperature. After being stirred at 110° C. overnight, the reaction mixture was diluted with a 2:1 solution of ethyl acetate and hexane. The solution was washed with water, brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=100/0 to 75/25) to obtain the title compound (355 mg, 90%).
[0000] (2) Synthesis of (1E,6E)-1-[2-bromo-4-(piperidin-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1090)
[0523] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-4-(piperidin-1-yl)benzaldehyde (30 mg 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (17.5 mg, 44%) having the following characteristics.
[0524] 1H NMR (δ, DMSO-d 6 ): 1.58 (m, 6H), 3.4 (m, 4H), 6.02 (s, 1H), 6.71 (d, J=16 Hz, 1H), 6.73 (d, J=16 Hz, 1H), 6.82 (d, J=8.5 Hz, 2H), 7.00 (dd, J=2, 9.1 Hz, 1H), 7.14 (d, J=2 Hz, 1H), 7.55 (d, J=16 Hz, 1H), 7.57 (d, J=8.5 Hz, 2H), 7.76 (br d, J=9 Hz, 1H), 7.79 (d, J=16 Hz, 1H).
[0525] Melting Point 238-248° C., MS (ESI+) m/z 454 (M+1).
Example 124
Synthesis of (1E,6E)-1-[4-(4-benzylpiperidin-1-yl)-2-bromophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1091)
[0526] (1) Synthesis of 4-(4-benzylpiperidin-1-yl)-2-bromobenzaldehyde
[0527] The title compound was synthesized using the same procedure employed for Example 123 (1), but with 4-benzylpiperidine (275 μL, 1.55 mmol) instead of piperidine (154 μL, 1.55 mmol). The product was obtained (302 mg, 57%).
[0000] (2) (1E,6E)-1-[4-(4-benzylpiperidin-1-yl)-2-bromophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1091)
[0528] The title compound was synthesized using the same procedure employed for Example 1, but with 4-(4-benzylpiperidin-1-yl)-2-bromobenzaldehyde (39 mg 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (18.0 mg, 38%) having the following characteristics.
[0529] 1H NMR (δ, acetone-d 6 ): 1.33 (m, 2H), 1.74 (br d, J=12.6 Hz, 2H), 1.83 (m, 1H), 2.99 (d, J=7.2 Hz, 2H), 2.87 (m, 2H), 3.93 (br d, J=12.6 Hz, 2H), 5.97 (s, 1H), 6.65 (d, J=16 Hz, 1H), 6.68 (d, J=16 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 6.99 (dd, J=2.4, 9.2 Hz, 1H), 7.15 (d, J=2.4 Hz, 1H), 7.14-7.3 (m, 5H), 7.57 (d, J=8.7 Hz, 2H), 7.61 (d, J=16 Hz, 1H), 7.73 (d, J=9.2 Hz, 1H), 7.95 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0530] Melting Point 155-161° C., MS (ESI+) m/z 544 (M+1).
Example 125
Synthesis of
[0531] (1E,6E)-1-[4-(4-benzyl-1,4-diazepan-1-yl)-2-bromophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1092)
[0000] (1) Synthesis of 4-(4-benzyl-1,4-diazepan-1-yl)-2-bromobenzaldehyde
[0532] The title compound was synthesized using the same procedure employed for Example 123 (1), but with N-benzylhomopiperazine (305 μL, 1.55 mmol) instead of piperidine (154 μL, 1.55 mmol). The product was obtained (498 mg, 90%).
[0000] (2) Synthesis of (1E,6E)-1-[4-(4-benzyl-1,4-diazepan-1-yl)-2-bromophenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1092)
[0533] The title compound was synthesized using the same procedure employed for Example 1, but with 4-(4-benzyl-1,4-diazepan-1-yl)-2-bromobenzaldehyde (41 mg 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (8.8 mg, 18%) having the following characteristics.
[0534] 1H NMR (3, acetone-d 6 ): 1.96 (m, 2H), 2.63 (t, J=5.5 Hz, 2H), 2.78 (t, J=5.0 Hz, 2H), 3.6-3.7 (m, 6H), 5.96 (s, 1H), 6.62 (d, J=16 Hz, 1H), 6.68 (d, J=16 Hz, 1H), 6.84 (dd, J=2.5, 9.0 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.00 (d, J=2.5 Hz, 1H), 7.2-7.35 (m, 5H), 7.58 (d, J=8.7 Hz, 2H), 7.61 (d, J=16 Hz, 1H), 7.73 (d, J=9.0 Hz, 1H), 7.98 (d, J=16 Hz, 1H).
[0535] MS (ESI+) m/z 559 (M+1).
Example 126
Synthesis of (1E,6E)-1-[2-bromo-4-(4-tert-butoxycarbonylpiperazin-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1093)
[0536] (1) Synthesis of 2-bromo-4-(4-tert-butoxycarbonylpiperazin-1-yl)benzaldehyde
[0537] The title compound was synthesized using the same procedure employed for Example 123 (1), but with N-tert-butoxycarbonylpiperazine (289 mg, 1.55 mmol) instead of piperidine (154 μL, 1.55 mmol). The product was obtained (392 mg, 72%).
[0000] (2) Synthesis of (1E,6E)-1-[2-bromo-4-(4-tert-butoxycarbonylpiperazin-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1093)
[0538] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-4-(4-tert-butoxycarbonylpiperazin-1-yl)benzaldehyde (41 mg 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol) The product was obtained as a solid (16.2 mg, 33%) having the following characteristics.
[0539] 1H NMR (δ, acetone-d 6 ): 1.47 (s, 9H), 3.36 (m, 4H), 3.56 (m, 4H), 5.99 (s, 1H), 6.69 (d, J=16 Hz, 1H), 6.70 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.04 (br d, J=9 Hz, 1H), 7.21 (d, J=2.6 Hz, 1H), 7.58 (d, J=8.7 Hz, 2H), 7.63 (d, J=16 Hz, 1H), 7.78 (d, J=8.9 Hz, 1H), 7.95 (d, J=16 Hz, 1H).
[0540] MS (ESI+) m/z 555 (M+1).
Example 127
Synthesis of (1E,6E)-1-[2-bromo-4-(4-tert-butoxycarbonyl-1,4-diazepan-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1094)
[0541] (1) Synthesis of 2-bromo-4-(4-tert-butoxycarbonyl-1,4-diazepan-1-yl)benzaldehyde
[0542] The title compound was synthesized using the same procedure employed for Example 123 (1), but with N-tert-butoxycarbonylhomopiperazine (321 μL, 1.55 mmol) instead of piperidine (154 μL, 1.55 mmol). The product was obtained (246 mg, 43%).
[0000] (2) Synthesis of (1E,6E)-1-[2-bromo-4-(4-tert-butoxycarbonyl-1,4-diazepan-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1094)
[0543] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-4-(4-tert-butoxycarbonyl-1,4-diazepan-1-yl)benzaldehyde (42 mg 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (17.6 mg, 35%) having the following characteristics.
[0544] 1H NMR (δ, acetone-d 6 ): 1.29 (s, 9H×0.5), 1.38 (s, 9H×0.5), 1.89 (m, 2H×0.5), 1.97 (m, 2H×0.5), 3.32 (m, 2H×0.5), 3.38 (m, 2H×0.5), 3.6-3.8 (m, 6H), 5.958 (s, 1H×0.5), 5.964 (s, 1H×0.5), 6.622 (d, J=16 Hz, 1H×0.5), 6.627 (d, J=16 Hz, 1H×0.5), 6.676 (d, J=16 Hz, 1H×0.5), 6.682 (d, J=16 Hz, 1H×0.5), 6.88 (br d, J=9 Hz, 1H), 6.906 (d, J=8.7 Hz, 2H×0.5), 6.913 (d, J=8.7 Hz, 2H×0.5), 7.05 (br s, 1H), 7.55-7.65 (m, 3H), 7.73 (br d, J=9 Hz, 1H), 7.97 (d, J=16 Hz, 1H), 8.9 (br s, OH).
[0545] MS (ESI+) m/z 569 (M+1).
Example 128
Synthesis of (1E,6E)-1-[2-bromo-4-(4-phenylpiperazin-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1095)
[0546] (1) Synthesis of 2-bromo-4-(4-phenylpiperazin-1-yl)benzaldehyde
[0547] The title compound was synthesized using the same procedure employed for Example 123 (1), but with 4-phenylpiperazine (235 μL, 1.55 mmol) instead of piperidine (154 μL, 1.55 mmol). The product was obtained (393 mg, 77%).
[0000] (2) Synthesis of (1E,6E)-1-[2-bromo-4-(4-phenylpiperazin-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU1095)
[0548] The title compound was synthesized using the same procedure employed for Example 1, but with 2-bromo-4-(4-phenylpiperazin-1-yl)benzaldehyde (38 mg 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol). The product was obtained as a solid (11.2 mg, 24%) having the following characteristics.
[0549] 1H NMR (δ, DMSO-d 6 ): 3.27 (m, 4H), 3.49 (m, 4H), 6.04 (s, 1H), 6.73 (d, J=16 Hz, 1H), 6.75-6.9 (m, 2H), 6.83 (d, J=8.6 Hz, 2H), 7.00 (d, J=8.0 Hz, 2H), 7.10 (br d, J=9 Hz, 1H), 7.22-7.30 (m, 3H), 7.57 (d, J=16 Hz, 1H), 7.59 (d, J=8.6 Hz, 2H), 7.81 (d, J=16 Hz, 1H), 7.83 (d, J=8.8 Hz, 1H).
[0550] Melting Point 195-204° C., MS (ESI+) m/z 531 (M+1).
Example 129
Synthesis of (1E,6E)-1-[2-bromo-4-(piperazin-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione dihydrochloride(CU1097)
[0551] To a solution of (1E,6E)-1-[2-bromo-4-(4-tert-butoxycarbonylpiperazin-1-yl)phenyl]-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione (35 mg, 0.063 mmol, synthesized in Example 126) in 1.0 mL of ethyl acetate was added 3M HCl (1.0 mL) at room temperature. After being stirred at room temperature overnight, the reaction mixture was concentrated in vacuo. The residue was treated with diethyl ether, and the resulting solid was collected by filtration. The solid was rinsed with ether, and dried under reduced pressure to obtain the title compound as a solid (28.0 mg, 84%).
[0552] 1H NMR (δ, DMSO-d 6 ): 3.19 (m, 4H), 3.55 (m, 4H), 6.05 (s, 1H), 6.74 (d, J=16 Hz, 1H), 6.83 (d, J=16 Hz, 1H), 6.84 (d, J=8.5 Hz, 2H), 7.09 (br d, J=9.0 Hz, 1H), 7.27 (d, J=2.4 Hz, 1H), 7.58 (d, J=16 Hz, 1H), 7.59 (d, J=8.5 Hz, 2H), 7.79 (d, J=16 Hz, 1H), 7.85 (d, J=9.0 Hz, 1H), 9.2 (br s, 2H).
[0553] MS (ESI+) m/z 455 (M+1).
Comparative Example 1
Synthesis of (1E,6E)-1-(2-amino-5-hydroxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU488)
[0554] To a solution of (1E,6E)-1-(5-hydroxy-2-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione (26 mg, 73 μmol, synthesized in Example 4) in 3.0 mL of ethyl acetate was added anhydrous tin(II) chloride (57 mg, 0.30 mmol) at room temperature. After being stirred at 60° C. for 1.5 h, the reaction mixture was cooled to room temperature, and was diluted with 10% methanol/chloroform and saturated NaHCO 3 aqueous solution, successively. The mixture was shaken before filtration to remove inorganic salts. The organic layer after separation was washed with brine, and dried over MgSO 4 . After filtration, the filtrate was concentrated in vacuo, and the residue was purified by silica gel column chromatography (hexane/ethyl acetate=60/40 to 30/70) to obtain the title compound as a solid (6.8 mg, 37%) having the following characteristics.
[0555] 1 H NMR NMR (δ, acetone-d 6 ) 4.7 (br s 2H NH) 6.01 (s, 1H) 6.58 (d, J=16 Hz, 1H), 6.67 (d, J=16 Hz, 1H), 6.70 (d, J=8.7 Hz, 1H), 6.72 (dd, J=2.4, 8.7 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 6.97 (d, J=2.4 Hz, 1H), 7.57 (d, J=8.7 Hz, 2H), 7.61 (d, J=16 Hz, 1H), 7.85 (d, J=16 Hz, 1H).
[0556] Melting Point 186-192° C., MS (ESI+) m/z 346.3 (M+Na).
Comparative Example 2
Synthesis of (1E,6E)-1-(2-amino-5-benzyloxyphenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione(CU489)
[0557] The title compound was synthesized using the same procedure employed for Comparative Example 1, but with (1E,6E)-1-(5-benzyloxy-2-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione (10 mg, synthesized in Example 30) instead of (1E,6E)-1-(5-hydroxy-2-nitrophenyl)-7-(4-hydroxyphenyl)hepta-1,6-diene-3,5-dione (silica gel column chromatography: hexane/ethyl acetate=75/25 to 60/40). The product was obtained as a solid (3.3 mg, 35%) having the following characteristics.
[0558] 1 H NMR (δ, acetone-d 6 ): 4.8 (br s, 2H, NH), 5.07 (s, 2H), 6.01 (s, 1H), 6.67 (d, J=16 Hz, 1H), 6.69 (d, J=16 Hz, 1H), 6.78 (d, J=8.7 Hz, 1H), 6.89 (dd, J=2.9, 8.7 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 7.19 (d, J=2.9 Hz, 1H), 7.32 (t, J=7.2 Hz, 1H), 7.39 (t, J=7.2 Hz, 2H), 7.48 (d, J=7.2 Hz, 2H), 7.56 (d, J=8.7 Hz, 2H), 7.61 (d, J=16 Hz, 1H), 7.86 (d, J=16 Hz, 1H).
[0559] Melting Point 175-179° C., MS (ESI+) m/z 436.7 (M+Na).
Comparative Example 3
Synthesis of (1E,6E)-1-(4-hydroxyphenyl)-7-(3-methoxy-4-nitrophenyl)hepta-1,6-diene-3,5-dione(CU050)
[0560] The title compound was synthesized using the same procedure employed for Example 1, but with 3-methoxy-4-nitrobenzaldehyde (20 mg, 0.11 mmol) instead of 2-chloro-4-hydroxybenzaldehyde (17 mg, 0.11 mmol) The product was obtained as a solid (4.2 mg, 13%) having the following characteristics.
[0561] 1 H NMR (δ, acetone-d 6 ): 4.05 (s, 3H), 6.10 (s, 1H), 6.72 (d, J=16 Hz, 1H), 6.91 (d, J=8.7 Hz, 2H), 7.05 (d, J=16 Hz, 1H), 7.45 (dd, J=8.2 Hz, 1H), 7.60 (d, J=8.7 Hz, 2H), 7.66 (d, J=16 Hz, 1H), 7.66 (d, J=˜2 Hz, 1H), 7.68 (d, J=16 Hz, 1H), 7.89 (d, J=8.2 Hz, 1H), 8.9 (br s, OH).
[0562] Melting Point 190-192° C., MS (ESI+) m/z 368 (M+1).
Test Example 1
Measurement of 50% Inhibition Concentration (IC 50 ) of β-Secretase (BACE-1) Enzyme
[0563] Compounds were dissolved in 0.1 M sodium acetate buffer (with 150 mM sodium chloride, pH 4.5) and 10% dimethylsulfoxide (DMSO). The solution with no compound was used as a negative control. Then, 15 μL of these solutions (final compound concentration: 0.3, 0.9, 3.0, 9.0, and 30.0 μM), 1 unit/mL of recombinant human β-secretase (rhBACE-1, Invitrogen), and 15 μL of the fluorescent substrate peptide were mixed in a black 384-well microtiter plate (Coaster). After mixtures were incubated in the dark at 37° C. for 2.5 hr, the fluorescence intensities of the mixtures were measured by fluorescence microplate reader (Wallac) at 545 nm for excitation and at 590 nm for emission. The inhibition ratio of each compound was calculated using the intensity of the solution without any compound as a negative control. The sequence of the peptide was Ser-Glu-Val-Asn-Leu-Asp-Ala-Glu-Lys-Arg, and labeled with fluorescent donor (Cy3) at Ser-1 and with quencher (Cy5Q) at Lys-9, respectively (Invitrogen) Inhibitory activities of each compound are shown in FIG. 1 .
[0564] As shown in FIG. 1 , the compounds with halogen, nitro, trifluoromethyl, methoxycarbonyl, phenyl, or naphthyl residues at R 1 , inhibited BACE-1 enzyme activity at low concentrate.
Test Example 2
Measurement of the Inhibitory Effect of CU532 on Aβ-40 and Aβ-42 Production in Rat Primary Cultured Cell
[0565] Cerebral cortex was obtained from 19-20 day-old embryonic Wistar rat. The tissue was minced, dissociated using scalpel blades and Pasteur pipette in Hunks bufferd solution, and centrifuged at 100 rpm. Precipitated cells were filtered using 100 μM cell strainer, and single cells were prepared. These cells were suspended in Eagle's Minimum Essential Medium (EMEM) containing 10% Fetal bovine serum, and plated into 48-well tissue culture plates (Becton Dickinson) at 200 μL/well and 1.7×10 5 cells/cm 2 . Cultures were incubated at 37° C. in a humidified atmosphere of 5% CO 2 . After 3, 5, and 7 days in culture, the medium was replaced, and after 9 days, CU532 was dissolved in DMSO and diluted in culture media so that the final concentration of DMSO in culture media was 0.1%, and each solution was added to each well at 200 mL/well for 72 hr. The control solution contained 0.1% DMSO. After 72 hr, Aβ-40 and Aβ-42 in culture media were measured using by Aβ ELISA kit (Wako). 100 μL of the culture medium and standard diluents were added to the antibody-coated plate, and incubated at 4° C. over night. Then the plate was washed by wash buffer 5 times and 100 μL of HRP-labeled detection antibody solution was added to the plate. After 1 hour, the plate was washed 5 times, and TMB chromogenic reagent was added to the plate. After 30 minute, stop solution was added and absorbance at 450 nm of the solution was measured by microplate reader (BIORAD). The concentration of Aβ in culture medium was caliculated from the standard curve.
[0566] As shown in FIG. 2 , CU532 significantly decreased the amount of Aβ-40 or Aβ-42 in culture medium at 1 μM or 0.3 μM, respectively. But curcumin (cur) had no inhibitory effect on Aβ production.
Comparative Test Example 1
[0567] The IC 50 of the compound (CU488) synthesized in Comparative Example 1 was determined in the same manner as in Test Example 1. CU488 is a compound obtained by converting the R 1 group in the general formula (I) in the compound (CU131) synthesized in Example 4 from an electron-withdrawing nitro group to an electron-donating amino group.
[0568] While the IC50 of CU131 was 0.91 μM, the IC50 of CU488 was 7.3 μM. This result shows that the β-secretase inhibiting activity is markedly reduced by converting the R 1 group from an electron-withdrawing group to an electron-donating group.
Comparative Test Example 2
[0569] The IC50 of the compound synthesized in Comparative Example 2 (CU489) was determined in the same manner as in Test Example 1. CU489 is a compound obtained by converting the R 1 group in the general formula (I) in the compound (CU475) synthesized in Example 30 from an electron-withdrawing nitro group to an electron-donating amino group.
[0570] While the IC50 of CU475 was 0.74 μM, the IC50 of CU489 was 5.6 μM. This result shows that the β-secretase inhibiting activity is markedly reduced by converting the R 1 group from an electron-withdrawing group to an electron-donating group.
Comparative Test Example 3
[0571] The IC50 of the compound (CU050) synthesized in Comparative Example 3 was determined in the same manner as in Test Example 1. CU050 is a compound obtained by transferring the nitro group in the compound (CU481) synthesized in Example 33 from R 1 to R 3 in the general formula (I).
[0572] While the IC 50 of CU481 was 1.2 μM, the IC50 of CU050 was 16 μM. This result shows that the β-secretase inhibiting activity is markedly reduced by transferring an electron-withdrawing group to a position other than R 1 .
[0573] The present specification encompasses the contents of the specification and/or drawings in a Japanese patent application (Japanese Patent Application No. 2008-141996), based on which the present application claims priority. Furthermore, all publications, patents, and patent applications which are cited in the specification are hereby incorporated in their entirety by reference into the present specification.
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To develop a highly safe measure to treat Alzheimer's disease using a secretase-inhibiting substance, there is provided a compound represented by the following general formula (I) or a salt thereof:
wherein A represents a phenyl group or the like, R 1 represents a chlorine atom, a bromine atom, or a nitro group or the like, R 2 , R 3 , R 4 , and R 5 each represent a hydrogen atom or the like, and L represents CH 2 —CH 2 or CH═CH.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. provisional Pat. App. No. 61/487,945, filed May 19, 2011, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments of the present invention generally relate to a seal around a braided cable.
2. Description of the Related Art
In the oil and gas industry, the term wireline typically refers to a cable used by operators of oil and gas wells to lower downhole tools, such as logging sensors, into a wellbore for purposes of well intervention and reservoir evaluation. The wireline may be a braided line and may contain an inner core of insulated wires, which provide power to equipment located at the end of the wireline, and provides a pathway for electrical telemetry for communication between the surface and equipment at the end of the wireline. The wireline resides on the surface, wound around a large diameter (e.g., 3 to 10 feet diameter) spool of a winch. The winch may be portable (e.g., on the back of a truck) or a semi-permanent part of the drilling rig. The winch may include a motor and drive train operable to turn the spool, thereby raising and lowering the tools into and out of the well.
A pressure control head is also employed during wireline operations to contain pressure originating from the wellbore. However, braided cable presents problems as pressure is likely to communicate between and under the multiple strands of the braid. For this reason, the pressure control head includes a grease injector for injecting thick grease into and around the cable in conjunction with a stuffing box for sealing against an outer surface of the cable while allowing the wireline to slide through. However, if a more semi-permanent stationary seal is required around the braided cable (for example, in the deployment of a power cable suspended electric submersible pump (ESP) system) continuous grease injection may not be convenient.
SUMMARY OF THE INVENTION
Embodiments of the present invention generally relate to a seal around a braided cable. In one embodiment, a method of deploying a downhole tool into a wellbore includes: lowering a cable into the wellbore; after lowering the cable, engaging a mold with an outer surface of the cable; injecting sealant into the mold and into armor of the cable, thereby sealing a portion of the cable; lowering the downhole tool to a deployment depth using the cable; engaging a seal with the sealed portion of the cable; and operating the downhole tool using the cable.
In another embodiment, a cable for deploying and operating a downhole tool includes: one or more electrical conductors extending a length of the cable; a jacket disposed around each conductor and extending the cable length; one or more layers of armor disposed around the jackets; sealant impregnated in the armor and extending only a portion of the cable length. The cable length is greater than or equal to five hundred feet. A length of the sealed portion is less than or equal to one-tenth of the cable length.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIGS. 1A-1C illustrate deployment of an electric submersible pump (ESP) into a wellbore, according to one embodiment of the present invention. FIG. 1A illustrates the ESP and a stuffing box being lowered toward a production tree. FIG. 1B illustrates installation of a mold around the cable. FIG. 1C illustrates the ESP deployed and operating.
FIGS. 2A-2D illustrate molding a portion of a cable with sealant. FIG. 2A illustrates the cable. FIG. 2B illustrates the mold assembled around the cable. FIG. 2C illustrates injection of sealant into the mold. FIG. 2D illustrates a portion of the cable impregnated by the sealant.
FIGS. 3A-3C illustrate deployment of the ESP into the wellbore, according to another embodiment of the present invention. FIG. 3A illustrates a mold connected to the blowout preventer (BOP). FIG. 3B illustrates the ESP and the stuffing box being lowered toward the tree. FIG. 3C illustrates the ESP deployed and operating.
FIGS. 4A-4D illustrate molding a portion of the cable with sealant. FIG. 4A is an enlargement of a portion of FIG. 3A illustrating the cable extending through the mold. FIG. 4B illustrates seals of the mold engaged with the cable. FIG. 4C illustrates injection of sealant into the mold. FIG. 4D illustrates a portion of the cable impregnated by the sealant.
DETAILED DESCRIPTION
FIGS. 1A-1C illustrate deployment of an electric submersible pump (ESP) 105 into a wellbore 5 , according to one embodiment of the present invention. FIG. 1A illustrates the ESP 105 and a stuffing box 115 being lowered toward a production tree 50 . The ESP 105 may be part of an artificial lift system (ALS) 100 . The ALS 100 may include the ESP 105 , a blowout preventer (BOP) 110 or BOP stack (only one BOP shown), the stuffing box 115 , and a launch and recovery system (LARS) 120 .
The wellbore 5 has been drilled from a surface 1 s of the earth into a hydrocarbon-bearing (i.e., crude oil and/or natural gas) reservoir 25 . A string of casing 10 c has been run into the wellbore 5 , hung from a wellhead 15 , and set therein with cement (not shown). The casing 10 c has been perforated 30 to provide to provide fluid communication between the reservoir 25 and a bore of the casing 10 c . A string of production tubing 10 p extends from the wellhead 15 to the reservoir 25 to transport production fluid 35 ( FIG. 1C ) from the reservoir 25 to the surface 1 s . A packer 12 has been set between the production tubing 10 p and the casing 10 c to isolate an annulus 10 a formed between the production tubing and the casing from production fluid 35 .
The production (aka Christmas) tree 50 may be installed on the wellhead 15 . The production tree 50 may include a master valve 51 , tee 52 , a swab valve 53 , a cap (not shown), and a production choke 55 . Production fluid 35 from the reservoir 25 may enter a bore of the production tubing 10 p , travel through the tubing bore to the surface 1 s . The production fluid may continue through the master valve 51 , the tee 52 , and through the choke 55 to a flow line (not shown). The production fluid 35 may continue through the flowline to surface separation, treatment, and storage equipment (not shown). The reservoir 25 may be dead due to depletion or kill fluid or the reservoir may be live and isolated by a subsurface safety valve (not shown), thereby obviating the need for a lubricator (not shown). Alternatively, the wellbore 5 may be live and the lubricator may be employed to lower the ESP into the wellbore.
To prepare for insertion of the ESP 105 into the wellbore 5 , one or more trucks (not shown) may deliver the ALS system 100 to the wellsite. The LARS 120 may include a control room 121 , a winch 124 having cable 130 wrapped therearound, a boom 125 , a generator 122 , a controller 123 , and a skid frame 126 . The generator 122 may be diesel-powered and provide alternating current (AC) power. The LARS controller 123 may include a transformer (not shown) for stepping the voltage of the AC power signal from the generator 122 from a low voltage signal to a medium voltage signal. The low voltage signal may be less than or equal to one kilovolt (kV) and the medium voltage signal may be greater than one kV, such as three to ten kV. The LARS controller 123 may further include a rectifier for converting the medium voltage AC signal to a medium voltage direct current (DC) power signal for transmission downhole via the cable 130 . The LARS controller 123 may be in electrical communication with the cable 130 via leads and an electrical coupling (not shown), such as brushes or slip rings, to allow power transmission through the cable while the winch 124 winds and unwinds the cable 130 . The LARS controller 123 may further include a data modem (not shown) and a multiplexer (not shown) for modulating and multiplexing a data signal to/from the downhole controller with the DC power signal. The winch 124 may include an electric or hydraulic motor (not shown) and a drum rotatable by the motor for winding or unwinding of the cable 130 .
The ESP 105 may include an electric motor 101 , a power conversion module (PCM) 102 , a seal section 103 , a pump 104 , an isolation device 106 , a cablehead 107 , and a flat cable 108 . Housings of each of the ESP components may be longitudinally and rotationally connected, such as by flanged or threaded connections. The cablehead 107 may include a cable fastener (not shown), such as slips or a clamp for longitudinally connecting the ESP to the cable 130 . Since the power signal may be DC, the cable 130 may only include two conductors arranged coaxially (discussed more below).
The cable 130 may be longitudinally coupled to the cablehead 107 by a shearable connection (not shown). The cable 130 may be sufficiently strong so that a margin exists between the deployment weight and the strength of the cable. For example, if the deployment weight is ten thousand pounds, the shearable connection may be set to fail at fifteen thousand pounds and the cable may be rated to twenty thousand pounds. The cablehead 107 may further include a fishneck so that if the ESP 105 become trapped in the wellbore 5 , such as by jamming of the isolation device 106 or buildup of sand, the cable 130 may be freed from rest of the components by operating the shearable connection and a fishing tool (not shown), such as an overshot, may be deployed to retrieve the ESP 105 .
The cablehead 107 may also include leads (not shown) extending therethrough and through the isolation device 106 . The leads may provide electrical communication between the conductors of the cable 130 and conductors of the flat cable 108 . The flat cable 108 may extend along the pump 104 and the seal section 102 to the PCM 102 . The flat cable 108 may have a low profile to account for limited annular clearance between the components 103 , 104 and the production tubing 10 p . Since the flat cable 108 may conduct the DC signal, the flat cable may only require two conductors (not shown) and may only need to support its own weight. The flat cable 108 may be armored by a metal or alloy.
The motor 101 may be an induction motor, a switched reluctance motor (SRM) or a permanent magnet motor, such as a brushless DC motor (BLDC). The motor 101 may be filled with a dielectric, thermally conductive liquid lubricant, such as motor oil. The motor 101 may be cooled by thermal communication with the production fluid 35 . The motor 101 may include a thrust bearing (not shown) for supporting a drive shaft (not shown). In operation, the motor 101 may rotate the drive shaft, thereby driving a pump shaft (not shown) of the pump 104 . The drive shaft may be directly connected to the pump shaft (no gearbox).
The induction motor may be a two-pole, three-phase, squirrel-cage induction type and may run at a nominal speed of thirty-five hundred rpm at sixty Hz. The SRM motor may include a multi-lobed rotor made from a magnetic material and a multi-lobed stator. Each lobe of the stator may be wound and opposing lobes may be connected in series to define each phase. For example, the SRM motor may be three-phase (six stator lobes) and include a four-lobed rotor. The BLDC motor may be two pole and three phase. The BLDC motor may include the stator having the three phase winding, a permanent magnet rotor, and a rotor position sensor. The permanent magnet rotor may be made of one or more rare earth, ceramic, or cermet magnets. The rotor position sensor may be a Hall-effect sensor, a rotary encoder, or sensorless (i.e., measurement of back EMF in undriven coils by the motor controller).
The PCM 102 may include a power supply, a motor controller (not shown), a modem (not shown), and demultiplexer (not shown). The power supply may include one or more DC/DC converters, each converter including an inverter, a transformer, and a rectifier for converting the DC power signal into an AC power signal and reducing the voltage from medium to low. Each converter may be a single phase active bridge circuit as discussed and illustrated in PCT Publication WO 2008/148613, which is herein incorporated by reference in its entirety. The power supply may include multiple DC/DC converters in series to gradually reduce the DC voltage from medium to low. For the SRM and BLDC motors, the low voltage DC signal may then be supplied to the motor controller. For the induction motor, the power supply may further include a three-phase inverter for receiving the low voltage DC power signal from the DC/DC converters and outputting a three phase low voltage AC power signal to the motor controller.
For the induction motor, the motor controller may be a switchboard (i.e., logic circuit) for simple control of the motor at a nominal speed or a variable speed drive (VSD) for complex control of the motor. The VSD controller may include a microprocessor for varying the motor speed to achieve an optimum for the given conditions. The VSD may also gradually or soft start the motor, thereby reducing start-up strain on the shaft and the power supply and minimizing impact of adverse well conditions.
For the SRM or BLDC motors, the motor controller may receive the low voltage DC power signal from the power supply and sequentially switch phases of the motor, thereby supplying an output signal to drive the phases of the motor. The output signal may be stepped, trapezoidal, or sinusoidal. The BLDC motor controller may be in communication with the rotor position sensor and include a bank of transistors or thyristors and a chopper drive for complex control (i.e., variable speed drive and/or soft start capability). The SRM motor controller may include a logic circuit for simple control (i.e. predetermined speed) or a microprocessor for complex control (i.e., variable speed drive and/or soft start capability). The SRM motor controller may use one or two-phase excitation, be unipolar or bi-polar, and control the speed of the motor by controlling the switching frequency. The SRM motor controller may include an asymmetric bridge or half-bridge.
The modem and demultiplexer may demultiplex a data signal from the DC power signal, demodulate the signal, and transmit the data signal to the motor controller. The motor controller may be in data communication with one or more sensors (not shown) distributed throughout the ESP 105 . A pressure and temperature (PT) sensor may be in fluid communication with the reservoir fluid 35 entering an inlet of the pump 104 . A gas to oil ratio (GOR) sensor may also be in fluid communication with the reservoir fluid 35 entering the pump inlet. A second PT sensor may be in fluid communication with the reservoir fluid 35 discharged from an outlet of the pump 104 . A temperature sensor (or PT sensor) may be in fluid communication with the lubricant to ensure that the motor 101 and PCM 102 are being sufficiently cooled. Multiple temperature sensors may also be included in the PCM 102 for monitoring and recording temperatures of the various electronic components. A voltage meter and current (VAMP) sensor may be in electrical communication with the cable 130 to monitor power loss from the cable. A second VAMP sensor may be in electrical communication with the power supply output to monitor performance of the power supply. Further, one or more vibration sensors may monitor operation of the motor 101 , the pump 104 , and/or the seal section 103 . A flow meter may be in fluid communication with the pump outlet for monitoring a flow rate of the pump 104 . Utilizing data from the sensors, the motor controller may monitor for adverse conditions, such as pump-off, gas lock, or abnormal power performance and take remedial action before damage to the pump 104 and/or motor 101 occurs.
The seal section 103 may isolate the reservoir fluid 35 being pumped through the pump 104 from the lubricant in the motor 101 by equalizing the lubricant pressure with the pressure of the reservoir fluid 35 . The seal section 103 may rotationally connect the drive shaft to the pump shaft. The seal section 103 may house a thrust bearing capable of supporting thrust load from the pump 104 . The seal section 103 may be positive type or labyrinth type. The positive type may include an elastic, fluid-barrier bag to allow for thermal expansion of the motor lubricant during operation. The labyrinth type may include tube paths extending between a lubricant chamber and a reservoir fluid chamber providing limited fluid communication between the chambers.
The pump inlet may be standard type, static gas separator type, or rotary gas separator type depending on the GOR of the production fluid 35 . The standard type inlet may include a plurality of ports allowing reservoir fluid 35 to enter a lower or first stage of the pump 104 . The standard inlet may include a screen to filter particulates from the reservoir fluid 35 . The static gas separator type may include a reverse-flow path to separate a gas portion of the reservoir fluid 35 from a liquid portion of the reservoir fluid 35 .
The isolation device 106 may include a packer, an anchor, and an actuator. The actuator may be operated mechanically by articulation of the cable 130 , electrically by power from the cable, or hydraulically by discharge pressure from the pump 104 . The packer may be made from a polymer, such as a thermoplastic, elastomer, or copolymer, such as rubber, polyurethane, or PTFE. The isolation device 106 may have a bore formed therethrough in fluid communication with the pump outlet and have one or more discharge ports formed above the packer for discharging the pressurized reservoir fluid into the production tubing 10 p . Once the ESP 105 has reached deployment depth, the isolation device actuator may be operated, thereby setting the anchor and expanding the packer against the production tubing 10 p , isolating the pump inlet from the pump outlet, and rotationally connecting the ESP 105 to the production tubing. The anchor may also longitudinally support the ESP 105 .
Additionally, the isolation device 106 may include a bypass vent (not shown) for releasing gas separated by the pump inlet that may collect below the isolation device and preventing gas lock of the pump 104 . A pressure relief valve (not shown) may be disposed in the bypass vent. Additionally, a downhole tractor (not shown) may be integrated into the cable 130 to facilitate the delivery of the ESP 105 , especially for highly deviated wells, such as those having an inclination of more than forty-five degrees or dogleg severity in excess of five degrees per one hundred feet. The drive and wheels of the tractor may be collapsed against the cable and deployed when required by a signal from the surface.
The pump 104 may be centrifugal or positive displacement. The centrifugal pump may be a radial flow or mixed axial/radial flow. The positive displacement pump may be progressive cavity. The pump 104 may include one or more stages (not shown). Each stage of the centrifugal pump may include an impeller and a diffuser. The impeller may be rotationally and longitudinally connected to the pump shaft, such as by a key. The diffuser may be longitudinally and rotationally coupled to a housing of the pump, such as by compression between a head and base screwed into the housing. Rotation of the impeller may impart velocity to the reservoir fluid 35 and flow through the stationary diffuser may convert a portion of the velocity into pressure. The pump 104 may deliver the pressurized reservoir fluid 35 to the isolation device bore.
Alternatively, the pump 104 may be a high speed compact pump discussed and illustrated at FIGS. 1C and 1D of U.S. patent application Ser. No. 12/794,547, filed Jun. 4, 2010, which is herein incorporated by reference in its entirety. High speed may be greater than or equal to ten thousand, fifteen thousand, or twenty thousand revolutions per minute (RPM). The compact pump may include one or more stages, such as three. Each stage may include a housing, a mandrel, and an annular passage formed between the housing and the mandrel. The mandrel may be disposed in the housing. The mandrel may include a rotor, one or more helicoidal rotor vanes, a diffuser, and one or more diffuser vanes. The rotor may include a shaft portion and an impeller portion. The rotor may be supported from the diffuser for rotation relative to the diffuser and the housing by a hydrodynamic radial bearing formed between an inner surface of the diffuser and an outer surface of the shaft portion. The rotor vanes may interweave to form a pumping cavity therebetween. A pitch of the pumping cavity may increase from an inlet of the stage to an outlet of the stage. The rotor may be longitudinally and rotationally connected to the motor drive shaft and be rotated by operation of the motor. As the rotor is rotated, the production fluid 35 may be pumped along the cavity from the inlet toward the outlet. The annular passage may have a nozzle portion, a throat portion, and a diffuser portion from the inlet to the outlet of each stage, thereby forming a Venturi.
The tree cap may be removed from the tree 50 . The BOP 110 may be connected to the swab valve 53 , such as by fastening. The BOP 110 may include one or more ram BOPS, such as two. The first ram BOP may include a pair of blind-shear rams (or separate blind rams and shear rams) capable of cutting the cable 130 when actuated and sealing the bore, and a second ram BOP may include a pair of cable rams for sealing against an outer surface of the cable 130 when actuated. The LARS 120 may further include a hydraulic power unit (HPU, not shown) for operating the BOP stack 110 . Once the BOP 110 has been installed, the cable 130 may then be inserted through the stuffing box 115 and fastened to the cablehead 105 . The boom 125 may be used to hoist the ESP and stuffing box over the BOP 110 . The swab valve 53 and master valve 51 may then be opened. The ESP 105 may be lowered through the tree 50 and into the wellbore until the stuffing box 115 engages the BOP 110 . Lowering may be halted and the stuffing box 115 may be fastened to the BOP 110 , such as by a flanged connection. Lowering of the ESP 105 into the wellbore 5 may resume until the ESP is proximately above deployment depth.
FIG. 1B illustrates installation of a mold 200 around the cable 130 . The winch 124 may be locked with the ESP 105 in the wellbore 5 proximately above deployment depth. Alternatively, the isolation device 106 may be set to support the ESP 105 . The mold 200 may be assembled around the cable 130 above the stuffing box 115 .
FIGS. 2A-2D illustrate molding a portion 150 of the cable 130 with sealant 250 . FIG. 2A illustrates the cable 130 . The cable 130 may include an inner core 131 , an inner jacket 132 , a shield 133 , an outer jacket 136 , and one or more layers 138 i,o of armor.
The inner core 131 may be the first conductor and made from an electrically conductive material, such as aluminum, copper, or alloys thereof. The inner core 131 may be solid or stranded (shown). The inner jacket 132 may electrically isolate the core 131 from the shield 133 and be made from a dielectric material, such as a polymer. The shield 133 may serve as the second conductor and be made from the electrically conductive material. The shield 133 may be tubular (shown), braided, or a foil covered by a braid. The outer jacket 136 may electrically isolate the shield 133 from the armor 138 i,o and be made from an oil-resistant dielectric material. The armor may be made from one or more layers 138 i,o of high strength material (i.e., tensile strength greater than or equal to one hundred, one fifty, or two hundred kpsi) to support the deployment weight (weight of the cable 130 and the weight of the ESP 105 )) so that the cable 130 may be used to deploy and remove the ESP 105 into/from the wellbore 5 . The high strength material may be a metal or alloy and corrosion resistant, such as galvanized steel or a nickel alloy depending on the corrosiveness of the reservoir fluid 35 . The armor may include two contra-helically wound layers 138 i,o of wire or strip.
Additionally, the cable 130 may include a sheath 135 disposed between the shield 133 and the outer jacket 136 . The sheath 135 may be made from lubricative material, such as polytetrafluoroethylene (PTFE) or lead, and may be tape helically wound around the shield 133 . If lead is used for the sheath 135 , a layer of bedding 134 may insulate the shield 133 from the sheath and be made from the dielectric material. Additionally, a buffer 137 may be disposed between the armor layers 138 i,o . The buffer 137 may be tape and may be made from the lubricative material. The buffer 137 may be perforated to allow sealant flow to the inner armor layer 138 i
Due to the coaxial arrangement, the cable 130 may have an outer diameter less than or equal to one and one-quarter inches, one inch, or three-quarters of an inch. Alternatively, the conductors 131 , 133 may be eccentrically arranged and/or the cable 130 may include three or more conductors, such as three, and conduct three-phase AC power to the motor 101 (obviating the PCM 102 ). Alternatively, the cable 130 may include only one conductor and the production tubing 10 p may be used for the other conductor.
FIG. 2B illustrates the mold 200 assembled around the cable 130 . The mold 200 may be delivered to the wellsite by a service truck (not shown). The service truck may include a reaction injector and a crane or platform to lift the mold to a top of the stuffing box. The reaction injector may include a pair of supply tanks each having a liquid reactive component (aka resin and hardener) stored therein. The supply tanks or the components may or may not be heated. The service truck may further include a pair of feed pumps, each having an inlet connected to a respective supply tank. An outlet of each supply pump may be connected to a mix head and an outlet of the mix head may connect to the mold 200 . The service truck may further include an HPU for powering the supply pumps. The service truck may further include a controller for proportioning the feed pumps. The feed pumps may be operated to simultaneously supply the liquid reactive components to the mix head. The mix head may impinge the liquid components to begin polymerization of the sealant mixture 250 . The sealant mixture 250 may continue from the mix head into the mold 200 .
Alternatively, the service truck may include an injector, a crane or platform to lift the injector and the mold to a top of the stuffing box, and an HPU to power the injector. The injector may include a hopper, a barrel, a driver, and a heater. The heater may surround the mold side of the barrel. The driver may be a rotating screw disposed in the barrel. The screw may have a feed section, transition section, and a metering section. The feed section may receive sealant pellets from the hopper and convey them to the transition section. The transition section may compress the pellets into a molten sealant and pump the molten sealant to the metering section. The screw may be supported by a hydraulic ram that is displaced away from the mold by the sealant feed through the screw. The hydraulic ram may then reverse to inject the molten sealant into the mold. Alternatively, the driver may be a hydraulic plunger and a torpedo spreader.
The mold 200 may include a split housing 205 and upper 210 u and lower 210 b seals ( FIG. 1B ). The housing 205 may include a pair of mating semi-tubular segments 205 a,b . Each housing segment 205 a,b may have radial couplings, such as flanges 208 , formed therealong and half of a longitudinal coupling 211 formed at one or both longitudinal ends thereof. The radial flanges 208 of each housing segment 205 a,b may be connected to the mating radial flanges by fasteners 207 , such as bolts and nuts. A gasket 209 may be disposed in a groove formed in one of the housing segments for sealing the radial connection. Alternatively, the radial couplings may instead be a hinge and latch. Each seal 210 u,b may include a pair of mating semi-annular segments. One segment of each seal 210 u,b may include a coupling (not shown) formed at ends thereof, such as a ball and the other segment may include a mating coupling, such as a socket, so that the couplings mate when the housing 205 is assembled.
An inner diameter of the mold housing 205 may be slightly greater than an outer diameter of the cable 130 , thereby forming an annulus 212 between the mold housing and the cable. The housing 205 may have a sprue 206 formed through a wall of one of the segments 205 a,b and in fluid communication with the annulus 212 . An inner diameter of the mold seals 210 u,b may be slightly less than an outer diameter of the cable 130 so that the mold seals engage an outer surface of the cable when the mold 200 is assembled.
The service truck crane/platform may lift each of the housing segments 205 a,b on to the stuffing box 115 . The housing segments 205 a,b may be radially assembled around the cable 130 using the fasteners 207 . The assembled housing 205 may then be connected to the stuffing box 115 via the flange 211 . Alternatively, the housing 205 may just rest on the stuffing box 115 .
FIG. 2C illustrates injection of sealant 250 into the mold 200 . The sealant 250 may be a polymer, such as a thermoplastic, elastomer, copolymer, or thermoset, such as polyisoprene, polybutadiene, polyisobutylene, polychloroprene, butadiene-styrene rubber, styrene-butadiene copolymer (thermoplastic elastomer), butadiene-acrylonitrile, acrylonitrile butadiene styrene (ABS), silicone, ethylene propylene diene monomer (EPDM) rubber, or polyurethane.
Once the mold 200 has been assembled around the cable 130 , the mix head may be lifted to the mold 200 by the service truck crane or the service truck platform may lift the reaction injector to the mold 200 . The mix head may be connected to the sprue 206 . The supply pumps may then be operated to pump the liquid reactants to the mix head. The sealant mixture 250 may continue from the mix head into the mold 200 . Air displaced by the sealant mixture 250 may vent from the mold via leakage through and along the armor 138 i,o . The sealant mixture 250 may flow around and along the annulus 212 until the sealant mixture 250 encounters the seals 210 u,b . Pressure in the mold 200 may increase and the sealant mixture 250 may be forced into the armor 138 i,o . Sealant penetration into the cable 130 may be stopped by the outer jacket 136 . Pumping of the sealant mixture 250 may continue until the mold 200 is filled. The mold 200 may be heated by exothermic polymerization of the mixture 250 . A melting temperature of the mold seals 210 u,b , gasket 209 , and outer jacket 136 may be suitable to withstand the exothermic reaction.
FIG. 2D illustrates a portion 150 of the cable 130 impregnated by the sealant 250 . Once the sealant 250 has cured and cooled to at least a point sufficient to maintain structural integrity, the mix head may be disconnected from the mold 200 and the mold 200 may be disconnected from the stuffing box 115 . The fasteners 207 may then be removed. The service truck may further include a hydraulic spreader. The spreader may be connected to the mold 200 and operated to separate the mold. The service truck may stow the mold 200 and mix head and leave the wellsite.
A length of the sealed portion 150 may be greater than or equal to a length of a seal of the stuffing box 115 . For example, the sealed portion length may be greater than or equal to one foot, three feet, five feet, six feet, or ten feet. A length of the cable 130 may be greater than or equal to five hundred or one thousand feet. The sealed portion length may be substantially less than a length of the cable 130 , such as less than or equal to one-tenth, one hundredth, or one thousandth the cable length. An outer diameter of the sealed portion 150 may be slightly greater than an outer diameter of the rest of the cable 130 . Alternatively, the outer diameter of the sealed portion 150 may be equal to an outer diameter of the rest of the cable 130 , such as by eliminating the annulus 212 or trimming the sealed portion.
FIG. 1C illustrates the ESP 105 deployed and operating. The winch 124 may then be unlocked and operated to lower the ESP 105 to deployment depth. As the ESP 105 is lowered, the sealed portion 150 may be lowered into alignment with the stuffing box seal. The isolation device 106 may then be set to engage the production tubing 10 p and the stuffing box 115 may be operated to engaged the sealed portion 150 . The ESP 105 may then be operated to pump production fluid 35 from the wellbore 5 to the tree 50 and through the tree to the surface separation, treatment, and storage equipment.
FIGS. 3A-3C illustrate deployment of the ESP 105 into the wellbore, 5 according to another embodiment of the present invention. FIG. 3A illustrates a mold 300 connected to the BOP 110 . The service truck discussed above in conjunction with the mold 200 may deliver the mold 300 to the wellsite. The tree cap may be removed from the tree 50 . The BOP 110 may be connected to the swab valve 53 . The swab valve 53 and master valve 51 may then be opened. The cable 130 may then be inserted through the mold 300 . A cablehead (not shown) may be fastened to the cable 130 and used to lift the mold 300 over the BOP 110 and lower the mold on to the BOP. The mold 300 may then be fastened to the BOP 110 . Alternatively, the platform/crane of the service truck may be used to lift the mold 300 on to the BOP 110 . The mold 300 may then be fastened to the BOP 110 and the cable 130 may be inserted through the mold and the tree 50 into the wellbore 5 . The cable 130 may then be lowered into the wellbore 5 until proximately above the ESP deployment depth.
FIGS. 4A-4D illustrate molding a portion 150 of the cable 130 with the sealant 250 . FIG. 4A is an enlargement of a portion of FIG. 3A illustrating the cable 130 extending through the mold 300 . The mold 300 may include a runner 305 , and upper 315 u and lower 315 b stuffing boxes. The runner 305 may include one or more tubular sections 305 u,b connected by a coupling 308 . Each section 305 u,b may include a housing 309 and an insert 307 . An annular coupling 308 may connect to each of the runner sections, such as by a threaded connection. Each housing 309 may also connect to a housing 316 of a respective stuffing box 315 u,b , such as by a threaded connection. The coupling 308 may have a shoulder formed therein for receiving an end of each insert 307 and each stuffing box housing 316 may have a shoulder for receiving the other end of each insert. An inner diameter of the inserts 307 may be slightly greater than an outer diameter of the cable 130 , thereby forming an annulus 312 between the inserts 307 and the cable 130 . The coupling 308 may have a sprue 306 formed through a wall thereof in fluid communication with the annulus 312 .
Each stuffing box 315 u,b may include a tubular housing 316 , a seal 320 , a piston 318 , and a spring 317 . Each housing 316 may include one or more sections and each housing section may be connected, such as by threads. A port 319 may be formed through the housing in communication with the piston 318 . The port 319 may be connected to the service truck HPU via a hydraulic conduit (not shown). When operated by hydraulic fluid, the piston 318 may longitudinally compress the seal 320 , thereby radially expanding the seal 320 inward into engagement with the cable 130 . The spring 317 may bias the piston 318 away from the seal 320 . Alternatively, the spring 317 may be omitted and bias from the seal 320 may be used to disengage the seal from the cable 130 .
FIG. 4B illustrates seals 320 of the mold 300 engaged with the cable 130 . Once the cable 130 has been lowered to a depth proximately above the ESP deployment depth, hydraulic fluid may be supplied to the stuffing box ports 319 , thereby engaging the stuffing box seals 320 with the cable 130 .
FIG. 4C illustrates injection of sealant 250 into the mold 300 . Once the seals 320 engage the cable 130 , the mix head may be connected to the sprue 306 . The sealant mixture 250 may then be pumped into the mold 300 . Air displaced by the sealant mixture 250 may vent from the die via leakage through and along the armor 138 i,o . The sealant mixture 250 may flow around and along the annulus 312 until the sealant mixture 250 encounters the seals 320 . Pressure in the mold 300 may increase and the sealant mixture 250 may be forced into the armor 138 i,o . Sealant penetration into the cable 130 may be stopped by the outer jacket 136 . Pumping of the sealant mixture 250 may continue until the mold 300 is filled.
FIG. 4D illustrates a portion 150 of the cable 130 impregnated by the sealant 250 . Once the sealant 250 has cured and cooled to at least a point sufficient to maintain structural integrity, hydraulic pressure may be relieved from the ports 319 . The winch 124 may then be operated to pull the sealed portion 150 free from the mold 300 and may continue winding the cable 130 until an end of the cable is above the mold 300 . The mix head may be disconnected from the mold 300 . The mold 300 may be disconnected from the BOP 110 . The service truck may stow the mold 300 and mix head and leave the wellsite.
FIG. 3B illustrates the ESP 105 and the stuffing box 115 being lowered toward the tree 50 . The cable 130 may then be inserted through the stuffing box 115 and fastened to the cablehead 105 . The boom 125 may be used to hoist the ESP 105 and stuffing box 115 over the BOP 110 . The ESP 105 may be lowered through the tree 50 and into the wellbore 5 until the stuffing box 115 engages the BOP 110 . Lowering may be halted and the stuffing box 115 may be fastened to the BOP 110 . Lowering of the ESP 105 into the wellbore 5 may resume until the ESP is at the deployment depth.
FIG. 3C illustrates the ESP 105 deployed and operating. As the ESP 105 is lowered to the deployment depth, the sealed portion 150 may be lowered into alignment with the stuffing box seal. The isolation device 106 may then be set to engage the production tubing 10 p and the stuffing box 115 may be operated to engaged the sealed portion 150 . The ESP 105 may then be operated to pump production fluid 35 from the wellbore 5 to the tree 50 and through the tree to the surface separation, treatment, and storage equipment.
Advantageously, the sealed portion 150 obviates the need for grease injection while the ESP 105 is operating. Once the ESP 105 needs to be retrieved from the wellbore 5 for maintenance and/or replacement, the cable 130 may be inspected and reused to deploy the repaired/replaced ESP into the wellbore, the cable may be replaced and resealed, or the sealed portion may be cut and the remaining cable resealed to deploy the repaired/replaced ESP into the wellbore.
Alternatively, the cable 130 (with sealed portion 150 ) may be used to deploy and operate other downhole tools besides an ESP, such as a compressor.
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 of deploying a downhole tool into a wellbore includes: lowering a cable into the wellbore; after lowering the cable, engaging a mold with an outer surface of the cable; injecting sealant into the mold and into armor of the cable, thereby sealing a portion of the cable; lowering the downhole tool to a deployment depth using the cable; engaging a seal with the sealed portion of the cable; and operating the downhole tool using the cable.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application Ser. No. 62/204,211, filed Aug. 12, 2015, entitled “BELT ASSEMBLY FOR HIGH-SPEED INKJET PRINTING,” which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a belt assembly for a printer. It has been developed primarily to provide a media feed mechanism suitable for high-speed inkjet printing.
BACKGROUND OF THE INVENTION
[0003] The Applicant has developed a range of Memjet® inkjet printers as described in, for example, WO2011/143700, WO2011/143699 and WO2009/089567, the contents of which are herein incorporated by reference. Memjet® printers employ a stationary printhead in combination with a feed mechanism which feeds print media past the printhead in a single pass. Memjet® printers therefore provide much higher printing speeds than conventional scanning inkjet printers.
[0004] High-speed single-pass inkjet printing requires accurate media handling, especially in the print zone of the printhead, in order to provide acceptable print quality. For relatively narrow print zones (e.g. A4 size or narrower), a system of entry and exit rollers in combination with a fixed media platen generally provides sufficient stability in the print zone (see, for example, U.S. Pat. No. 8,523,316, the contents of which are herein incorporated by reference). However, for wider media widths and/or faster print speeds, more complex media feed mechanisms are required to provide acceptable print quality. For example, U.S. Pat. No. 8,540,361 describes a feed mechanism suitable for wideformat printing comprising a combination of a fixed vacuum platen, an upstream drive roller and a downstream vacuum belt mechanism.
[0005] Vacuum belt mechanisms are an attractive means for moving print media at high speeds through a print zone. Various vacuum belt mechanisms for high-speed printing are described in, for example, US 2007/0247505, US 2007/0035605, US 2008/0218576, U.S. Pat. No. 6,328,439, U.S. Pat. No. 6,698,878 and WO02/78958. Referring to FIGS. 1A and 1B , prior art vacuum belt mechanisms typically comprise an endless belt 1 tensioned between a first roller 3 positioned upstream of a print zone 5 and a second roller 7 positioned downstream of the print zone. A printhead assembly 9 is positioned over an upper surface of the belt 1 while a vacuum blower 11 is positioned below the belt for suctioning print media onto the upper surface. The printhead assembly 9 is liftable away from the belt to allow intervention from a maintenance station 13 , when required ( FIG. 2A ). Likewise, the entire vacuum belt mechanism 10 may be movable away from printhead assembly 9 to facilitate clearance of paper jams.
[0006] A problem with prior art vacuum belt mechanisms, such as the mechanism described in connection with FIG. 1A , is that the belt may become fouled with ink. Ink mist generated in the print zone during printing is drawn towards the belt by the vacuum blower, thereby fouling the belt and, consequently, fouling paper in contact with the belt. Furthermore, it is desirable for inkjet printheads to spit ink regularly so as to avoid nozzles becoming clogged with a plug of viscous ink. Typically, inkjet printheads perform a number of inter-page spits so as to reduce the frequency of maintenance interventions. However, endless belts are not amenable to inter-page spitting due to ink fouling.
[0007] It would be desirable to provide a printer having a belt assembly suitable for high-speed inkjet printing.
SUMMARY OF THE INVENTION
[0008] The present invention provides a printer comprising:
a printhead assembly having a print zone; a belt assembly for feeding print media past the print zone in a media feed direction, the belt assembly comprising:
an endless belt tensioned between a first roller upstream of the print zone and a second roller downstream of the print zone; a drive mechanism for moving the endless belt in the media feed direction; and a fixed platen positioned in the print zone,
wherein the endless belt is guided around and below the fixed platen.
[0014] The printer of the present invention enjoys the advantages of high-speed media feeding using an endless belt, whilst advantageously avoiding the usual problems of ink fouling the belt.
[0015] Preferably, the fixed platen comprises a spittoon for receiving ink. The spittoon advantageously collects ink spitted from the printhead, such as inter-page spits which are used to maintain healthy nozzles during a print job.
[0016] Preferably, the printhead assembly comprises one or more fixed inkjet printheads configured for singe-pass printing.
[0017] Preferably, the printer further comprises a printhead lift mechanism for moving the printhead assembly between a printing position and a maintenance position.
[0018] Preferably, the printer further comprises a maintenance station for capping and/or wiping the printhead in the maintenance position.
[0019] Preferably, the printer further comprises a belt lift mechanism for moving the belt assembly towards and away from the printhead assembly.
[0020] Preferably, the endless belt comprises an apertured belt and the belt assembly further comprises at least one vacuum blower for suctioning print media onto a surface of the apertured belt.
[0021] Preferably, the belt assembly comprises one or more rollers for guiding the endless belt below the fixed platen.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings, in which:
[0023] FIG. 1A is a schematic side view of a prior art vacuum belt assembly in a printing position;
[0024] FIG. 1B shows the prior art vacuum belt assembly of FIG. 1A in a maintenance position;
[0025] FIG. 2A is a schematic side view of a printer according to the present invention in a printing position;
[0026] FIG. 2B shows the printer of FIG. 2A in a maintenance position;
[0027] FIG. 3 shows an alternative pathway of a belt around a fixed platen; and
[0028] FIG. 4 is a schematic plan view of an apertured belt and fixed platen.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Referring to FIGS. 2A and 2B , there is shown a printer 100 comprising a belt assembly 21 and a printhead assembly 9 , in accordance with the present invention. The printhead assembly 9 has an associated print zone 5 which is defined by the printable area of the printhead assembly. The printhead assembly 9 may be comprised of one or more fixed inkjet printheads, each of which may be comprised of a plurality of individual printhead chips. By way of example, U.S. Pat. No. 8,540,361 (the contents of which are incorporated herein by reference) describes a printhead assembly comprising five staggered printheads, each printhead comprising eleven printhead chips butted in a row. Alternatively, the printhead assembly 9 may comprise a single printhead, as described in U.S. Pat. No. 8,523,316. Alternatively, the printhead assembly 9 may comprise a pair of overlapping printheads.
[0030] The printhead assembly 9 is positioned over a fixed platen 20 positioned in the print zone 5 of the printhead assembly. An endless belt 1 feeds print media (e.g. paper 22 ) from an upstream side of the printhead assembly 9 to a downstream side. The endless belt 1 is tensioned between a first roller 3 positioned upstream of the printhead assembly 9 and a second roller 7 positioned downstream of the printhead assembly. The first roller 3 is an idler roller while the second roller 7 is a drive roller operatively connected to a drive mechanism indicated schematically by arrow 24 . In the embodiment shown in FIG. 2A , additional rollers 26 guide the endless belt 1 around a loop. It will be appreciated that the number and position of additional rollers 26 is not particularly important to the present invention.
[0031] An upstream vacuum blower 11 A and a downstream vacuum blower 11 B impart a suction force onto the belt 1 so as to draw the paper 22 onto an upper surface of the belt. As shown in FIG. 4 , the belt 1 has a plurality of apertures 28 so that the paper 22 experiences a suction force through the belt.
[0032] A plurality of guide rollers 30 A-D are positioned to guide the endless belt 1 in a path around and below the fixed platen 20 . Thus, the endless belt 1 does not move through the print zone 5 and the sheet of paper 22 is supported by the fixed platen 20 when moving through the print zone. The number and position of guide rollers 30 and the precise path of the endless belt 1 around the fixed platen 20 is not particularly important. For example, by way of an alternative arrangement, the endless belt 1 may follow a generally triangular path around the fixed platen 20 with one central guide roller 30 E positioned below the fixed platen ( FIG. 3 ). These and other guide roller arrangements will be readily apparent to the person skilled in the art.
[0033] Turning to FIG. 4 , the fixed platen 20 comprises a spittoon 32 in the form of an opening positioned opposite the print zone 5 . The spittoon 32 is positioned to collect ink spitted from the printhead assembly 9 , such as inter-page spits which are used to maintain nozzle health during print jobs. The spittoon 32 may comprise an absorbent material and/or a suitable arrangement for wicking ink away from the fixed platen 20 . Alternatively or additionally, the spittoon 32 may be connected to a vacuum source (not shown). For example, the fixed platen 20 may be in the form of a vacuum platen to further assist with paper control through the print zone 5 .
[0034] Referring again to FIG. 2A , the entire belt assembly 21 , including the fixed platen 20 and endless belt 1 , is operatively connected to a belt lift mechanism, which is schematically represented by arrow 34 . The belt lift mechanism 34 moves the belt assembly 21 towards and away from the printhead assembly 9 to facilitate clearance of paper jams. Suitable sensors (not shown) may be provided for detecting paper jams and actuating the belt lift mechanism 34 to lower the belt assembly 21 when a paper jam is detected.
[0035] Similarly, the printhead assembly 9 is operatively connected to a printhead lift mechanism, which is schematically represented by arrow 36 . The printhead lift mechanism 36 moves the printhead assembly 9 towards and away from the fixed platen 20 and belt 1 to enable maintenance of the printhead assembly by the maintenance station 13 . The maintenance station 13 is operatively connected to a translation mechanism 38 for slidably moving the maintenance station towards and away from the printhead assembly 9 . U.S. Pat. No. 9,061,531, the contents of which are incorporated herein by reference, describes a printhead lift mechanism and sliding maintenance station suitable for maintaining a fixed inkjet printhead. Typically, the maintenance station 13 comprises a capping module and a wiping module, as described in U.S. Pat. No. 9,061,531.
[0036] FIG. 2B shows the printer 100 in a maintenance position whereby the printhead assembly 9 is lifted away from the fixed platen 20 and belt 1 by the printhead lift mechanism 36 , and the maintenance station 13 has slid beneath the printhead assembly 9 by operation of the translation mechanism 38 . The printhead(s) may be capped or wiped in this maintenance position.
[0037] FIG. 2A shows the printer 100 in a printing position. The endless belt 1 is driven at constant speed by the drive mechanism 24 to convey the paper 22 in the media feed direction. The paper 22 is initially fed onto an upper surface of an upstream portion 40 of the belt 1 by a suitable paper picker (not shown). The paper 22 is suctioned onto the belt 1 by the upstream vacuum blower 11 A and moved towards the print zone 5 . The paper 22 is then transferred from the belt 1 onto the fixed platen 20 to move through the print zone 5 . Finally, the paper 22 is transferred from the fixed platen 20 onto a downstream portion 42 of the belt 1 and moved away from the print zone 5 . The endless belt 1 and vacuum blowers 11 A and 11 B enable smooth transportation of the paper 22 at constant speed with excellent control of paper movement. Moreover, diverting the endless belt 1 around and below the fixed platen 20 in the print zone 5 avoids fouling of the belt by ink mist or spitted ink. The spittoon 32 in the fixed platen 20 collects any non-printing ink, which can be readily removed without contaminating the belt 1 .
[0038] It will, of course, be appreciated that the present invention has been described by way of example only and that modifications of detail may be made within the scope of the invention, which is defined in the accompanying claims.
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A printer includes: a printhead assembly having a print zone and a belt assembly for feeding print media past the print zone in a media feed direction. The belt assembly includes: an endless belt tensioned between a first roller upstream of the print zone and a second roller downstream of the print zone; a drive mechanism for moving the endless belt in the media feed direction; and a fixed platen positioned in the print zone. The endless belt is guided around and below the fixed platen.
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RELATED APPLICATIONS
[0001] This application is a divisional application of and claims the benefit of U.S. Ser. No. 10/568,896, filed on Aug. 29, 2006, which is claims the benefit of and priority to PCT Application No. PCT/EP2004/006088 filed on Jun. 5, 2004 (claiming priority from German Application Nos. 10 2004 018 777.0 filed Apr. 19, 2004 and 103 38 719.6 filed Aug. 22, 2003), entitled “Counter Track Joint for Large Deflection Angles”.
TECHNICAL FIELD
[0002] The invention relates to a constant velocity joint in the form of a counter track joint with the following characteristics:
[0003] an outer joint part which comprises a longitudinal axis L 12 and an attaching end and an aperture end arranged so as to be axially opposite one another, and which is provided with outer ball tracks;
[0004] an inner joint part which comprises a longitudinal axis L 13 and attaching means for a shaft pointing towards the aperture end of the outer joint part, and which is provided with inner ball tracks;
[0005] the outer ball tracks and the inner ball tracks form pairs of tracks with one another, the pairs of tracks each accommodate a torque transmitting ball;
[0006] an annular ball cage is positioned between the outer joint part and the inner joint part and comprises circumferentially distributed cage windows which each accommodate at least one of the torque transmitting balls,
[0007] the centers of the balls are held by the cage in a joint center plane EM and, upon articulation of the joint, are guided onto the angle-bisecting plane between the longitudinal axes L 12 , L 13 ,
[0008] for a first part of the pairs of tracks, the opening angle α 1 between the tangents T 22 1 ′, T 23 1 ′ at track base lines extending parallel to the tangents T 22 1 , T 23 1 at the center lines M 22 1 , M 23 1 of the ball tracks in the joint center plane EM when the joint is in the aligned condition with coinciding longitudinal axes L 12 , L 13 , opens from the attaching end to the aperture end. For a second part of the pairs of tracks, the opening angle α 2 between the tangents T 22 2 ′, T 23 2 ′ at track base lines extending parallel to the tangents T 22 2 , T 23 2 at the center lines of the ball tracks in the joint center plane when the joint is in the aligned condition with coinciding longitudinal axes L 12 , L 13 opens from the aperture end to the attaching end. With reference to the joint center plane EM, the center lines of pairs of tracks are substantially mirror-image like relative to one another.
BACKGROUND
[0009] Prior art counter track joints comprise an even number of pairs of tracks. The first half of said pairs of tracks opens towards the aperture end of the outer joint part. The other half of said pairs of tracks opens towards the attaching end of the outer joint part. The pairs of tracks of the first type and second type are arranged so as to alternate if viewed in the circumferential direction. The tracks are arranged on meridian planes R which, in the circumferential direction, comprise uniform pitch angles of 360°/n, with n being the number of pairs of tracks, e.g. 6, 8, 10.
[0010] The alternating pairs of tracks are curved in such a way that, in the joint center plane EM, they comprise a tangent angle α 1 , α 2 at the track base lines, which angles are identical in size, but differ in respect of orientation, and the track extensions of the alternating pairs of tracks are mirrored with reference to the joint center plane.
[0011] Prior art counter track joints permit only a relatively small articulation angle of 35°, which is due to the pairs of tracks opening towards the attaching end of the outer joint part and closing towards the aperture end and having to be relatively short towards the aperture end to allow the cage to be mounted in the outer joint part.
[0012] U.S. Publication No. 2004/0116192 proposes counter track joints wherein the second pairs of tracks are provided with different track shapes which also include track center lines extending in an S-shaped way and having a turning point in the outer joint part and in the inner joint part. The track center lines are defined as being the path of the centers of the balls in the ball tracks.
SUMMARY OF THE INVENTION
[0013] The present invention provides fixed joints of the above-described type with increased articulation angles.
[0014] A first solution provides a constant velocity joint in the form of a counter track joint having:
[0015] an outer joint part which comprises a longitudinal axis L 12 and an attaching end and an aperture end arranged so as to be axially opposite one another, and which is provided with outer ball tracks; and
[0016] an inner joint part which comprises a longitudinal axis L 13 and an attachment for a shaft pointing towards the aperture end of the outer joint part, and which is provided with inner ball tracks.
[0017] The outer ball tracks and the inner ball tracks form pairs of tracks with one another, the pairs of tracks each accommodate a torque transmitting ball.
[0018] An annular ball cage is positioned between the outer joint part and the inner joint part and comprises circumferentially distributed cage windows which each accommodate at least one of the torque transmitting balls.
[0019] The centers of the balls are held by the cage in a joint center plane and, upon articulation of the joint, are guided onto the angle-bisecting plane between the longitudinal axes.
[0020] The center lines M 22 , M 23 of the ball tracks of pairs of tracks are positioned in radial planes R through the joint. For a first part of the pairs of tracks, the opening angle α 1 between the tangents T 22 1 ′, T 23 1 ′ at track base lines extending parallel to the tangents T 22 1 , T 23 1 at the center lines M 22 1 , M 23 1 of the ball tracks in the joint center plane EM when the joint is in the aligned condition with coinciding longitudinal axes L 12 , L 13 opens from the attaching end to the aperture end.
[0021] For a second part of the pairs of tracks, the opening angle α 2 between the tangents T 22 2 ′, T 23 2 ′ at track base lines extending parallel to the tangents T 22 2 , T 23 2 at the center lines M 22 2 , M 23 2 of the ball tracks 22 2 , 23 2 in the joint center plane EM when the joint is in the aligned condition with coinciding longitudinal axes L 12 , L 13 opens from the aperture end to the attaching end. The following applies to the center lines of the second pairs of tracks;
[0022] in the outer joint part, the center line M 22 2 of the ball tracks in the region from the joint center plane EM to the attaching end radially inwardly leaves a reference radius RB whose radius center MB is positioned in the point of intersection of a perpendicular line on the tangent T 22 2 ′ at the center line M 22 2 of the ball track in the joint center plane EM and of the longitudinal axis L 12 ;
[0023] in the inner joint part, the center line M 23 2 of the ball tracks in the region from the joint center plane EM to the aperture end radially inwardly leaves a reference radius RB′ whose radius center MB′ is positioned in the point of intersection of a perpendicular line on the tangent T 23 2 ′ at the centre line M 23 2 of the ball track in the joint center plane EM and of the longitudinal axis (L 13 ).
[0024] In the outer joint part, the center line M 22 2 of the ball tracks in the region from the joint center plane EM to the aperture end moves radially outwardly beyond said reference radius RB.
[0025] In the inner joint part, the center line M 23 2 of the ball tracks in the region from the joint center plane EM to the attaching end moves radially outwardly beyond said reference radius RB′.
[0026] The track shape given here permits the maximum articulation angle to be increased relative to prior art track shapes. The characteristic mentioned first according to which the center lines leave the reference radii inwardly can start directly at the joint center plane or even at a later stage, and it can behave so as to increase progressively. The second characteristic mentioned according to which the center lines move outwardly beyond the reference radius includes a direct outward movement away from the reference radius as well as a later crossing of the reference radius and subsequent outward movement.
[0027] According to a further embodiment, the constant velocity joint is provided with the following further characteristics of the second pairs of tracks:
[0028] in the outer joint part, the local radius of curvature R 1 of the center line M 22 2 in the joint center plane EM is smaller than the reference radius RB; and
[0029] in the inner joint part, the local radius of curvature R 1 ′ of the center line M 23 2 in the joint centre plane EM is smaller than the reference radius RB′.
[0030] According to another embodiment, the constant velocity joint is provided with the following further characteristics of the second pairs of tracks:
[0031] in the outer joint part, the center line M 22 2 of the ball tracks extends from the joint center plane EM to the attaching end radially outside a reference radius RZ whose radius center is positioned in the joint center M; and in the inner joint part, the center line M 23 2 of the ball tracks extends from the joint center plane EM to the aperture end radially outside a reference radius RZ′ whose radius center is positioned in the joint center M.
[0032] A further advantageous embodiment refers to the following further characteristics of the second pairs of tracks:
[0033] in the outer joint part, the center line M 22 2 of the ball tracks extends from the joint center plane EM to the aperture end radially outside a reference radius RB and,
[0034] in the inner joint part, the center line M 23 2 of the ball tracks extends from the joint center plane EM to the attaching end radially outside a reference radius RB′.
[0035] According to a further embodiment, the following further characteristics are proposed: in the outer joint part, the center line M 22 2 of the ball tracks extends from the joint center plane EM to the aperture end radially inside a reference radius RZ around the joint center M; and
[0036] in the inner joint part, the center line M 23 2 of the ball tacks extends from the joint center plane EM to the attaching end radially inside a reference radius RZ′ around the joint center M.
[0037] According to a further embodiment, the following further characteristics of the second ball tracks are proposed:
[0038] the center lines M 22 2 , M 23 2 of the outer ball tracks and inner ball tracks each comprise at least two arched portions which are curved in opposite senses and which adjoin one another in a turning point.
[0039] The turning points W 22 2 of the outer ball tracks are positioned at a distance from the center plane EM towards the aperture end.
[0040] The turning points W 23 2 of the inner ball tracks are positioned at a distance from the center plane EM towards the attaching end.
[0041] The turning points W 22 2 , W 23 2 are each positioned below a maximum of the distance of the center lines M 22 2 , M 23 2 from the longitudinal axes L 12 , L 13 .
[0042] A further embodiment comprises the following characteristics of the second pairs of tracks:
[0043] the track center lines M 22 2 of the outer ball tracks comprise a first arch with the radius R 1 whose center M 1 is offset by a first axial offset O 1 a from the center plane EM of the joint towards the attaching end and by a first radial offset O 1 r from the longitudinal axis L 12 outwardly towards the ball track and, in the region adjoining said arch, towards the attaching end. They comprise a second arch with the radius R 2 whose center M 2 is offset by a second axial offset O 2 a from the center plane EM of the joint towards the aperture end and offset outwardly from the longitudinal axis L 12 by a second radial offset O 2 r which is greater than the sum of the first radius R 1 and the first radial offset O 1 r.
[0044] The track center lines M 23 2 of the inner ball tracks comprise a first arch with the radius R 1 ′ whose center M 1 ′ is offset by a first axial offset O 1 a ′ from the center plane EM of the joint towards the aperture end and offset outwardly by a first radial offset O 1 r ′ from the longitudinal axis L 13 to the ball track and, in the region adjoining said arch, towards the aperture end, they comprise a second arch with the radius R 2 ′ whose center is offset by a second axial offset O 2 a ′ from the centre plane EM of the joint towards the attaching end and offset outwardly from the longitudinal axis L 13 by a second radial offset O 2 r ′ which is greater than the sum of the first radius R 1 ′ and the first radial offset O 1 r′.
[0045] More particularly, the following further characteristics of the second pairs of tracks are proposed:
[0046] the radius of curvature of the center lines M 22 of the outer ball tracks decreases in the extension from the center plane EM to the attaching end and the radius of curvature of the centre line M 23 of the inner ball tracks decreases in the extension from the center plane EM to the aperture end.
[0047] More particularly, the following further characteristics of the second pairs of tracks are proposed:
[0048] the track center lines M 22 2 of the outer ball tracks comprise a third arch with the radius of curvature R 3 which tangentially, while having the same sense of curvature, adjoins the first arch with the radius of curvature R 1 and whose radius of curvature R 3 is smaller than the radius of curvature R 1 , and
[0049] the track center lines M 23 2 of the inner ball tracks comprise a third arch with the radius of curvature R 3 ′ which tangentially, while having the same sense of curvature, adjoins the first arch with the radius of curvature R 1 ′ and whose radius of curvature R 3 ′ is smaller than the radius of curvature R 1 ′.
[0050] According to a further embodiment, in the second pairs of tracks, along the extension of the center line M 22 2 of the outer ball tracks, towards the aperture end, the second arch is adjoined by an axis-parallel straight line G 3 and, along the extension of the center line of the inner all tracks M 23 2 , towards the attaching end, the second arch is adjoined by an axis-parallel straight line G 3 ′.
[0051] According to an alternative embodiment, in the second pairs of tracks, along the extension of the centre line M 22 2 of the outer ball tracks, towards the aperture end, the second arch is adjoined by a straight line which approaches the longitudinal axis L 12 and that, along the extension of the center line M 23 2 of the inner ball tracks, towards the attaching end, the second arch is adjoined by a straight line which approaches the longitudinal axis L 13 .
[0052] According to a further characteristic in the second pairs of tracks, the center lines M 22 , M 23 of the ball tracks in the joint center plane EM intersect one another at an angle of 4 to 32°, wherein the tangents T 22 , T 23 at the center lines M 22 , M 23 of the ball tracks of all pairs of tracks when the joint is in the aligned condition form identical opening angles α.
[0053] Preferably, first pairs of tracks and second pairs of tracks are arranged so as to alternate around the circumference. The radial planes R 1 of the first pairs of tracks and the radial planes R 2 of the second pairs of tracks, in the circumferential direction, can, more particularly, comprise identical pitch angles. In a special embodiment, the first pairs of tracks and the second pairs of tracks do not extend symmetrically relative to the joint center plane EM. More particularly, the first pairs of tracks—analogously to the pairs of tracks of UF joints—can be designed to be undercut-free when viewed from the joint aperture end.
[0054] According to a further embodiment, the pitch circle radius PCR 1 of the balls of the first pairs of tracks is smaller than the pitch circle radius PCR 2 of the balls of the second pairs of tracks.
[0055] A second solution provides a constant velocity joint in the form of a fixed joint with the following characteristics:
[0056] an outer joint part which comprises a longitudinal axis L 12 and an attaching end and an aperture end arranged so as to be axially opposite one another, and which is provided with outer ball tracks;
[0057] an inner joint part which comprises a longitudinal axis L 13 and an attachment for a shaft pointing towards the aperture end of the outer joint part, and which is provided with inner ball tracks,
[0058] the outer ball tracks and the inner ball tracks form pairs of tracks with one another, the pairs of track each accommodate a torque transmitting ball; and
[0059] an annular ball cage is positioned between the outer joint part and the inner joint part and comprises circumferentially distributed cage windows which each accommodate at least one of the torque transmitting balls.
[0060] The centers of the balls are held by the cage in a joint center plane EM and, upon articulation of the joint, are guided onto the angle-bisecting plane between the longitudinal axes L 12 , L 13 .
[0061] The center lines M 22 , M 23 of the ball tracks of pairs of tracks are positioned in pairs of track planes BE, BE* which extend parallel relative to one another and symmetrically relative to radial planes R 1 , R 2 through the longitudinal axes L 12 , L 13 .
[0062] For a first part of the pairs of tracks, the opening angle α 1 between the tangents T 22 1 ′ T 23 1 ′ at track base lines extending parallel to the tangents T 22 1 , T 23 1 at the center lines M 22 1 , M 23 1 of the ball tracks in the joint center plane EM when the joint is in the aligned condition with coinciding longitudinal axes L 12 , L 13 opens from the attaching end to the aperture end.
[0063] For a second part of the pairs of tracks, the opening angle α 2 between the tangents T 22 2 ′, T 23 2 ′ at track base lines extending parallel to the tangents T 22 2 , T 23 2 at the center lines M 22 2 , M 23 2 of the ball tracks in the joint center plane EM when the joint is in the aligned condition with coinciding longitudinal axes L 12 , L 13 opens from the aperture end to the attaching end. The following applies to the center lines of the second pairs of tracks.
[0064] In the outer joint part, the center line M 22 2 of the ball tracks in the region from the joint center plane EM to the attaching end radially inwardly leaves a reference radius RB whose radius center MBE is positioned in the point of intersection of a perpendicular line on the tangent T 22 2 at the center line M 22 2 of the ball track in the joint center plane EM and of a parallel axis PE, PE* relative to the longitudinal axis L 12 through a track plane BE, BE*.
[0065] In the inner joint part, the center line M 23 2 of the ball tracks in the region from the joint center plane EM to the aperture end radially inwardly leaves a reference radius RB′ whose radius center MBE′ is positioned in the point of intersection of a perpendicular line on the tangent T 23 2 ′ at the center line M 23 2 of the ball track in the joint center plane EM and of a parallel axis PE, PE* relative to the longitudinal axis L 13 through a track plane BE, BE*.
[0066] In the outer joint part, the center line M 22 2 of the ball tracks in the region from the joint center plane EM to the aperture end moves radially outwardly beyond said reference radius RB.
[0067] In the inner joint part, the center line M 23 2 of the ball tracks 23 2 in the region from the joint center plane EM to the attaching end moves radially outwardly beyond said reference radius RB′.
[0068] The solution proposed here differs from the solution proposed first wherein the center lines of the pairs of tracks are positioned in radial planes through the center axes of the joint in that, in the present case, the center lines of pairs of tracks of two adjoining balls extend in two parallel track planes BE, BE* which extend parallel to and symmetrically to a radial plane R. As in the case of the first solution, the radial plane R is defined by the longitudinal axes L 12 , L 13 when the joint is in the aligned condition. With the track shape, in principle, being the same as in the first solution, the track shapes of the second solution, however, refer to parallel axes PE, PE* which are positioned in a reference plane EX through the longitudinal axes L 12 , L 13 , which reference plane EX is positioned perpendicularly on the radial plane R. The track shapes of the second solution also refer to reference centers ME which are positioned on said parallel axes PE, PE* and in the point of intersection of the parallel axes with the joint center plane EM.
[0069] A third solution provides a constant velocity universal joint in the form of a fixed joint with the following characteristics:
[0070] an outer joint part which comprises a longitudinal axis L 12 and an attaching end and an aperture end arranged so as to be axially opposite one another, and which is provided with outer ball tracks;
[0071] an inner joint part which comprises a longitudinal axis L 13 and an attachment for a shaft pointing towards the aperture end of the outer joint part, and which is provided with inner ball tracks,
[0072] the outer ball tracks and the inner ball tracks form pairs of tracks with one another; and the pairs of tracks each accommodate a torque transmitting ball,
[0073] an annular ball cage is positioned between the outer joint part and the inner joint part and comprises circumferentially distributed cage windows which each accommodate at least one of the torque transmitting balls.
[0074] The centers of the balls are held by the cage in a joint center plane and, upon articulation of the joint, are guided onto the angle-bisecting plane between the longitudinal axes L 12 , L 13 .
[0075] The center lines M 22 1 , M 23 1 of adjoining ball tracks in the outer joint part are positioned in pairs of first track planes BE, BE* which extend parallel relative to one another and symmetrically relative to radial rays RS 1 , RS 2 through the joint center M.
[0076] The center lines M 23 1 , M 23 2 of adjoining ball tracks in the inner joint part are positioned in pairs of second track planes BE′, BE*′ which extend parallel relative to one another and symmetrically relative to radial rays RS 1 , RS 2 through the joint center M.
[0077] The first track planes BE, BE* and the second track planes BE′, BE*′, together with radial planes RP 1 , RP 2 through the longitudinal axes L 12 , L 13 , form identically sized angles y, y′ which extend in opposite directions.
[0078] For a first part of the pairs of tracks, the opening angle α 1 between the tangents T 22 1 ′, T 23 1 ′ at track base lines extending parallel to the tangents T 22 1 ′, T 23 1 ′ at the center lines M 22 1 , M 23 1 , of the ball tracks in the joint center plane EM when the joint is in the aligned condition with coinciding longitudinal axes L 12 , L 13 , opens from the attaching end to the aperture end.
[0079] For a second part of the pairs of tracks, the opening angle α 2 between the tangents T 22 2 ′, T 23 2 ′ at track base lines extending parallel to the tangents T 22 2 , T 23 2 at the center lines M 22 2 , M 23 2 of the ball tracks in the joint center plane EM when the joint is in the aligned condition with coinciding longitudinal axes L 12 , L 13 opens from the aperture end to the attaching end. The following applies to the center lines of the second pairs of tracks.
[0080] In the outer joint part, the center line M 22 2 of the ball tracks in the region from the joint center plane EM to the attaching end radially inwardly leaves a reference radius RB whose radius center MBE is positioned in the point of intersection of a perpendicular line on the tangent T 22 2 at the centre line M 22 2 of the ball track in the joint center plane EM and of a reference axis PE, PE* through a track plane BE, BE*.
[0081] In the inner joint part, the center line M 23 2 of the ball tracks in the region from the joint center plane EM to the aperture end radially inwardly leaves a reference radius RB′ whose radius center MBE′ is positioned in the point of intersection of a perpendicular line on the tangent T 23 2 at the center line M 23 2 of the ball tracks in the joint center plane EM and of a reference axis PE′, PE*′ through a track plane BE′, BE*′.
[0082] In the outer joint part, the center line M 22 2 of the ball tracks in the region from the joint center plane EM to the aperture end moves radially outwardly beyond said reference radius RB.
[0083] In the inner joint part, the center line M 23 2 of the ball tracks in the region from the joint center plane EM to the attaching end moves radially outwardly beyond said reference radius RB′.
[0084] According to the third solution proposed here, the center lines of pairs of tracks of two adjoining balls in the outer joint part extend in two parallel planes BE, BE* which extend symmetrically to and parallel to a reference plane EB through the joint center, which reference plane EB, together with a radial plane R, forms an angle y positioned in a second reference plane EX arranged perpendicularly on the radial plane, and in the inner part they extend in two parallel reference BE′, BE*′ which extend symmetrically to and parallel to a reference plane EB′ through the joint center, which reference plane EB′, together with a radial plane R, forms an angle y′ positioned in a second reference plane EX arranged perpendicularly on the radial plane. Said radial plane R, as in the case of the second solution, is defined by the longitudinal axes L 12 , L 13 when the joint is in the aligned condition. With, in principle, the same track shape as in the second alternative, the track shapes according to the third solution, however, refer to parallel axes in the inner joint part and outer joint part, which axes are arranged so as to extend, in parallel, relative to one another in pairs, which intersect one another in pairs and which are positioned in a second reference plane EX through the longitudinal axes L 12 , L 13 which is arranged perpendicularly on the radial plane R; they also refer to reference centers which are positioned on said parallel axes and in the point of intersection of the parallel axes with the joint center plane EM.
[0085] Joints according to the above-described second and third solutions comprise a number of track pairs which can be divided by two if only one track is positioned in each track plane BE, BE*, BE′ BE*′. They comprise a number of track pairs which can be divided by four if each of the track planes BE, BE*, BE′, BE*′ contains two symmetrically shaped pairs of tracks arranged substantially opposite one another.
[0086] As explained above, the further embodiments of joints according to the second and third solutions—while the respective reference places are changed—substantially correspond to joint embodiments according to the first solution. This results in the following:
[0087] A first advantageous embodiment comprises the following further characteristics of the second pairs of tracks:
[0088] in the outer joint part, the local radius R 1 of the centre line M 22 2 in the joint center plane EM is smaller than the reference radius RB, and
[0089] in the inner joint part, the local radius R 1 ′ of the center line M 23 2 in the joint centre plane EM is smaller than the reference radius RB′.
[0090] A first advantageous embodiment comprises the following further characteristics of the second pairs of tracks:
[0091] in the outer joint part, the center line M 22 2 of the ball tracks extends from the joint center plane EM to the attaching side radially outside a reference radius RZ whose radius center is positioned in the joint center plane EM on one of the reference axes PE, PE*, and
[0092] in the inner joint part, the center line M 23 2 of the ball tracks extends from the joint center plane EM to the aperture end radially outside a reference radius RZ′ whose radius center is positioned in the joint center plane EM on one of the reference axes PE, PE*, PE′, PE*′.
[0093] A further advantageous embodiment is characterised by the following further characteristics:
[0094] in the outer joint part, the center line M 22 2 of the ball tracks extends from the joint center plane EM to the aperture end radially outside the reference radius RB and
[0095] in the inner joint part, the center line M 23 2 of the ball tracks extends from the joint center plane EM to the attaching end radially outside the reference radius RB′.
[0096] Furthermore, the following further characteristics are proposed for the second pairs of tracks:
[0097] in the outer joint part, the center line M 22 2 of the ball tracks extends from the joint center plane EM to the aperture end radially inside a reference radius RZ whose radius center is positioned in the joint center plane EM on one of the parallel axes PE, PE*.
[0098] In the inner joint part, the center line M 23 2 of the ball tracks extends from the joint center plane EM to the attaching end radially inside a reference radius RZ′ whose radius center is positioned in the joint center plane EM on one of the parallel axes PE, PE*, PE′, PE*′.
[0099] A further proposal concerns the following characteristics of the second pairs of tracks: the center lines M 22 2 , M 23 2 of the outer ball tracks and inner ball tracks each comprise at least two arched portions which are curved in opposite senses and which adjoin one another in a turning point.
[0100] The turning points W 22 2 of the outer ball tracks are positioned in a track plane BE, BE* at a distance from the center plane EM towards the aperture end.
[0101] The turning points W 23 2 of the inner ball tracks are positioned in a track plane BE, BE*, BE′, BE*′ at a distance from the center plane EM towards the aperture end,
[0102] the turning points W 22 2 , W 23 2 are each positioned below a maximum of the distance between the center lines M 22 2 , M 23 2 and the parallel axes PE, PE*, PE′, PE*′.
[0103] A further embodiment comprises the following characteristics of the second pairs of tracks:
[0104] the track center lines M 22 2 of the outer ball tracks comprise a first arch with the radius R 1 whose center M 1 in a track plane BE, BE* is offset by a first axial offset O 1 a from the center plane EM of the joint towards the attaching end and by a first radial offset O 1 r outwardly from a parallel axis PE, PE* and, in the region adjoining said arch, towards attaching end, they comprise a second arch with the radius R 2 whose center M 2 in the track plane BE, BE* is offset by a second axial offset O 2 a from the center plane EM of the joint towards the aperture end and is outwardly offset from the parallel axis PE, PE′ by a second radial offset O 2 r which is greater than the sum of the first radius R 1 and the first radial offset O 1 r.
[0105] The track center lines M 23 2 of the outer ball tracks comprise a first arch with the radius R 1 ′ whose center M 1 ′ in a track plane BE, BE*, BE′, BE*′ is offset by a first axial offset O 1 a ′ from the center plane EM of the joint towards the aperture end and is offset outwardly by a first radial offset from a parallel axis PE, PE*, PE′, PE*′ and, in the region adjoining said arch, towards the aperture end, they comprise a second arch with the radius R 2 ′ whose center M 2 ′ in the track plane BE, BE*, BE′, BE*′ is offset by a second axial offset O 2 a ′ from the center plane EM of the joint towards the attaching end and is outwardly offset from the parallel axis PE, PE*, PE′, PE*′ ′ by a second radial offset O 2 r ′ which is greater than the sum of the first radius R 1 ′ and the first radial offset O 1 r′.
[0106] A further proposal comprises the following characteristics of the second pairs of tracks: the radius of curvature of the center lines M 22 of the outer ball tracks decreases in the extension from the center plane EM towards the attaching end and the radius of curvature of the center plane M 23 of the inner ball tracks decreases in the extension from the center plane EM to the aperture end.
[0107] A further proposal comprises the following characteristics of the second pairs of tracks: the track center lines of the outer ball tracks 22 2 comprise a third arch with the radius R 3 which, tangentially, while having the same sense of curvature, adjoins the first arch with the radius R 1 and whose radius R 3 is smaller than the radius R 1 .
[0108] The track center lines M 23 2 of the inner ball tracks comprise a third arch with the radius R 3 ′ which, tangentially, while having the same sense of curvature, adjoins the first arch with the radius R 1 ′ and whose radius R 3 ′ is smaller than the radius R 1 ′.
[0109] Furthermore, in the second pairs of tracks, along the extension of the center line M 22 of the outer ball tracks, towards the aperture end, the second arch is adjoined by an axis-parallel straight line G 3 and that, along the extension of the center line M 23 of the inner ball tracks, the second arch, towards the attaching end, is adjoined by an axis-parallel straight line G 3 ′.
[0110] According to an alternative embodiment, in the second pairs of tracks along the extension of the center line M 22 2 of the outer ball tracks, towards the aperture end, the second arch is adjoined by a straight line which approaches the parallel axis PE, PE′ and that along the extension of the center line M 23 2 of the inner ball tracks, the second arch, towards the attaching end, is adjoined by a straight line which approaches the parallel axis PE, PE*, PE′, PE*′.
[0111] In this case, too, in the second pairs of tracks, the center lines M 22 , M 23 of the ball tracks in the joint center plane EM intersect one another at an angle of 4 to 32°, wherein the tangents T 22 , T 23 at the center lines M 22 , M 23 of the ball tracks 22 , 23 of all pairs of tracks form identical opening angles α when the joint is in the aligned condition.
[0112] A joint of the shape described here comprises a number of pairs of balls which can be divided by four. More particularly, the balls of two adjoining pairs of tracks positioned in parallel track planes BE, BE′ are received in a common cage window of the ball cage.
[0113] As already explained above, the track planes BE, BE*, according to the second solution, can extend parallel to the longitudinal axes L 12 , L 13 and the track planes BE, BE*, BE′ BE*′, according to the third solution, can extend at a helix angle y, y′ relative to the longitudinal axes L 12 , L 13 .
[0114] According to a further embodiment, the pitch angle 2 φ between the pairs of tracks whose balls are received in a common cage window is smaller than the pitch angle between adjoining pairs of tracks whose balls are received in different windows.
[0115] Between the helix angle y and the pitch angle 2 φ there can exist the relation y=α/2·tan φ, with α/2 being the track inclination angle and half the opening angle respectively.
[0116] Furthermore, of two directly adjoining pairs of tracks, one constitutes a first pair of tracks and one a second pair of tracks. In addition, of two pairs of tracks positioned in one track plane, one constitutes a first pair of tracks and one a second pair of tracks, i.e. two substantially radially opposed tracks open towards the aperture end on the one hand and towards the attaching end on the other hand.
[0117] The invention will be explained in greater detail with reference to the drawings which show preferred embodiments of inventive joints as compared to a joint according to the state of the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0118] FIG. 1 shows an inventive joint according to the first solution:
a) in a cross-section; b) in a longitudinal section along sectional line A-A; and c) in a longitudinal section along sectional line B-B.
[0122] FIG. 2 shows an inventive joint according to the second solution:
a) in a cross-section; b) in a longitudinal section along sectional line A-A; and c) in a longitudinal section along sectional line B-B.
[0126] FIG. 3 shows an inventive joint according to FIG. 2 of the third solution:
a) in a cross-section; and b) in a longitudinal section along sectional line A-A.
[0129] FIG. 4 shows geometric relations with reference to a pair of balls in a joint according to FIG. 3 :
a) in a cross-section; b) in a longitudinal section through a track plane; and c) in a longitudinal section through a pair of balls.
[0133] FIG. 5 shows the longitudinal axes and the track centre lines of the second tracks of an inventive joint in a first embodiment:
a) for the outer joint part; and b) for the inner joint part.
[0136] FIG. 6 shows the longitudinal axes and the track centre lines of the second tracks of an inventive joint in a second embodiment:
a) for the outer joint part; and b) for the inner joint part.
DETAILED DESCRIPTION
[0139] FIGS. 1 a to 1 c will be described jointly below. A joint 11 comprises an outer joint part 12 , an inner joint part 13 , torque transmitting balls 14 as well as a ball cage 15 . The cage comprises a spherical outer face 16 which is guided in the outer joint part and a spherical inner cage face 17 which is guided on the inner joint part, with said second contact not being compulsory. The balls 14 are held in circumferentially distributed cage windows 18 in the ball cage 15 in a joint center plane EM. The outer joint part 12 is shown to comprise a longitudinal axis L 12 and the inner joint part is shown to comprise a longitudinal axis L 13 . The point of intersection of the longitudinal axes L 12 , L 13 with the joint center plane EM forms the joint center M. The outer joint part 12 comprises a base 19 which can change into an attaching journal for example, as well as an aperture 20 into which it is possible to insert a journal connectable to the inner joint part. For this purpose, the inner joint part 13 comprises an insertion aperture 21 . Hereafter, the position of the base 19 indicates the axial direction “towards the attaching end” and the position of the aperture 20 indicates the axial direction “towards the aperture end”. These terms are also used with reference to the inner joint part, with the actual attachment of a shaft to the inner joint part not being taken into account.
[0140] Starting from the center plane EM, the ball contact angles β max /2 have been entered for the maximum articulation angle β max /2 of the inner joint part 13 relative to the outer joint part 12 in both directions. First pairs of tracks 22 1 , 23 1 with first balls 14 1 and second pairs of tracks 22 2 , 23 2 with second balls 14 2 have been arranged so as to alternate around the circumference. The shape of the first pairs of tracks 22 1 , 23 1 can be taken from section A-A and the shape of the second pairs of tracks 22 2 , 23 2 from section B-B. The first balls 14 1 are in contact with first outer ball tracks 22 1 in the outer joint part and first inner ball tracks 23 1 in the inner joint part. The center lines M 22 1 , M 23 1 of said tracks are of the type as used in UF tracks and are composed of a circular arch and a tangentially adjoining straight line. In the aligned position as illustrated, the tangents T 22 1 ′, T 23 1 ′ at the balls 14 1 in the contact points with the tracks 22 1 , 23 1 form an opening angle α 1 which opens towards the aperture end. The second balls 14 2 are guided in outer ball tracks 22 2 in the outer joint part and inner ball tracks 23 2 , in the inner joint part. The balls 14 2 are shown to be in contact with the track base of the ball tracks, which contact does not necessarily have to be provided. In the aligned position as illustrated, the tangents T 22 2 ′, T 23 2 ′ at the balls 14 2 in the contact points with the tracks 22 2 , 23 2 form an opening angle α 2 which opens towards the attaching end. For describing the ball tracks 22 , 23 , reference is made below to the center lines M 22 2 , M 23 2 of the ball tracks. The center plane EM is shown to comprise tangents T 22 2 , T 23 2 at the center lines which tangents are positioned parallel to the above-mentioned tangents T 22 2 ′, T 23 2 ′. The angle α 2 between said tangents T 22 2 , T 23 2 ranges between 4 and 32°.
[0141] It can be seen that each pair of tracks is positioned with its center lines M 22 , M 23 in a radial plane RP 1 , RP 2 through the joint, that said radial planes R are at identical angular distances from one another and that one ball 14 each is accommodated by a cage window 18 in the ball cage 15 .
[0142] The pitch circle radius of the first balls 14 1 and the pitch circle radius of the second balls 14 2 can differ in size with their size ratio ranging from 0.8 to 1.0.
[0143] FIGS. 2 a to 2 c will be described jointly below. They show a joint 11 in an embodiment which has been modified as compared to the embodiment according to FIG. 1 .
[0144] Nevertheless, identical details have been given the same reference numbers as in FIGS. 1 a to 1 c. An inventive joint 11 in said second embodiment comprises ball tracks 22 , 23 which are positioned in track planes BE, BE* which are arranged in pairs symmetrically relative to radial planes R through the joint. FIG. 2 b shows an angled section according sectional line A-A, which angled section, on the one hand, extends through the track plane BE and a first pair of tracks 22 1 , 23 1 with a first ball 14 1 and, on the other hand, through a radial plane between two pairs of tracks. FIG. 2 c shows a bent section according to sectional line B-B, which bent section extends through a track plane BE* and a second pair of tracks with second ball tracks 22 2 , 23 2 on the one hand and through a radial plane between two pairs of tracks on the other hand. It is possible to see pairs of track pairs which are distributed around the circumference and which comprise a first pair of tracks 22 1 , 23 1 and a second pair of tracks 22 2 , 23 2 and which are held in a common cage window 18 . The pitch angle of said pairs of track pairs is smaller than that between two adjoining pairs of tracks which are not associated with a pair of track pairs. In the embodiment shows here, first pairs of tracks and second pairs of tracks alternate around the circumference.
[0145] As can be seen in FIG. 2 b, the first balls 14 1 are guided in first pairs of tracks consisting of outer tracks 22 1 and inner tracks 23 1 which are of the type as contained in UF joints, which means that the center lines M 22 , M 23 of said pairs of tracks are composed of radii and adjoining tangential straight lines. The tangents T 22 1 , T 23 1 ′ at the balls in the tracks form a first opening angle α 1 which opens towards the aperture end of the outer joint part.
[0146] FIG. 2 c shows a second ball 14 2 which is held in second outer ball tracks 22 2 and second inner ball tracks 23 2 . Tangents T 22 2 , T 23 2 ′ at the balls 14 2 form an opening angle α 2 with one another which opens towards the attaching end of the outer joint part. As far as the track extension is concerned, reference will be made below to the center lines M 22 2 , M 23 2 . In the joint center plane EM, the tangents T 22 2 , T 23 2 at the center line M 22 2 , M 23 2 intersect one another at the above-mentioned angle α 2 .
[0147] The track planes BE, BE* contain parallel axes PE, PE* extending relative to the longitudinal axes at the shortest distance, which thus form sectional lines between the track planes and a reference plane EX 1 , EX 2 positioned perpendicularly relative to the respective radial plane RP 1 , RP 2 . On the parallel axes PE, PE*, there are positioned track centers ME, ME* at the shortest distance from the joint center M. If there are arranged four pairs of tracks symmetrically to three or four radial planes R with identical pitch angles relative to one another, there are obtained joints with twelve or sixteen pairs of tracks 22 , 23 and, accordingly, with twelve or sixteen balls 14 . In accordance with FIG. 2 a, the center ME 1 , ME 1 * shown in FIGS. 2 b and 2 c is not the joint center, but the track curve center in one of the track planes BE 1 , BE 1 *.
[0148] FIGS. 3 a and 3 b will be described jointly below, where like details have been give like reference numbers accompanied by a “′”. In principle, FIG. 3 a corresponds to FIG. 2 a, but in this case, the sectional line A-A extends parallel to a reference plane EX 1 through the balls of a pair of track pairs. FIG. 3 b shows a first reference plane EB for outer ball tracks, which is positioned perpendicularly on said reference plane EX 1 and contains a radial ray RS through the joint centre M. Said reference plane EB′, together with the radial plane R extending through the longitudinal axes L 12 , L 13 , forms a helix angle γ. Parallel to the reference plane EB, there are positioned the reference planes BE and BE* in which there extend the center lines of the outer ball tracks of a pair of tracks. Furthermore, FIG. 3 b shows a first reference plane EB′ for inner ball tracks which is also positioned perpendicularly on said reference plane EX and contains the radial ray RS through the joint center M. Said reference plane EB′, together with the radial plane R through the longitudinal axes L 12 , L 13 forms a helix angle γ′ which is identical in size and extends in the opposite direction to γ. The track planes BE′, BE*′ containing the center lines of the inner ball tracks of a pair of tracks extend parallel to the reference plane EB′. The center lines of each pair of tracks intersect one another in the joint center plane EM.
[0149] FIGS. 4 a and 4 c will be described jointly below, where like details have been give like reference numbers accompanied by a “′”. FIG. 4 a shows a cross-section through a ball assembly which consists of four pairs of balls 141 , 142 according to FIG. 3 and which is positioned in the joint centre plane. The pitch angle between the balls 141 , 142 of a pair of balls and the radial plane RP 1 positioned therebetween amounts to φo and φo′ respectively. The ball tracks are arranged at a distance from a reference plane EX 1 , which distance corresponds to the pitch circle radius PCR multiplied by the cosine of φo. The perpendicular distance of the balls of a pair of balls from said radial plane RP 1 has been given the symbol a. The track planes BE 1 ′ BE 1 * as shown represent the passage of the track planes BE′, BE*′ of the inner ball tracks through the joint center plane.
[0150] In FIG. 4 b, in the section through one of the track planes BE 1 ′ BE 1 *, the track opening angle between the tangents T 22 , T 23 at the track center lines of a second pair of tracks has been given as α 2 , with the drawn-in angle legs representing the tangents T 22 ′, T 23 ′ at the track base lines of the track. α2/2 thus corresponds to half the opening angle and track inclination angle respectively.
[0151] FIG. 4 c shows a pair of balls 14 1 , 14 2 with the outer track planes EB, EB* and the inner track planes EB′, EB*′. The penetration points D 1 , D 2 as shown in FIG. 4 b are also given.
[0152] The following equations apply to the ideal case wherein said track tangents T 22 , T 23 penetrate the radial planes R in the axes L 12 , L 13 , i.e. the penetration points D 1 and D 2 are positioned on the longitudinal axes L 12 , L 13 .
[0153] The following relations apply:
[0000]
a
=
PCR
·
sin
γ
0
′
(
1
)
PCR
·
cos
γ
0
′
x
=
tan
?
with
x
=
PCR
·
cos
γ
0
′
tan
?
(
2
)
a
x
=
sin
?
i
.
e
.
sin
?
=
PCR
·
sin
γ
0
′
PCR
·
cos
γ
0
′
·
tan
?
?
indicates text missing or illegible when filed
(
3
)
[0000] for small angles
[0000]
α
2
2
[0000] and γ the following approximation applies:
[0000]
sin
≈
arc
,
tan
≈
arc
arc
?
≈
tan
γ
0
′
·
arc
?
?
?
?
indicates text missing or illegible when filed
[0154] FIG. 5 a shows the track center line M 22 of an outer ball track 22 according to any one of FIGS. 1 to 3 , which track center line M 22 extends parallel to a track base line. The center line M 22 of a track in the outer part is composed of a first arched portion with a first radius R 1 around a center M 1 with the first axial offset O 1 a and a radial offset O 1 r as well as of a second arched portion with a second radius R 2 with a second axial offset O 2 a and a second radial offset O 2 r. Second radial offset O 2 r is greater than the sum of the first radius R 1 and the first radial offset O 1 r. The transition is indicated by a turning point W 22 . The second radius R 2 is tangentially adjoined by a straight line G 3 extending parallel to the axis L 12 , PE, PE*. The center plane EM is shown to comprise the tangent T 22 and the center line M 22 which intersects a longitudinal axis L 12 , PE, PE* at an angle α/2. A perpendicular line on the tangent T 22 intersects the longitudinal axis L 12 , PE; PE* in the reference center MB, MBE of a reference radius RB. First radius R 1 is smaller than reference radius RB. A further reference radius RZ is entered around the track center M, ME. To the left of the center plane EM, towards the attaching end 19 , the center line M 22 extends inside the radius RB and outside the radius RZ. To the right of the center plane EM, towards the aperture end 20 , the center line M 22 extends substantially outside the radius RB. The radial ball movement of a ball on its path along the ball track with reference to the track center M, ME has been given the reference symbol e. This corresponds to the minimum thickness of the ball cage in the region of the cage window, with a safety allowance being required to avoid edge bearing.
[0155] FIG. 5 b shows the track center lines M 23 of the associated inner ball tracks 23 according to any one of FIGS. 1 to 3 , which track center lines M 23 extend parallel relative to the track base lines. The center line M 23 of a track 23 in the inner part 13 is composed of a first arched portion with a first radius R 1 ′ around a center M 1 ′ and of a second arched portion with a second radius R 2 ′ around a centre M 2 ′. The transition is indicated by a turning point W 23 . The second radius R 2 ′ is adjoined by a straight line G 3 ′ which extends parallel relative to the axis L 13 , PE, PE*, PE′, PE*′. The center M 1 ′ comprises an axial offset O 1 a ′ and a radial offset O 1 r ′ and the center M 2 ′ comprises an axial offset O 2 a ′ and a radial offset O 2 r ′. Second radial offset O 2 r ′ is greater than the sum of the first radius R 1 ′ and the first radial offset O 1 r ′. In the center plane EM, there is shown the tangent T 23 at the center line M 23 , which intersects a longitudinal axis L 13 , PE, PE*, PE′, PE*′ at the angle α/2. A perpendicular line at the tangent T 23 intersects the longitudinal axis L 13 , PE; PE*, PE′, PE*′ in the reference center MB′, MBE′ of a reference radius RB′. Second radius R 1 ′ is smaller than reference radius RB′. A further reference radius RZ′ has been entered around the track center M, ME. To the right of the center plane EM, towards the aperture end 20 , the center line M 23 extends inside the radius RB′ and outside the radius RZ′. To the left of the center plane EM, towards the attaching end 19 , the center line M 23 extends at least predominately outside the radius RB′. The radial ball movement of a ball on its path along the ball track with reference to the track center M, ME has been given the reference symbol e. The two center lines M 22 , M 23 of FIGS. 5 a, 5 b intersect one another in the joint center plane EM at the angle α and extend mirror-symmetrically relative to said centre plane.
[0156] According to an alternative embodiment, in the second pairs of tracks, along the extension of the center line M 22 2 of the outer ball tracks, towards the aperture end, the second arch is adjoined by a straight line which approaches the longitudinal axis L 12 and that, along the extension of the center line M 23 2 of the inner ball tracks, towards the attaching end, the second arch is adjoined by a straight line which approaches the longitudinal axis L 13 .
[0157] FIG. 6 a, in a modified embodiment, shows the track center line M 22 of an outer ball track 22 , which track center line M 22 extends parallel to a track base line. The center line M 22 of a track in the outer joint part is composed of a first radius R 1 around a center M 1 with a first axial offset O 1 a and a radial offset O 1 r as well as of a second radius R 2 with a second axial offset O 2 a and a second radial offset 02 r as well as of a third radius R 3 which adjoins the radius R 1 opposite to the radius R 2 , which is smaller than the radius R 1 and is curved in the same direction, with the position of its center M 3 not being given detailed dimensions. The transition between the first and second radius is indicated by the turning point W 22 . The second radius R 2 is tangentially adjoined by a straight line G 3 which extends parallel to the axis L 12 , PE, PE*. In the center plane EM, there are shown the tangent T 22 and the center line M 22 which intersects a longitudinal axis L 12 , PE, PE* at the angle α/2. A perpendicular line on the tangent T 22 intersects the longitudinal axis L 12 , PE; PE* in the reference center MB, MBE of a reference radius RB. A further reference radius has been entered around the track center M, ME. To the left of the center plane, towards the attaching end 19 , the center line M 22 extends inside the radius RB and outside the radius RZ. To the right of the center plane EM, towards the aperture end 20 , the center line M 22 extends predominately outside the radius RB. The radial ball movement of a ball on its path along the ball track with reference to the track center M, ME has been given the reference symbol e. This corresponds to the minimum thickness of the ball cage in the region of the cage windows, with a safety allowance having to be provided to avoid edge bearing.
[0158] FIG. 6 b, in a modified embodiment, shows the track center line M 23 of an inner ball track 23 , which track center line M 23 extends parallel to a track base line. The center line M 23 of a track 23 in the inner joint part 13 is composed of a first radius R 1 around a center M 1 ′, of a second radius R 2 ′ around a center M 2 ′ as well as of a third radius R 3 ′ which adjoins the radius R 1 ′ opposite to the radius R 2 ′, which is smaller than said radius R 1 and is curved in the same direction. The second radius R 2 ′ is adjoined by a straight line G 3 which extends parallel to the axis L 13 , PE, PE*, PE′. PE*′. The center M 2 ′ comprises an axial offset O 1 a ′ and a radial offset O 1 r ′ and the center M 2 ′ comprises an axial offset O 2 a ′ and a radial offset O 2 r ′. The position of the center M 3 ′ has not been given detailed dimensions. In the center plane EM, there are shown the tangent T 23 and the center line M 23 which intersects a longitudinal axis L 13 , PE, PE*, PE′, PE*′ at the angle α/2. A perpendicular line on the tangent T 23 intersects the longitudinal axis L 12 , PE; PE*, PE′, PE*′ in the reference center MB′, MBE′ of a reference radius RB′. A further reference radius RZ′ has been centered around the track center M, ME. To the right of the center plane EM, towards the aperture end 20 , the center line M 23 extends inside the radius RB′ and outside the radius RZ′. To the left of the center plane EM, towards the attaching end 19 , the center line M 23 extends predominately outside the radius RB′. The radial ball movement of a ball on its path along the ball track with reference to the track center M, ME has been given the reference symbol e. The two center lines M 22 , M 23 of FIGS. 6 a, 6 b intersect one another in the joint center plane EM at the angle α and extend mirror-symmetrically relative to said center plane.
Counter Track Joint for Large Articulation Angles
LIST OF REFERENCE NUMBERS
[0159] 11 joint
[0160] 12 outer joint part
[0161] 13 inner joint part
[0162] 14 ball
[0163] 15 cage
[0164] 16 outer cage face
[0165] 17 inner cage face
[0166] 18 cage window
[0167] 19 base
[0168] 20 aperture
[0169] 21 insertion aperture
[0170] 22 outer ball track
[0171] 23 inner ball track
[0172] 24 track base of outer ball track
[0173] 25 track base of inner ball track
[0174] 26 track flank
[0175] 27 track flank
[0176] EM joint centre plane
[0177] L 12 longitudinal axis of outer part
[0178] L 13 longitudinal axis of inner part
[0179] M 22 centre line of track 22
[0180] M 23 centre line of track 23
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A constant velocity counter track joint having an outer joint part with outer ball tracks having first tracks opening toward the aperture end and second tracks opening toward the attaching end. The center line of the second tracks, departs, radially inwardly, a first reference radius centered in the point of intersection of a perpendicular line on the tangent at the center line of the ball track and the longitudinal axis. In the inner joint part, the center line of the ball tracks departs, radially inwardly, a second reference radius centered in the point of intersection of a perpendicular line on the tangent at the center line of the ball track and the longitudinal axis. In the outer joint part, the center line of the ball tracks towards the aperture end, moves radially outwardly beyond said first reference radius. In the inner joint part, the center line of the ball tracks towards the attaching end, moves radially outwardly beyond said second reference radius.
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SUMMARY OF THE INVENTION
It is common for laptop computers, tablet computers, smart phone computers and other computer devices that have a video display capability to have an image sensing device, or camera built into the computer device. Typically, the camera occupies a position on the chassis of the device that is peripheral to the video display screen. This makes it not fully practical for video conferencing purposes. As a result of the camera being at the periphery of the screen, the screen displays the other person's face, but the camera is showing that thee from a position above that person's line of sight. That is because the other person is looking at the screen, not at the camera. The result is that when the device is used for video conferencing, the participants in the conference do not seem to be looking straight at the other participants. This affects the subliminal psychological cues associated with normal in-person conversations and as a result, makes video conferencing not fully natural. This invention makes it possible to avoid this problem.
In this invention a camera is placed in the line of sight of the viewing screen so that a video conferencing user can simultaneously look squarely into the face of the other participant at the same time as looking straight into the camera. When both participants in a video conference are using a device equipped with the invention, the result is a very natural conversation. When one of the participants is using the device, the result is still a great improvement over the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : Computer display with a clip, support arm and camera device.
FIG. 2 : Laptop computer with a stowable camera support arm.
FIG. 3 : LCD screen close-up showing pixels and control lines
FIG. 4 : LCD screen cross section showing backlight and camera position
FIG. 5 : Front view of backlight with camera.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There are a number of ways the video camera may be placed in the middle of the computer display screen line of sight. In a first embodiment, the camera is mounted to an adjustable support that has a clip or other mechanical attachment to the chassis of the video display device. The clip ( 3 ) attaches the support arm ( 1 ) to the top and center of the computer video display ( 4 ) and then the arm hangs down toward the center of the screen. ( 2 ) The length of the arm is adjusted so that the camera is at the approximate center point of the screen. The arm can have a pivot ( 3 ) so that while the clip stays in place, the arm can be moved away from the screen when not in use. In a variation on this embodiment, the clip could attach to the side or bottom of the display screen. Practitioners of ordinary skill will recognize that a “computer video display” may also be a television set or other video display device that is utilized for video conferencing purposes. The external camera that is clipped to the display screen can be operatively connected to the computer in order to pass image data to the computer in typical ways, including USB port, Fire Wire, parallel port, Ethernet or any other way of attaching the output of the light collection device to a computer interface.
In a second embodiment, a support arm ( 50 ) comprising the camera at one end ( 10 ) is attached at the other end to a hinge embedded in the chassis of a laptop computer, as shown in FIG. 1 ( 50 ). When the user wants to use the invention, the support arm can be lifted into position by elevating the first end of the support arm and rotating the arm about the hinge on the second end. The hinge may be any kind of pivoting bearing the length of the support arm will generally be the distance from the second hinge to the center of the laptop display screen ( 30 ). In this embodiment, the movable arm can be stowed in a slot ( 40 ) so that it does not detract from the utility of the display screen in other operational contexts.
Where the “center of the screen” is explained, in other embodiments could also be the “center of a display window on the screen”. That is because so long as the camera is at the center of the line of site to the other user's face, the apparent result is the same. On larger display screens, the computer user may cause the computer system to open a virtual window that is smaller than the physical screen size and position that window arbitrarily in the area of the physical screen. For example, a user may put the video conferencing window in the lower left of the screen in order to open another virtual window that displays a document to the right of that. But so long as the camera is at the center of that virtual window presenting the other user's face, the improved result will be the same because the user will be looking squarely at the other user's face while looking directly into the camera. Embodiments of the invention include using a flexible support arm, that is, rather than using a stiff piece of plastic or metal, to use a flexible material. One end of the flexible support may be fixed to the device chassis without a hinge or pivoting bearing and thereby permitting the user to adjust the position of the camera by means of manipulating the flexible support arm.
In yet another embodiment, the camera is manufactured to be embedded in the middle of the computer display screen. The typical LCD screen is an array of pixels ( 200 ) controlled by signal lines for the x and y axis, respectively ( 300 ), ( 100 ). In one embodiment, the invention is embedded in a back-lit LCD display, where there is a backlight ( 201 ), ( 301 ) and a set of operative layers comprising the active matrix layer ( 401 ) and a transparent conductive layer ( 501 ). The camera ( 101 ) resides behind the operative layers of the LCD screen ( 401 ), ( 501 ) but in front of the backlight. ( 201 ). The camera sensor is attached to electronics using wires that may be embedded on the surface of the backlight ( 601 ) or if there is a hole in the backlight, passed through to the back of the backlight. In one embodiment, the light source is devised so that portion of the light source surrounding the camera can be separately addressed and turned off. ( 301 ). FIG. 5 shows a front-view of the light source, ( 1001 ) with the separately addressed region ( 2001 ) and the camera ( 3001 ). When the region ( 2001 ) is turned off, the camera ( 3001 ) will collect light coming back through the LCD panel the other way. This is accomplished by preferentially selecting the gate and data line grid so that a plurality of pixel electrodes are continuously set to transmit light. In this embodiment, control logic in the computer can override the video data signals arriving at the x address line ( 300 ) and the y address line ( 100 ) and instead drive them to a state that causes the selected pixels ( 200 ) to be transparent. In another embodiment, the software driver operated by the computer overrides the video data stream intended for the display in order to set the appropriate region of the screen to be transparent.
In yet another embodiment, the imaging device is integrated with the backlight assembly. In this embodiment, the backlight is fabricated so that it has a minute hole in the middle of the screen area. The imaging device occupies that hole, either by being embedded in the backlight assembly or by laying behind the backlight assembly and situated so that light passing back through the hole enters the active optical path of the camera. In other embodiments, the imaging device is comprised of a mirror or fiber optic connection can route light from the hole in the backlight and a camera that whose optical path receives the light from the mirror or fiber optic connector. The camera component of the imaging device can then be arranged in any position relative to the backlight. Light entering the hole will pass through using the mirror or fiber optic connection to the camera placed in an arbitrary position relative to the light path through the hole.
Given that even color LCD screens transmit white light, the light coming back through the LCD screen into the camera should be by and large, white. This will occur so long as each pixel for the color filter element, e.g. the Red, Green and Blue are all transparent for the selected pixels. At the camera, the three color components will together effectively pass white light through. This is demonstrable because the reverse is true: a white backlight looks like a white screen even though the light is passing through separate Red, Green and Blue pixels.
Nonetheless, by traversing through layers of the transparent conductive layers and the liquid crystal layer itself as well as glass, there may be spectral losses and overall light intensity loss. These can be made up for by devoting a larger number of pixels to the camera, and having a larger camera sensor. The microprocessor that receives data from the camera and works with the camera image data can apply amplification and apply color filtering in the digital domain to compensate for the color biasing that is inherent in the materials that the light passes through. Increased noise resulting from amplification of the camera signal can be reduced by utilizing typical digital signal processing techniques that are optimized for displaying a face that is close to the camera.
In yet another embodiment, the imaging device may be integrated into the operative layers of the video display screen. In this embodiment, the glass layer behind the active matrix ( 401 ) can be shaped in its cross section to produce a lens at one region of its surface. A CCD device can be fabricated on the glass behind the lensing area. In this way, the CCD will act as a camera for light passing through the LCD screen from the outside. Furthermore, the Red Green and Blue pixels can provide color filtering to each of the CCD pixels, further improving the CCD image quality. In the reverse, the light from the backlight can scatter through the CCD device when the screen is not being used for video conferencing.
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A video display device adapted for video conferencing where a camera is placed in the line of sight of the screen. If both users of a video conference are using this device, they will look straight at each other and one will appear to be looking directly into the other's face.
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BACKGROUND OF THE INVENTION
The invention concerns a method for the production of an aromate concentrate suitable for use as blending component for fuel, from feed hydrocarbon mixtures displaying boiling range substantially between 40° and 170° C. and containing several aromates in addition to non-aromates. The feed hydrocarbon mixture, without previous separation into individual fractions, is subjected to an extractive distillation with the use of N-substituted morpholine, the substituents of which display no more than seven C-atoms, as selective solvent, with substantially all of the low-boiling non-aromates having a boiling range up to about 105° C. and a majority of the higher-boiling non-aromates having a boiling range between about 105° and 160° C. being distilled off as raffinate from the top of the extractive distillation column, whereas the main amount of the aromates, as well as the residual non-aromates, together with the employed solvent, being discharged as extract from the sump of the extractive distillation column, whereupon the hydrocarbons in the extract are distillatively separated from the solvent in a subsequently disposed solvent separation column and employed in whole or in part as blending component, while the solvent is returned to the extractive distillation column.
A method of this general type is known from German Offenlegungsschrift DE-OS 36 12 384, employing aromate-containing hydrocarbon mixtures as feed hydrocarbon mixtures. Particularly suitable for this purpose are reformate and platformate with not too high a content of benzene, from the working up of petroleum. However, mixtures of such reformate and platformate with pyrolysis benzene can also be employed.
With these entry products, the boiling limit indeed normally lies at 170° C. However, it has turned out in practice that this boiling limit is not maintained in many cases, since the initial production processes result in a formation of condensation and polymerization products which display a higher boiling point than 170° C., and which correspondingly contaminate the reformate and platformate. Thus, for example, a typical reformate from the working-up of petroleum displays a portion of higher-boiling components with a boiling point greater than 170° C., to an extent of about 3% by weight. The composition of this higher boiling fraction is as follows:
______________________________________Compound KP°C. % by weight______________________________________m-cymol 175 3.4hemmellitol 176.1 14.3p-cymol 177.1 12.3N-butylbenzene 183 2.8indane 177.8 9.91,2-diethylbenzene 183.4 24.3durene 196.8 4.7I-durene 198 16.2tetralin 207.6 0.1trimethylethylbenzene 213 3.0naphthalene 218 4.0methyltetralin 229 0.1β-methylnaphthalene 241 2.0α-methylnaphthalene 245 1.2diphenyl 255 0.8dimethylnaphthalene 268 0.9TOTAL = 100.0______________________________________
Since the portion of these higher-boiling condensation and polymerization products, which shall be designated hereafter as heavy aromates, can amount in individual cases to substantially more than 3% by weight in the reformate and platformate, there can result difficulties during the performance of the method according to DE-OS 36 12 384.
It has been proven in practice that these heavy aromates become concentrated in the selective solvent. With progressive operational periods, this leads to ever stronger contamination of the solvent led in circulation, so that its selectivity is steadily decreased and the separation effect in the extractive distillation is correspondingly diminished. Attempts to separate out the heavy aromates by distillation of the solvent have provided no satisfactory results, even with high distillation expenditures, since part of the heavy aromate fraction boils in the same temperature range as the solvent. Inasmuch as a distillative separation is practically impossible, this problem could only be solved previously by providing a complete exchange of fresh solvent for the contaminated solvent after a certain operational period. Obviously, this technique is extremely costly, and thereby not economical. In addition, destruction of the contaminated solvent results in further cost, since it cannot be introduced to any other use or purpose.
SUMMARY OF THE INVENTION
It is therefore an object according to the present invention to so improve the above-described methods, as to avoid these mentioned difficulties.
This object is attained according to the present invention by cooling a partial stream of the solvent discharged from the solvent separation column to a temperature between 40° and 80° C. and then adding water in an amount of 5 to 20 parts by volume per 100 parts by volume of solvent, whereupon this mixture is led into a phase separator, in which the heavy aromates contained in the solvent are separated from the solvent-water mixture as the light phase, and then the solvent-water mixture discharged from the phase separator is split up into its components, which are re-employed in the method.
The method according to the present invention is therefore based upon recognition of the fact that the heavy aromates and the solvent, particularly the N-formylmorpholine preferably employed in practice, display different solubility characteristics in water. Whereas the solvent, particularly N-formylmorpholine, is soluble without limit in water, the heavy aromates dissolve in water only in very small amounts. Since the heavy aromates display, moreover, a clear difference in density compared to the solvent-water mixture (0.86 kg/1 compared to about 1.05 kg/1 of solvent-water mixture, with use of N-formylmorpholine), it can without difficulty be separated from the solvent-water mixture as the light phase in a phase separator. The solvent-water mixture is discharged therewith from the phase separator as the heavy phase. It cannot, however without more be returned to the solvent circulation of the extractive distillation, since there still exists the danger of a hydrolytic decomposition of the solvent. Accordingly, it is initially necessary to divide the solvent-water mixture into its components, before they can be re-employed in the method.
Two method variations are provided according to the present invention for this division:
According to the first variation, the solvent-water mixture is introduced into the sump of the column which serves for recovery of solvent from the raffinate. Together with the hydrocarbons of the raffinate (non-aromates), the water is azeotropically distilled off at the top from the column and condensed together with the hydrocarbons of the raffinate, from which they can be separated in a so-called reflux container by means of phase separation. Subsequently, the water can be returned for re-employment in the method. The solvent, freed of water,,remains in the sump of the column, and is excluded across a separating flask and returned to the method. Any entrained hydrocarbons of the raffinate are separated therewith in the separating flask and returned to the column. Such an azeotropic water separation offers the advantage that nearly all of the water is distilled off from the sump of the column, since the hydrocarbons of the raffinate (non-aromates) are present in great excess. If at all, only traces of water are still carried along in the solvent circulation. However, their concentration is in no case greater than the amount of water which can normally be contained in the feed hydrocarbon mixture. Accordingly, the danger of a hydrolysis of the solvent by means of such carried along water is not to be feared.
With the second variation, the separation of the solvent-water mixture occurs in a solvent regeneration column. Before its entry into this column, toluene and/or xylene is added to the solvent-water mixture. The water is then azeotropically distilled off with the added toluene and/or xylene in the column, and then separated from these aromates in a subsequently disposed separation arrangement by means of phase separation. In order to keep the water extensively solvent-free, reflux to the column must be relinquished.
The novel features which are considered characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flow-chart representation of the method according to the present invention, in which the division of the solvent-water mixture follows in the column which serves for recovery of the solvent from the raffinate (first method variation).
FIG. 2 is a schematic flow-chart representation of the method according to the present invention, in which the division of the solvent-water mixture follows in the solvent regeneration column (second method variation).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the method variation represented in the flow-chart of FIG. 1, the feed hydrocarbon mixture is introduced for working-up without any pre-fractionation, across conduit 1 into the middle part of extractive distillation column 2, which is provided with plates. The hydrocarbons of the raffinate escape across the top from the extractive distillation column 2, and are led across conduit 4 into column 5, in which the hydrocarbons of the raffinate (top-product) are distillatively separated from the solvent remainder. The latter are discharged across conduit 6, whereas the hydrocarbons of the raffinate, freed of solvent, escape across the top from column 5 and are discharged across conduit 7. The hydrocarbons of the extract (bottom product) are discharged together with the main amount of the solvent across conduit 8 from the sump of the extractive distillation column 2, and are led from there into the middle part of the solvent separation column 9, which can, if necessary, also be provided with plates. In this column, the hydrocarbons of the extract, composed mainly of aromates, are separated from the solvent, whereby the recovered solvent, which becomes concentrated in the sump of the driver column 9, is returned across conduit 3 to the extractive distillation column 2, and re-introduced therein at the top. The hydrocarbons of the extract, freed of solvent, are, in contrast, discharged from solvent separation column 9 across conduits 10 and 11 and then led to their further utilization. The following variations are possible:
1. The operational conditions in the extractive distillation column 2 are so adjusted that the benzene contained in the feed hydrocarbon mixture is extensively concentrated in the extract, the result being a benzene-poor raffinate. Then, in solvent separation column 9, the benzene contained in the extract is distillatively separated from the other aromates, and discharged as top product across conduit 10 as a salable pure benzene with a non-aromate content of less than 1000 ppm, whereas the aromate concentrate serving as blending component, which in this case is practically more or less benzene-free, is removed as a side stream across conduit 11 or across a side column, not shown in the drawing, at this place, from solvent separation column 9.
2. In this case, the operational conditions of the extractive distillation column 2 are so adjusted that a part of the benzene contained in the feed hydrocarbon mixture goes into the raffinate, and there remains in the aromate content of the extract only such a benzene content that does not exceed a desired maximal value lying below 5% by weight. With the working-up of the extract in the solvent separation column 9, the produced aroma concentrate serving as blending component is discharged exclusively across conduit 10, whereas the side escape across conduit 11 remains out of operation.
3. When on the one hand, the benzene content of the feed hydrocarbon mixture is relatively low, and, on the other hand, the concentration of this benzene content in the aromate concentrate serving as blending component is not considered to be troublesome, then the extractive distillation column 2 can be driven under such operational conditions that the entire amount of benzene can pass practically completely into the extract. In a departure from the method variation 1, however, no separation of the benzene from the other aromates occurs in the solvent separation column 9, in this case. That is, in this case the aromate concentrate is discharged in its entirety across conduit 10 from the solvent separation column 9, and the side drain over conduit 11 remains out of operation.
In order to avoid the above-described concentration of heavy aromates in the solvent, it is provided according to the present invention that a partial stream is branched off from the solvent which is returned across conduit 3 to the extractive distillation column. This partial stream, which lies within the order of magnitude of 1 to 5% by volume of the total amount of solvent led in circulation, travels across conduit 12 into the solvent cooler 13, and from there across mixing pump 14 into the phase separator 15. The water necessary for separation of the heavy aromates is added to the partial stream of solvent before mixing pump 14 by means of conduit 16. This addition of water lies within the order of magnitude of 5 to 20 parts by volume per 100 parts by volume of solvent in conduit 12. In phase separator 15 the heavy aromates are separated as a light phase from the solvent-water mixture, and discharged across conduit 17, whereas the solvent-water mixture which forms the heavy phase is removed across conduit 18 from the phase separator 15 and led into the sump of column 5. The water contained in the solvent-water mixture, together with the hydrocarbons of the raffinate, are azeotropically distilled off across the top from column 5. This hydrocarbon-water mixture is led across conduit 7 into the cooler 19, and then subsequently into the reflux container 20, in which the water is separated from the hydrocarbons of the raffinate by means of phase separation. Whereas the water is discharged across conduit 16 and added anew to the partial stream of solvent in conduit 12, the hydrocarbons from the raffinate are led initially into conduit 21, from which a small partial stream is discharged across conduit 22 and provided as reflux to column 5, while the main amount of hydrocarbons is removed across conduit 23 from the method, and introduced to its further utilization. Meanwhile, the solvent is introduced across conduit 6 into the separating flask 24, in which the carried-along hydrocarbons of the raffinate are separated by means of phase separation, and returned from there across conduit 25 into the sump of column 5. The solvent, freed of hydrocarbons, is meanwhile discharged across conduit 26 and added to the feed hydrocarbon mixture in conduit 1, together with which it is led into the extractive distillation column 2. Another possibility is to add this solvent, across conduit 26, to the solvent circulation in conduit 3.
The method represented in the flow scheme according to FIG. 2 corresponds essentially with the method according to FIG. 1, with corresponding numerical designations obviously having the same meaning. In contrast to the method according to FIG. 1, however, the solvent-water mixture discharged here across conduit 18 from the phase separator 15 is introduced into the solvent regeneration column 27, which displays a reinforced distillation part 28. Before entry into this column, toluene and/or xylene is added to the solvent-water mixture across conduit 29 and/or conduit 30. The added amount of toluene and/ or xylene lies, according to the azeotrope ratio, within the range between 15 and 40 parts by volume per 100 parts by volume water in the solvent-water mixture. The water contained in the solvent-water mixture, together with the added aromates (toluene and/or xylene), is azeotropically distilled off from the solvent regeneration column 27, and discharged across conduit 31. The water-free solvent is returned from the solvent regeneration column 27 sump across conduit 35 into the solvent circulation in conduit 3. In the reflux container 32, the driven-off water is separated from the aromates by phase separation, and can be discharged across conduit 33. The water is led from there, although this is not represented in the flow scheme of FIG. 2, into conduit 16 for purposes of re-use. The aromates are discharged across conduit 30 and led back to conduit 18, where they are added anew to the solvent-water mixture. However, a partial stream of the aromates is discharged across conduit 34, which goes to the reinforced distillation part 28 of the solvent regeneration column 27, as reflux. To the extent that the amount of aromates returned across conduit 30 is not sufficient, a corresponding supplementation must be supplied across conduit 29. Herewith, by appropriate operation of the extractive distillation column 2 and the solvent separation column 9, a partial stream of the toluene-xylene fraction discharged across conduit 11 can be employed. It is essential to point out that for the mentioned purpose, the xylene is preferred over the toluene, since xylene contains about 40% by weight water in the azeotrope, whereas toluene contains only about 13.5% by weight water in the azeotrope. In contrast, benzene, with only 9% by weight water in the azeotrope, is completely eliminated, since here consequently the necessary amounts of benzene for the water removal would be too great.
The flow schemes represented in the diagrams contain only those apparatus parts unconditionally necessary for illustration of the method according to the present invention. All additional arrangements not directly involved in the invention, are not represented. This applies in particular to the heat exchanger for heat exchange between the individual process streams, the circulation cooker for heating the individual columns, the arrangements for regeneration, respectively, replenishment of the consumed solvent, as well as all of the measuring and regulating arrangements.
The manner of operation of the method according to the present invention is finally proven by means of two operational examples. These operational examples refer only to the treatment according to the invention of the partial stream of solvent, whereas the associated recovery of the aromate concentrate suitable as blending component, which is indeed not the subject of the invention, is not more closely illustrated. It has been proven in practice during operation of a plant for the recovery of this aromate concentrate, that a heavy aromate content in the solvent within the order of magnitude of about 5% by weight in no way impairs the selectivity of the solvent It is first upon an increase in the content of heavy aromates to greater than or equal to 10% by weight, that there occurs a clear reduction in the selectivity of the solvent. It follows from this that in practice, the solvent can be circulated in the plant until a heavy aromate content of 10% by weight is reached. It is first then that a partial stream of the solvent must be discharged for the purpose of separation of heavy aromates, and treated according to the present invention. Based upon the above-mentioned experience in practice, it is sufficient when the heavy aromate content in this partial stream is lowered to a value of 5% by weight. Example 1 concerns herewith the first method variation, while Example 2 involves the second variation.
______________________________________EXAMPLE 1:______________________________________Conduit 12 90 kg N-formylmorpholine 10 kg heavy aromatesConduit 16 15 kg waterConduit 17 5 kg heavy aromatesConduit 18 90 kg N-formylmorpholine 15 kg water 5 kg heavy aromatesConduit 7 Non-aromates of the raffinate 15 kg waterConduit 26 90 kg N-formylmorpholine 5 kg heavy aromates______________________________________
______________________________________EXAMPLE 2:______________________________________Conduit 12 90 kg N-formylmorpholine 10 kg heavy aromatesConduit 16 15 kg waterConduit 17 5 kg heavy aromatesConduit 18 90 kg N-formylmorpholine 15 kg water 5 kg heavy aromatesConduits 29 and 30 total 5 kg toluene-xylene mixtureConduit 35 90 kg N-formylmorpholine 5 kg heavy aromatesConduit 31 5 kg toluene-xylene mixture 15 kg water______________________________________
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of production methods differing from the types described above.
While the invention has been illustrated and described as embodied in a method for the production of an aromate concentrate suitable for use as blending component for fuel, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
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In the method for the production of an aromate concentrate suitable for use as blending component for gasifier fuel, feed hydrocarbon mixtures having boiling ranges substantially between 40° and 170° C., are subjected, without any previous separation into individual fractions, to an extractive distillation employing N-substituted morpholine, substituents of which display no more than seven C-atoms, as selective solvent. Herewith, the lower boiling non-aromates with a boiling range up to about 105° C., practically completely, and most of the higher boiling non-aromates with a boiling range between about 105° and 160° C., are recovered as raffinate, whereas the aromates, which are to be employed in whole or in part as blending component, come down in the extract of the extractive distillation. In order to separate heavy aromates from solvent, a partial stream of the circulating solvent is mixed with water, and the heavy aromates are separated as a light phase from the solvent-water mixture. The solvent-water mixture is then separated into its components, which are re-utilized.
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SUMMARY
A portable, pocket sized instrument for measuring wind speed and indicating wind direction wherein a multiple numer of vanes of varying size and spacing are radially and orthogonally fixed to a disc and wherein the force of the wind against the vanes causes the disc to rotate against the restraining torque of a spring. Wind speed is indicated by angular rotation of the disc and wind direction is indicated by the orientation of the instrument at the time of maximum reading. A foldable handle protects the mechanism and increases the convenience of positioning the instrument.
1. Field of the Invention
The invention pertains to the art of wind speed and direction measuring instruments of the portable type which can be hand held and easily stored.
2. Description of the Prior Art
Those conversant with the art of wind measuring instruments are aware that many different designs have been developed employing various physical principles and arrangements. As examples, Dwyer U.S. Pat. No. 2,993,374 balances the height to which a very light plastic bead rises against the wind pressure. Electric static on the bead or moisture it absorbs tends to make the unit inoperative. Furthermore, the lack of damping allows the bead to strongly oscillate about its average position making it difficult to read, especially under gusty conditions. Simerl, U.S. Pat. No. 4,102,188, uses rotor cups whose rate of rotation when exposed to the wind drives an electric meter. The exposed rotor cups, particularly when rotating at high speed are subject to breakage should they strike some object while being hand held and may cause some injury to the fingers of the holder. Furthermore it can only indicate wind speed but not wind direction. Snider, U.S. Pat. No. 2,889,707 and Beckman, U.S. Pat. No. 3,877,303 each use a single vane which rotates about a pin but is constrained by a spring. As a consequence of their design the vane is limited to an angular rotation of less than 90°. As a result of the limited degree of rotation the accuracy and resolution of readings, particularly at low air speeds, is poor.
OBJECTIVES
The principal objective of this invention is to provide a portable instrument that is capable of measuring wind speed and indicating wind direction. It is a further objective to produce accurate and readable indications at very low wind speeds, of less than 5 miles per hour, as well as high wind speeds of 60 miles per hour on a single scale. Another objective is to contain and protect the moving elements of the instrument entirely within an enclosure. Still another objective is to optimally damp the motion of the speed indicating dial so that the instrument is easily used in all wind conditions, including gusty conditions. These and other advantages will become apparent from the accompanying drawings and description.
DRAWING DESCRIPTION
In the drawings:
FIG. 1 is a perspective view of the Instrument.
FIG. 2 is a section taken on line 2--2 of FIG. 1.
FIG. 3 is a sectional view taken on line 3--3 of FIG. 2.
FIG. 4 is a sectional view taken on line 4--4 of FIG. 2.
FIG. 5 is an enlarged fragmental section view of one bearing.
FIG. 6 is an enlarged fragmental section view of another embodiment of the bearing.
FIG. 7 is a front elevation of the disc.
DESCRIPTION OF PREFERRED EMBODIMENT
Although it is recognized that other configurations are possible, the drawings represent one specific embodiment of the invention.
Referring to the drawings:
FIG. 1 is a perspective view of the device. It consists of an essentially hollow rectangular case 1 which could be made of various materials, plastic being preferred and a foldable handle 20 which in the upward or folded position protects the inlet port 3 of the instrument and in the downward or unfolded position provides a convenient means of orienting the instrument into the wind.
On one face of the case 1 is a transparent window 2 which allows viewing of the internal readings. At the lower portion of the front end of case 1 is said inlet port 3 which admits the wind. At the opposite end of case 1 is an exit port 4 which allows the wind to escape. In FIG. 2 it is seen that connecting the inlet and outlet ports is a baffle 5 which forms a channel 17 with the bottom and sides of case 1 thru which the wind travels. Except for this channel all sides, top and bottom, of case 1 are closed. Mounted internal to the case is a thin disc 6, indicated by dotted lines. On the face of disc 6 are inscribed a set of numbers 7 as shown in FIG. 7. These represent wind velocity in miles per hours or meters per second or any other suitable velocity scale. A second or dual scale properly calibrated can also be printed in addition to the first scale but is not shown.
Disc 6, preferrably made of aluminum, contains a multiple number of vanes 8 which are orthogonal to its face as seen in FIGS. 3 and 4. The height and area of each vane becomes progressively smaller, the first vane being the largest, until a suitable minimum size is attained.
The radial distance from the center of disc 6 and the angular separation between the vanes is also varied. The first and second vanes, 8 1 and 8 2 , extend to the edge of the disc whereas the outer tip of the remainder of the vanes terminate within about 1/4" of the outer edge of the disc. Thus it can be seen that except for vanes 8 1 and 8 2 there is a clear annular rim, 18, of about 1/4" in depth around the edge of the disc. Mangets, 19, are placed on each side of the rim thereby creating a strong magnetic field through the aluminum rim. Motion between the aluminum rim and magnets create electric eddy currents which tend to oppose the motion of the disc and damp the amplitude of its oscillations.
As seen in FIGS. 3 and 4, disc 6 is physically fixed by means of collar 9 onto shaft 10 which has at each end very narrow diameter pins 11. Also physically mounted and fixed at its center to shaft 10 is a spiral spring 12. As viewed in FIG. 3 the outer end 13 of spiral spring 12 is held fixed in slot 14 of baffle 5.
Referring to FIGS. 3, 4 and 5 it is seen that shaft 10 with pins 11 is seated into low friction bearings 15. These bearings can be small diameter holes molded into the plastic or jeweled bearing inserts. FIG. 6 is an enlargement of one of the bearing sections showing cup 16 surrounding pin 11. Cup 16 contains damping grease, not shown, which surrounds pin 11. The viscosity and other characteristics of the damping grease are selected such as to provide good damping without significantly downgrading sensitivity. This damping, primarily for low speeds, complements the higher speed damping of the magnets. FIG. 5 illustrates the other end of the shaft without the grease cup.
When not in operation, handle 20 is folded up against the front end of case 1. In operation, handle 20 is opened downward and the front end of case 1 is held in the direction of the wind. The air current enters inlet port 3 and exerts a force on each of the vanes 8 which are momentarily within channel 17. The total torque tending to rotate disc 6 around bearings 15 is a function of the number of vanes in channel 17, the area of each vane, the radial distance of each vane from the bearing point, and, the square of the velocity of the air stream. Spiral spring 12 resists the rotation of disc 6. Initially at low wind speed, say at 5 miles per hour or less, the large vanes 8 1 and 8 2 are within channel 17. Thus although the wind force is at a minimum, the total area of the vanes is a maximum and the resultant torque is sufficient to rotate the disc 6 thru an angle of about 30°. This is adequate to produce an easy reading of wind speed with good resolution. As the wind speed increases, disc 6 rotates and smaller vanes and with a smaller radial distance enter the airstream. As a consequence when the wind speed reaches 60 MPH, disc 6 rotates through an angle of approximately 320°.
If the size of the vanes and their radial distance from the center were not reduced with the disc's rotation in response to increased wind speed, the angular rotation of the disc 6 would increase as the square of the wind speed. Thus a wind speed of 60 MPH would result in a rotation of 60/5×30° which equals 4320° or 12 complete rotations of the disc. However, it is necessary to constrain disc 6 rotation to a single revolution. Through the use of smaller vanes and decreased radial distance, the disc's rotation is limited to 320°. Table A below compares the angle of rotation that would occur if the said vanes 8 were kept constant in size and radial distance versus the angle achieved by varying vane size and distance.
TABLE A______________________________________Wind Speed Constant Vane Size Varied Vane Size(MPH) (Degree Rotation) (Degree Rotation)______________________________________ 5 30 3010 120 9020 420 20030 1080 23040 1920 26050 3000 29060 4320 320______________________________________
It is apparent from Table A that the degrees of rotation for the "varied vanes", as described herein, is nonlinear with wind speed. At the wind speeds up to 30 MPH, the disc's rotation is large; that is, at 30 MPH the disc rotates about 230°. Accordingly very good resolution and readability is obtained in the wind speed range of 0-30 MPH which is the range of greatest interest to those who would use this instrument. In the range of 30-60 MPH, the rate of increase in angular rotation with increased wind speed is less. As a consequence the full range of 0-60 MPH is achieved within a single complete revolution of disc 6.
The outer face of disc 6 which can be viewed through window 2, is calibrated with a printed scale of 0-60 MPH. The indicated reading of this scale will be maximum when the instrument is pointed directly into the wind. Thus the wind direction is determined by rotating the entire instrument until a maximum reading is obtained.
It can therefore be seen that the instrument as described can determine the winds speed and direction with high accuracy and resolution particularly at low wind speeds. Furthermore, the instrument being small in size can easily be carried in the pocket of the user.
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A portable, pocket sized instrument for measuring wind speed and indicating wind direction wherein a multiple number of vanes of varying size and spacing are radially and orthogonally fixed to a disc and wherein the force of the wind against the vanes causes the disc to rotate against the restraining torque of a spring. Wind speed is indicated by angular rotation of the disc and wind direction is indicated by the orientation of the instrument at the time of maximum reading. A foldable handle protects the mechanism and increases the convenience of positioning the instrument.
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TECHNICAL FIELD
[0001] The invention concerns generally the technology of controlling the transmission of digital information packets between an insecure information network and a protected domain. Especially the invention concerns the technology of combining the so-called application gateway functionality to a firewall that controls the transmission of TCP/IP-packets (Transmission Control Protocol/Internet Protocol).
BACKGROUND OF THE INVENTION
[0002] The conventional way of protecting a protected domain against hostile attacks from an insecure external information network is to route all data packets transmitted therebetween through a so-called firewall. At the priority date of this patent application the term “data packets” refers in this regard practically invariably to TCP/IP-packets. The protected domain is almost invariably a private corporate network, but firewall applications exist also for protecting individual computers as well as small home networks.
[0003] A conventional firewall performs packet-level filtering based on packet headers. This means that the firewall examines the TCP/IP header of each packet routed to it, and either rejects or passes the packet depending on a set of filtering rules defined by a supervisory user who is responsible for network security. As a very conventional example the supervisory user may impose a strict screening policy according to which only those incoming packets that according to their header originate from a previously known and trusted external host are passed through to the protected domain. A firewall can apply different filtering rules to incoming and outgoing packets, and even different filtering rules depending on which user (i.e. which IP address) of the protected domain is involved in the communication.
[0004] More versatility can be added to the basic firewall functionality by instructing the firewall to look at not only the TCP/IP header but also certain other header information within each packet. In packet-switched information networks TCP/IP packets are only used as the vehicle for transferring any kind of data. As an illustrative example one may consider IP as the way of defining a communications network between a multitude of independently addressable endpoints, and TCP as the way of setting up, maintaining and tearing down temporary communication connections within said communications network. Completely different protocols may then define the form and content of the data that is encapsulated as payload into TCP/IP packets for transmission. A versatile firewall may comprise e.g. a filtering rule according to which TCP/IP packets from a certain external source are only passed if they are related to an http (hypertext transfer protocol) connection but rejected otherwise. In order to implement such a rule the firewall looks closely enough at each packet to see, whether an http header follows the TCP/IP header in the packet.
[0005] Also the concept of stateful inspection has been introduced in connection with firewalls. At the priority date of this patent application the exact meaning of stateful inspection is not well established, but most often it is taken to mean some kind of time and connection dependent firewall functionality. This means that a filtering rule at the firewall is valid e.g. only for the duration of a certain TCP/IP connection; in other words the firewall functionality is tied to the state of each connection. The purpose of such stateful inspection is to “close the doors” after a trusted and accepted connection has come to an end, so that nobody can later deceptively utilize the same source address by pretending to be the trusted user residing at that address.
[0006] The common and most serious drawback of all packet filtering firewall solutions known at the priority date of this patent application is that no attention is actually paid to whether the payload data in the TCP/IP packets is what it pretends to be. At most a firewall recognizes that the stream of packets that belongs to a certain active TCP/IP connection appears to carry something defined by protocol X, which we can here denote as the third protocol (taken that the TCP and IP are the first and second protocols respectively). The firewall may check for indications about a certain third protocol being in use, and use such basic indications in making a filtering decision, but it is not capable of monitoring, whether there is anything suspicious in the way in which the third protocol is being used. For example various video protocols exist that involve procedures complicated enough for the firewall to be essentially incapable of monitoring, whether the exchanging of packets is proceeding as is should.
[0007] The known solution to the above-mentioned drawback is to replace a simple firewall with a more versatile monitoring and controlling arrangement known as an application gateway or just AG for short. An application gateway differs from a firewall in that the latter is just a packet-level filter that only performs filtering packet by packet on the basis of (TCP/IP) header information, while the former comprises complete knowledge about how a certain third protocol should work so that it can monitor, whether a certain connection proceeds according to said certain third protocol. One of the simplest imaginable application gateway approaches is to check, whether all packets that carry the header of a certain third protocol actually conform to the regulations concerning packet composition under said third protocol. More elaborate application gateway arrangements may e.g. monitor, whether a sequence of handshake messages exchanged under said third protocol conforms to the appropriate regulations concerning handshakes.
[0008] For example application gateways specific to the SMTP (Simple Mail Transfer Protocol) are known. These are security-enhancing devices that are coupled between the Internet and an e-mail server that runs the e-mail functionality of a corporate network. The task of an SMTP-specific application gateway is to monitor all TCP/IP connections that carry SMTP-related traffic, i.e. e-mails to and from the corporate network. The application gateway ensures that these connections only proceed according to the SMTP specifications.
[0009] The difference between a firewall and an application gateway has been illustrated so that while a firewall is merely a properly instructed mail sorter who reads the addresses of sender and recipient on each envelope and either forwards or shreds the sealed envelopes accordingly, an application gateway is the corporate lawyer who opens the envelope, reads the letter contained therein and evaluates its true meaning before either passing the letter on to its original intended recipient or taking some other appropriate action.
[0010] An application gateway is definitely an advancement beyond firewalls that only perform packet-level filtering. However, it represents a step backwards in throughput, complexity and susceptibility to software crash. Implementing application gateway functionality requires considerable computational effort, which inevitably increases the expected delay in letting through also packets that are completely legal and valid. Application gateways may require considerably more memory than firewalls, because monitoring the proceeding and state of connections requires the accumulation of connection history data concerning each monitored communication. It is sad but true that whenever one increases the amount of program code that is used to perform a certain task, an increase is also to be observed in the probability that the code simply contains an error or otherwise does something unexpected under some specific operational conditions.
[0011] The publication U.S. Pat. No. 5,623,601 (Vu) describes the basic concept of an application gateway. The “gateway station” of Vu contains application level proxies that perform data screening in order to reject potentially dangerous packets. All IP packets, ICMP (Internet Control Message Protocol) messages and source routing packets are intercepted. The publication mentions as a specific advantage that none of them are forwarded between the external, potentially hostile network and the private network; direct communication therebetween is effectively disabled. While providing a very good basic level of security, this approach has all the above-mentioned drawbacks that relate to limited throughput, high complexity and susceptibility to software crash due to the sheer amount of program code involved.
[0012] The publication U.S. Pat. No. 5 , 950 , 195 (Stockwell et al.) describes actually an application gateway arrangement, although it uses the term firewall. The publication specifically states that not only message traffic but also message content is reviewed. Also this solution involves problems regarding slow processing, complexity, and susceptibility to software crash.
[0013] The publication U.S. Pat. No. 6,182,226 B1 (Reid et al.) is comparable to those mentioned above in that it suggests implementing significant parts of application gateway functionality within the operating system kernel of the “firewall” computer. The kernel is the part of computer software that should operate as fast and as reliably as possible, which is in direct conflict with the teachings of Reid et al.
[0014] The publication U.S. Pat. No. 6,212,558 B1 (Antur et al.) provides a listing of firewall types that is in good accordance with the definitions used in this patent application. The publication suggests that the security functions could be distributed to several computer devices in the network. Remarkable interest is placed upon administrating a multitude of firewalls so that uniformity of security policies is maintained.
SUMMARY OF THE INVENTION
[0015] It is an object of the present invention to provide the level of security associated with application gateways while simultaneously enabling low complexity, short delays and high reliability in routine processing of packets. It is another object of the invention to provide an application gateway arrangement that is easy to administrate and update according to need. It is a further object of the invention to provide an application gateway arrangement that minimizes the amount of reconfiguration work needed on the workstations of a protected domain. It is yet another object of the invention to provide an application gateway arrangement that combines universal applicability with possibilities of customizing the application gateway functionality to the needs of specific organizations.
[0016] The objects of the invention are achieved by implementing packet-level processing in the operating system kernel of a firewall computer, by setting up at least one protocol-specific application gateway somewhere else than in the operating system kernel of the firewall computer, and by instructing the packet-level processing process to recognize packets associated with the protocol that the protocol-specific application gateway handles and to direct the recognized packets to the application gateway.
[0017] The characterizing features of the various methods according to the invention are recited in the characterizing portions of the independent patent claims directed to methods.
[0018] The characterizing features of the various systems according to the invention are recited in the characterizing portions of the independent patent claims directed to systems.
[0019] The characterizing features of the various devices according to the invention are recited in the characterizing portions of the independent patent claims directed to devices.
[0020] The characterizing features of the various software program products according to the invention are recited in the characterizing portions of the independent patent claims directed to software program products.
[0021] Various further advantageous embodiments of the invention are presented in the depending patent claims.
[0022] The fact that only basically filter-type packet-level processing is performed in the operating system kernel of a firewall computer helps to keep the kernel's complexity low and reliability correspondingly high. Application gateways can be handled as modules external to the basic firewall process, which makes it easy to add, remove, replace or update application gateways according to need. The application gateway(s) can be made completely transparent in terms of network addressing by adhering to a suitable address handling policy, which means that the workstations of the protected domain can remain completely unaware of any application gateway being used. Application gateways may be made to only pay attention to protocol-specific matters, thus making it easy for the manufacturer to reproduce and distribute large numbers of application gateways in a cost-effective way. Simultaneously it is possible to customize the application gateways in any desired way, because the basic approach does not limit the rules that the application gateways are programmed to enforce.
[0023] We use the generic terms “packet processing”, “packet processor component” and “packet processor part” to denote the process or the part of a process that regarding the invention produces the decisive result about redirecting: packets are examined just enough to find out, whether they should be redirected to an application gateway or not. In known architectures where the decision about redirecting follows from the application of certain packet-level filtering rules, packet processing in this sense is equal to packet-level filtering. However, the invention does not require any specific mechanism to be used for making the decisions about redirecting.
[0024] Once a packet processor component has recognized that a certain packet should be redirected to an application gateway, it is simple to achieve the actual redirecting e.g. by changing the values of certain destination address and destination port fields in the packet so that the new values indicate the application gateway as the destination. Conventional packet handling will then take care of routing the packet to the application gateway. Also other mechanisms are available for the redirecting.
[0025] The application gateway should in any case receive information about the original destination address and destination port of each packet. Various signalling schemes can be utilized to transfer such information between the packet processor component and the application gateway, if the information is not available any more in the redirected packet itself.
[0026] After successful application gateway processing the processed packet should be again directed towards their original destination. This task can be either on the responsibility of the application gateway, or on the responsibility of the packet processor component if the application gateway returns all packets to it after they have been subjected to application gateway processing.
BRIEF DESCRIPTION OF DRAWINGS
[0027] The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
[0028] [0028]FIG. 1 illustrates a principle of the invention,
[0029] [0029]FIGS. 2 a to 2 c illustrate certain alternative packet routes in a system according to the invention,
[0030] [0030]FIG. 3 illustrates the division of functionalities into kernel mode and user mode in the invention,
[0031] [0031]FIGS. 4 a to 4 h illustrate certain routing alternatives in a system according to the invention,
[0032] [0032]FIGS. 5 a to 5 c illustrate certain alternatives for device configuration in a system according to the invention,
[0033] [0033]FIGS. 6 a to 6 c illustrate methods according to certain embodiments of the invention,
[0034] [0034]FIGS. 7 a and 7 b illustrate methods according to certain other embodiments of the invention and
[0035] [0035]FIGS. 8 a and 8 b are block diagrams of arrangements according to certain embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The exemplary embodiments of the invention presented in this description are not to be interpreted to pose limitations to the applicability of the appended claims. The verb “to comprise” is used as an open limitation that does not exclude the existence of also unrecited features. The features recited in depending claims are mutually freely combinable unless otherwise explicitly stated.
[0037] [0037]FIG. 1 illustrates schematically a situation where an untrusted packet-switched information network 101 , typically the Internet, is separated from a private packet-switched information network 102 by a firewall device 103 . Coupled to the untrusted packet-switched information network 101 there are various data sources, of which FIG. 1 shows a first source 104 meant for transmitting data that inside the TCP/IP encapsulation conforms to a certain protocol A, a second source 105 that inside the TCP/IP encapsulation conforms to a certain protocol B, and a third source 106 that is forbidden in the sense that no packets from that source should be accepted into the private packet-switched information network 102 . An exemplary user 107 of the private packet-switched information network 102 also appears in FIG. 1.
[0038] According to the invention the firewall device 103 comprises a packet processor part 110 and an application gateway part 111 . FIG. 1 illustrates especially an embodiment of the invention where all connections between the firewall device 103 and the networks 101 and 102 go through the packet processor part 110 , and the application gateway part 111 is only at the end of a “blind track” from the packet processor part 110 with no external connections of its own. Later in this description we will discuss other possibilities for arranging the connections of the application gateway part 111 . All connections shown in FIG. 1 are bidirectional.
[0039] For the purpose of an example we will assume that the application gateway part 111 is strictly specific to protocol A. Additionally we will assume that packets originating from the second source 105 and containing data according to protocol B are considered safe by the firewall device 103 . These assumptions together with the forbiddenness of the third source 106 mean that the packet processor part 110 operates as follows: It examines incoming packets from the untrusted packet-switched information network 101 and directs to the application gateway part 111 all packets that come from the first source 104 , because they contain data that conforms to protocol A. After application-specific processing in the application gateway part 111 these packets continue to the original intended recipient 107 . All packets that come from the second source 105 and contain data that conforms to protocol B are let directly through to the private packet-switched information network 102 , while all packets that come from the third source 106 are simply rejected. FIGS. 2 a , 2 b and 2 c illustrate these alternatives respectively.
[0040] Division of Functions into Kernel Mode and User Mode
[0041] An important factor that affects the usability and reliability of the application gateway arrangement according to the invention is the division of duties between the packet processor part 110 and the application gateway part 111 , and the practical implementation of these divided duties as kernel mode and/or user mode processes. FIG. 3 illustrates these aspects of the invention. A fundamental principle in the division is that the functions that are on the responsibility of the packet processor part 110 are typically implemented as kernel mode processes, while the application gateway part 111 typically operates in user mode. Packet-level filtering is relatively simple to implement, which means that the program code that contains all the filtering instructions is simple and short enough to fit into a typical kernel and to run reliably under a variety of operating conditions, even exceptional ones. On the other hand the packet processor part 110 must also handle all packet traffic that goes through the firewall device, which advocates as fast and efficient continuous operation as possible; this is a further reason for implementing the packet processor part 110 in kernel mode.
[0042] Although fast and efficient operation would be advantageous also for the application gateway part 111 , it typically involves passages of program code that are too extensive and complicated to qualify as suitable for kernel mode. Regarding the overall operational reliability it is better to implement the application gateway functionalities in user mode.
[0043] The packet processor part 110 is responsible for receiving all packets that come through the firewall device. It is also naturally responsible for performing the known tasks of a packet-filtering firewall for all those packets that will not be subjected application gateway processing. We continue assuming that the application gateway is strictly protocol-specific, so all packets that contain data pertinent to other protocols are just subjected to firewall processing at the packet processor part. The variety of possibly encountered other protocols is extremely large, so we may well say that packets that contain data according to most of the possible protocols are never directed from the packet processor part 110 to the application gateway part 111 .
[0044] For those packets that indeed contain data pertinent to the protocol(s) handled by the application gateway part 111 the packet processor part 110 performs the necessary redirecting operations. In order to keep such redirecting transparent, or at least to keep it from interfering with the continued journey of the packets after application gateway processing, the packet processor part 110 must also signal certain additional information to the application gateway part 111 . We will describe both redirecting and signalling in detail later in this description. A yet another task of the packet processor part 110 is the redirecting of processed packets towards their original intended recipients after the application gateway part 111 has returned the packets. The last-mentioned naturally only applies if the application gateway part 111 does not take care of any redirecting independently.
[0045] The tasks of the application gateway part 111 are receiving packets from the packet processor part 110 , performing the actual application gateway processing, taking part in the signalling of additional information with the packet processor part 110 and returning processed packets so that they can be forwarded towards their original intended recipients.
[0046] At least one communications channel 301 must exist between the packet processor part 110 and the application gateway part 111 in order to convey both packets and additional signalling information. The actual implementation of the communications channel 301 can vary depending on whether the packet processor part 110 and the application gateway part 111 are implemented in a single physical device or in at least two different physical devices, and whether the signalling takes place “in-band” (i.e. as an integral part of the stream of conveyed packets) or “out-of-band” (i.e. otherwise).
[0047] Different Routings of Packets
[0048] [0048]FIGS. 4 a to 4 h illustrate certain alternative routing principles. Here we are only interested in packets that contain data pertinent to a protocol that is in principle handled by an application gateway part 111 , so in the following the routing of other kinds of packets is not considered; they would just go through the packet processor part 110 anyway. The communicating parties are a transmitting external host 401 and a receiving internal host 402 , or a transmitting internal host 412 and a receiving external host 411 respectively. The fourth party taking part in the packet routing is a packet processor part 110 . The illustrations appear in four pairs so that FIGS. 4 a and 4 b ; 4 c and 4 d ; 4 e and 4 f ; as well as 4 g and 4 h belong together.
[0049] The routing principle illustrated in FIGS. 4 a and 4 b is the full bidirectional blind track approach, where both the external and internal hosts remain completely unaware of there being an application gateway involved although the packets go through the application gateway part 111 . Routing to and from the application gateway part 111 is always performed by the packet processor part 110 .
[0050] The routing principle illustrated in FIGS. 4 c and 4 d is the full bidirectional zigzag route approach, where the packets transmitted by an external host 401 to an internal host 402 go through the packet processor part 110 and the application gateway part 111 in this order and continue from the latter directly to the internal host 402 , and the packets transmitted by an internal host 412 to an external host 411 follow the same route in reverse direction.
[0051] The routing principle illustrated in FIGS. 4 e and 4 f is one where incoming packets take the blind track route back and forth between the packet processor part 110 and the application gateway part 111 , while outgoing packets go straight through the packet processor part 110 without visiting the application gateway part 111 at all. Allowing outgoing packets to bypass the application gateway part 111 reflects an assumption according to which no harm can be caused to the protected network by these outgoing packets, as long as the corresponding incoming packets are subjected to application gateway processing.
[0052] The routing principle illustrated in FIGS. 4 g and 4 h is one where incoming packets take the zigzag route through the packet processor part 110 and the application gateway part 111 , while outgoing packets go straight through the packet processor part 110 without visiting the application gateway part 111 at all.
[0053] All those routing principles where packet traffic between the firewall device and both external and internal hosts goes through the packet processor part 110 , and the application gateway part 111 only constitutes the end of a blind track, share the advantageous feature that the existence of an application gateway does not require specific configuration of the internal hosts. For example in a situation where a new application gateway is added to handle a protocol that was formerly only dealt with by the packet processor part 110 , the only place that requires changes is the packet processor part 110 . This is a major advantage if the number of internal hosts is large, like in the private corporate network of a large company.
[0054] On the other hand it is perfectly possible, although potentially laborious, to configure the internal hosts so that all outgoing packets that contain data pertinent to the protocol handled by an application gateway are sent within the internal network to the application gateway part 111 , while all other outgoing packets are transmitted to the packet processor part 110 . It is even possible to make the internal hosts transmit all outgoing packets within the internal network to the application gateway part 111 , but such an approach saddles the application gateway part 111 with the additional task of rerouting all such packets to the packet processor part 110 that do not need application gateway processing. The rerouting would actually require a certain packet filtering functionality to be added as a preliminary stage of application gateway processing, which definitively means adding excessive processing and delay.
[0055] The laborious task of reconfiguring all internal hosts can be at least partly avoided by instructing the application gateway part to tamper with the incoming packets so that they become to contain appropriate return path instructions for a return path that goes through the application gateway part. This means that all packets that an internal host will transmit as a response to first having received packets through an application gateway part will also go out through the application gateway part without any explicit configuration changes having been made at the internal host.
[0056] The embodiments where the application gateway part 111 sends incoming packets directly to their final recipients without circulating them once more through the packet processor part 110 have naturally the advantage that the traffic load at the latter remains smaller. It is indeed one of the duties of the application gateway part 111 to keep track on the intended recipient of each packet it processes, so it is natural that it knows the recipients and is therefore capable of bypassing the packet processor part 110 in sending the processed packets further. Not circulating the processed packets back to the packet processor part 110 appears to be advantageous at least in those hardware arrangements where the application gateway part 111 is physically located in a different computer device than the packet processor part 110 .
[0057] Physical and/or Logical Machine Compositions
[0058] The machine composition for implementing the packet filter and application gateway parts that is simplest in terms of the number of involved devices is the one where both the packet processor part and the application gateway part are implemented in one and only computer device. In some cases it is more advantageous to use two or more devices to put the packet filter and application gateway functionalities into practice. Also in the case of a single physical device there are various alternative possibilities of setting up the architecture that defines the logically different functional entities and their mutual connections. FIGS. 5 a , 5 b and 5 c illustrate certain basic architectural alternatives. In FIG. 5 a there are three different application gateways 501 , 502 and 503 , each of which is arranged to handle a different protocol. Such a modular approach is most advantageous in a situation where frequent changes are possible in the number and/or nature of the protocols that are to be subjected to application gateway processing, because a certain change only affects a small part of the general arrangement and leaves most of it untouched.
[0059] In FIG. 5 b there are likewise three different application gateways 511 , 512 and 513 , but this time each of them is arranged to handle the same protocol. This approach is most advantageous in a situation where large variations are possible in the volume of packet traffic that needs to be subjected to application gateway processing. The packet filter 110 may follow the loading situation of each application gateway and use its routing capability to distribute the processing tasks as equally as possible, or according to some other distribution rule. In FIG. 5 c there is only one physical device 522 for implementing the application gateway processing according to any of a number of protocols.
[0060] All kinds of combinations of the basic principles illustrated in FIGS. 5 a , 5 b and 5 c are possible. Any of these principles and their combinations can also be used together with any of the routing principles described previously. Yet another possibility is to set up at least two parallelly operating packet processor parts that together use the same application gateway part(s).
[0061] Signalling in General
[0062] In order for the application gateway part to be able to perform efficient application gateway processing it must obtain information about the original source address, source port, destination address and destination port values of a packet it receives. In those cases where the application gateway part receives outgoing packets directly from an internal host this task is trivial. However, much more complicated situations arrive in those much more typical cases where the application gateway part receives packets from the packet processor part. This is especially true if the packet processor part also performs NATs (Network Address Translations).
[0063] Performing a NAT means generally that a network node, typically a firewall device, translates an IP address used within one network to a different IP address known within another network. For example a company may use a firewall device to map its local inside network addresses to one or more global outside IP addresses and correspondingly unmap the global IP addresses on incoming packets back into local IP addresses. Performing a NAT, or NATting, is a known way to enhance security, because each outgoing or incoming request must go through a translation process that also offers the opportunity to qualify or authenticate the request or match it to a previous request. NATting also conserves on the number of global IP addresses that a company needs. It lets the company use a single IP address in its communication with the world. NATting has been treated in an IETF (Internet Engineering Task Force) document RFC 1631, where the acronym RFC comes from Request For Comments. Said document is incorporated herein by reference.
[0064] NATting as such is a very advantageous way of achieving the desired redirecting of packets from the packet processor part to the application gateway part. A first reason for its advantageousness is that it is straightforward to perform with well-tested, robust and yet simple kernel mode routines that exist as such and are known as such. A second reason is that it does not increase the size of any packet so processed, which means that it is guaranteed not to cause packet size overflow even if the size of a certain packet to be processed was already at or very close to a certain maximum limit. A third reason is that NATting requires little or no specific attention to be paid to the devices and/or processes that take care of actually taking the packet from the packet processor part and carrying it to the application gateway part, regardless of the location of the packet processor part and the application gateway part within devices and/or networks: a NATted packet comprises, at the appropriate field, a destination address that identifies the application gateway part as its destination. It lies within the very essence of practically operable packet-switched networks that efficient and reliable devices and processes exist for taking each packet to the destination that is indicated in the packet's destination address. The packet processor part can simply leave it to the responsibility of the normal routing processes to take care of actually carrying NATted packets to the application gateway part.
[0065] It should be noted that NATting is available as means for redirecting packets from the packet processor part to the application gateway part regardless of whether the former uses NATting for anything else. Additionally it should be noted that just in order to redirect a packet to an application gateway part it is not required to touch the original source address of the packet at all. The packet processor part might leave the source address as it is, and only replace the destination address with that of the application gateway part. This would eliminate the need for separately signalling the original source address from the packet processor part to the application gateway part. Throughout this description wherever signalling of original source and destination addresses is mentioned one should keep in mind that signalling only the original destination address is sufficient if the redirecting operation left the source address untouched.
[0066] NATting also the source address is useful if the application gateway part is to return processed packets to the packet processor part, because then returning could be simply accomplished by swapping the source and destination addresses of each packet at the application gateway part and leaving it to the normal network routines to actually carry the packet back to the packet processor part. Embodiments of the invention can be produced where it is not necessary to use packet-associated signalling to make the application gateway part aware of the packet processor part's address. For example, if the application gateway part is located at the end of a “blind track”, one may simply define that all packets that leave the application gateway part should always go to the packet processor part because they have nowhere else to go. Alternatively the application gateway part may be separately configured to return packets to the packet processor part, without requiring the packet processor part to transmit its address every time when original values of address fields are signalled.
[0067] A NATted packet that comes from the packet processor part to the application gateway part does not explicitly reveal to the latter all required information. Therefore the packet processor part must take specific action to provide the application gateway part with the necessary information. We will refer to all such specific action measures as signalling. One should note that signalling is not necessarily unidirectional from the packet processor part to the application gateway part. The term signalling is meant to cover also the transmission of other information than just the packets themselves from the application gateway part to the packet processor part. Signalling may take place in-band, which means that the signalled information is carried in one way or another as a part of the stream of TCP/IP packet that is being transferred between the packet processor part and the application gateway part. The other possibility is out-of-band signalling, which means that some other means are utilized.
[0068] In order to simplify the structure of the application gateway part proper one may use a simple deNATting/reNATting layer in immediate association therewith. Such a layer would be located next to the application gateway part between it and the packet processor part. The deNATting/reNATting layer is in such embodiments the peer entity of the packet processor part regarding signalling. The packet processor part directs a packet towards the application gateway part and informs the deNATting/reNATting layer about the original source and destination information of the packet. The deNATting/reNATting layer receives the packet, performs deNATting by replacing the NATted source and destination information values with the original ones it received through signalling, and passes the deNATted packet to the application gateway part. The latter processes the packet as if it had received it directly from its original source, and remains unaware of the packet having already experienced NATting in a packet processor part and deNATting at a deNATting/reNATting layer. After the application gateway part has processed the packet it either forwards it directly towards its original destination, or gives it to the deNATting/reNATting layer for returning to the packet processor part. In the latter case the packet is subjected to reNATting and source/destination switching at the deNATting/reNATting layer, which causes it to return to the packet processor part.
[0069] The description of all embodiments of the invention where the packet processor part is said to practice signalling with the application gateway part can be generalized by taking into account that such signalling can also take place between the packet processor part and an deNATting/reNATting layer next to the application gateway part.
[0070] Inband Signalling
[0071] A first possible way of transmitting the signalled information in-band is to utilize TCP's known URGENT POINTER field and URG bit so that in a packet that contains signalled information the transmitting party sets the URG control bit and inserts into the URGENT POINTER field the current value of the urgent pointer as a positive offset from the sequence number in the corresponding TCP segment. The urgent pointer points to the sequence number of the octet following the urgent data, which in this example is the signalled information. In practice the signalled information would be placed at the very beginning of the TCP payload so that the value at the URGENT POINTER field tells, where in the TCP payload is the point where the signalled information ends and the actual, original TCP payload begins.
[0072] A second possible way of transmitting the signalled information in-band is related to the first in that a conventional feature of the TCP/IP protocol is used: one may utilize one or both of the Options fields that are present in both the IP and the TCP header portion of each TCP/IP packet. The rules that govern the use of the Options fields are known e.g. from the IETF Request For Comments documents number RFC 791 (IP) and RFC 793 (TCP) that are incorporated herein by reference.
[0073] A third possible way of transmitting the signalled information in-band is to utilize another conventional protocol as an encapsulation for a TCP/IP packet and the associated signalled information. For example one may encapsulate them into a Socks packet. Socks is a known protocol that a proxy server can use to accept requests from client users in a company's network so that it can forward them across the Internet. Socks uses sockets to represent and keep track of individual connections. More information about Socks can be found in an IETF document RFC 1928, which is incorporated herein by reference.
[0074] A fourth possible way of transmitting the signalled information in-band is to utilize certain customized protocol features that are defined just for this purpose. For example one may prescribe that the transmitting party always inserts the signalled information right after the header of a packet and before the payload part. Or the transmitting party may compose a completely new header that serves just to direct a packet to the receiving party, and prepend this new header to a conventional packet before the original header. The receiving party then just strips the appended header and reads the “signalled” information from the original header as if it had just received the packet from its original sender. Customized protocols work well if one can be sure that both the transmitting and receiving ends are familiar with the customization, and that the transmission channel therebetween does not cause distortions to the non-standard protocol features.
[0075] All in-band signalling mechanisms have one at least theoretically serious drawback. A packet that arrives at a packet processor part may already have a size equal to the absolute maximum tolerable packet size. In that case it is impossible to add any new fields or new headers or use any enveloping for inserting signalled information.
[0076] It is possible to use fragmenting defined in the known TCP/IP standards so that in case the addition of signalling information causes a maximum packet size overflow, the transmitting party simply fragments the resulting overgrown packet into two or splits it into two TCP packets (according to established language of this field fragmenting refers to manipulating packets on the IP level, while splitting refers to the TCP level). However, preparing for fragmenting or splitting would require the implementation of an almost complete TCP/IP stack, which is not desirable for an efficient kernel mode process such as a packet processor part.
[0077] Especially in embodiments where the packet processor part and the application gateway part are physically located in a single computer device one may define an internal MTU (Maximum Transmission Unit) that is large enough to accommodate any imaginable combinations of large TCP/IP packets and associated signalling information. This approach would dissolve the above-mentioned drawback because no matter how large the TCP/IP packet, internally one would always be allowed to add signalled information to it. However, such a solution would tend to limit the applicability of the invention, because it necessitates permission to modify the TCP/IP protocol stack as well as certain operating system features. Generally it is impossible to assume that even the internal MTU of a computer could be made arbitrarily large, because limitations in certain operating systems may set an absolute upper limit. It should also be noted that if the packet processor part and the application gateway part are not physically located within a single computer device, the transmission path therebetween may set limitations to packet size.
[0078] The drawback of potential maximum packet size overflow is actually not that serious, if we assume that not every packet needs to contain signalled information. It is very reasonable to assume that the need for signalled information will concentrate to the initiation phase of each TCP connection. The first packet that initiates a TCP connection is the so-called SYN packet, which comes almost always without any specific payload. The TCP standard itself allows data to be transmitted already in the SYN packet, but practice has shown that a vast majority of transmitted SYN packets are indeed empty so they are well suited for fattening up with some signalled information.
[0079] Out-of-Band Signaling
[0080] A first possible way of transmitting the signalled information out-of-band is to utilize the well-known UDP (User Datagram Protocol) that offers a limited amount of service when short messages are exchanged between computers in an IP network. It is known that network applications that want to save processing time because they have very small data units to exchange (and therefore very little message reassembling to do) may prefer UDP to TCP. The piece of signalled information is typically small enough to fit into a single UDP packet, so the transmitting party may simply compose an UDP packet with the signalled information as payload and transmit it to the receiving party. Composing and handling UDP packets of limited amount of readily available information is well within the scope of a kernel mode packet processing engine.
[0081] A second possible way of transmitting the signalled information out-of-band is to utilize some other known protocol than UDP, or indeed even a custom-built signalling packet exchanging protocol, for the same purpose.
[0082] A third possible way of transmitting the signalled information out-of-band, being only possible though in embodiments where the packet processor part and the application gateway part are physically located in a single computer device, is to utilize any of the known communications channels between kernel mode processes and user mode processes. Such communications channels are usually strictly specific to certain operating systems. For example in unix-type systems there exist several ways of utilizing sockets and socket reading functions that carry names such as recv, recvfrom, or recvmsg. Another unix-related possibility is to communicate through socket options; applicable functions carry names such as getsockopt and setsockopt. Yet other unix-related system functions that can be used are the known IOCNTL and FCNTL functions, the corresponding longer names being input-output control and file control respectively.
[0083] All out-of-band signalling schemes involve the problems of ensuring that the signalled information indeed reaches its destination and that it is correctly associated with the transmitted packets that it describes. Questions of the latter kind are addressed below under the header “connection identification”. Regarding the task of ensuring delivery, certain alternative options are again available. The most straightforward approach is to just send each out-of-band signalling message once and accept the fact that if the message is somehow lost, corrupted or fatally delayed, the signalled information will not reach its destination and the process that would have needed it will fail. This approach is not as bad as one might assume at first sight, because both the physical distance (in terms of cable length) and the logical distance (in terms of number of processes and devices that take part in handling the signalling message) involved are relatively short compared to general transmission over worldwide networks and the transmission reliability is therefore relatively high. Transmission reliability can be further enhanced through simple redundancy: instead of transmitting just once, each signalling message is transmitted in several copies.
[0084] A more elaborate out-of-band signalling scheme is based on bidirectionality and information-on-demand. Signalling messages are therein not transmitted spontaneously but only as responses to a query. For example when the application gateway part has received packets for which it does not yet know the required information about original source and destination, it sends an UDP packet to the packet processor part and lists therein the source/destination information it observed in a TCP/IP packet received from the packet processor part. The latter then responds to the querying UDP packet by returning another UDP packet that contains the required signalled information.
[0085] A hybrid out-of-band signalling scheme may also be presented combining the features of (redundant) spontaneous and responsive out-of-band signalling. According to the hybrid scheme the transmitting party sends one or more signalling messages spontaneously, and the receiving party only sends an inquiry if it still did not receive any signalling message within a certain time after it received a TCP/IP packet for which it needed information about original source and destination. The hybrid scheme (as well as the “more elaborate” scheme described above) can be based on the use of UDP or any other suitable messaging protocol.
[0086] Connection Identification
[0087] TCP/IP packets come in discrete packet streams, which is equal to saying that each TCP connection has a beginning, a limited duration and an end. During a TCP/IP connection the source and destination addresses and port numbers do not change, which means that is would be most economical to only make the packet processor part indicate to the application gateway through signalling the required information once per each connection, not packet per packet. This means that the event that triggers the signalling process is either the arrival of the first packet of a new TCP connection at the packet processor part, or—in embodiments based on interrogative signalling—the arrival of the first packet of a new TCP connection at the application gateway part, said packet having been redirected to the application gateway part by the packet processor part.
[0088] Only signalling the required information once per connection works fine, if the packet processor part does not change the original contents of the destination address field during redirecting or if one can be sure that no such simultaneous connections will occur that would be at risk of being confused. Changes in the original contents of the destination address field do not occur in those embodiments where the packet processor part prepends some new headers to the redirected packets, or more generally in all such embodiments that retain essentially all of the original header information readable in the redirected packets. The question of potentially confused simultaneous connections is highlighted in the following example.
[0089] Let us assume that a user at machine A initiates an ftp (file transfer protocol) connection to machine ftp1.company.com and a bit later to a different machine ftp2.company.com, and company.com has implemented a packet filter/application gateway system according to an embodiment of the present invention. The packet processor part with a stateful filtering engine is in machine fw.company.com. Let us further assume that the application gateway part handling all ftp traffic sits at port 1111 of a machine ag.company.com. Now, the packet processor part redirects the packets of the first connection to port 1111 of ag.company.com, and the ftp-handling application gateway part is informed that these packets should end up at the conventional port for ftp connections at ftp1.company.com. Later, when the user initiates the second connection to the second machine, the packet processor part redirects the packets that belong to this second connection to port 1111 of ag.company.com, and informs the ftp-handling application gateway part that these should go to ftp2.company.com.
[0090] Now the redirected packets of the second connection come from the same machine and same port as the first connection and end up at the same machine (machine ag.company.com) and the same port (port 1111) as the first connection. How can ag.company.com differentiate between these two connections? Actually, it cannot, if it only considers address and port information.
[0091] A naive solution would be to make the packet processor part include some kind of a connection identifier to all redirected packets. This adds communication overhead, might cause MTU problems, and is generally a bad idea.
[0092] A much better solution is to use a range of ports at ag.company.com, and make sure that the combination of source address/source port/destination address/destination port is unique for each connection that has been redirected to proceed via ag.company.com. This means that the packet processor part must choose the destination port for each separate TCP connection so that a unique combination is always obtained.
[0093] What if the machine A is a massive firewall machine (performing NAT) of some large corporation, so that the number of possible connections from A to company.com might be extremely large? UDP and TCP protocols have 65536 ports, so reserving, say, 1000 ports or even more for the range mentioned above would be possible. That would be enough for 1000 simultaneous connections from the machine A to systems in company.com. This limit can further be increased by arranging the packet processor part to change also the source address and port information in the packets, and indicating these along with the original destination information as discussed above. The packet processor part can, for example, change the source address and port information to refer to those of the firewall computer, fw.company.com, or any other suitable address. If both source port and destination port are used for identifying the connection and a range of 1000 ports are reserved for this use at fw.company.com and ag.company.com, 1000*1000 connections i.e. one million connections could be uniquely identified.
[0094] Packet Restoration
[0095] In those embodiments of the invention where the packet processor part receives processed packets from the application gateway part and transmits them further towards their original intended recipient there must exist a mechanism for restoring the packets so as to complete the transparency of the application gateway processing. In other words the packets that have been subjected to application gateway processing must leave the packet processor part as if they had never been diverted from their original route.
[0096] An advantageous solution for packet restoration goes as follows. At the beginning of a TCP connection, when the packet processor part for the first time sets up a certain relationship between original source/destination information and the modified source/destination information that is used to redirect the packet to the application gateway part, it stores this relationship in a look-up table. The modified source/destination information serves to bring the packet to the application gateway part, which performs its task and processes the packet. Similar replacing of the source/destination information is performed for all packets of the corresponding TCP connection. After having processed a packet the application gateway part switches the source and destination parts of the modified packet header, which causes the packet to be routed back to the packet processor part. There the occurred reversal of the source and destination parts of the modified packet header is taken into account when the packet processor part uses the previously mentioned look-up table to identify the original source/destination information. The packet processor part replaces the modified, switched source/destination / information with the original source/destination information, after which the packet is ready to be transmitted further.
[0097] Changes in the source/destination information fields in the way explained above may be called “double NATting”. The packet processor part NATs a packet for the first time in order to redirect it to an application gateway part. When the packet returns from the application gateway part after having been subjected to application gateway processing, the packet processor part NATs it for the second time in order to release it towards its original destination.
[0098] It is also possible to make the application gateway part restore the packets, because as was noted in the general description of signalling, the application gateway part needs to know the original source and destination information for the application gateway processing to be meaningful. Restoring the packets at the application gateway part is even mandatory in those embodiments of the invention where the packets do not go through the packet processor part any more after application gateway processing. Restoring packets at the application gateway part means simply that after having processed a packet the application gateway part reads the original source and destination information pertinent to that packet from its memory and writes it into the appropriate fields in the packet's header before releasing the packet for transmission towards its original intended recipient.
[0099] Care must be taken if the packet processor part and the application gateway part are physically implemented in a single computer device and if it is on the responsibility of the application gateway part to restore the packets. By default, namely, the packet processor part will have no means for telling an already processed packet from one that still awaits to be redirected to the application gateway part. Some means must be provided for keeping packets from ending up in an endless loop between the packet processor part and the application gateway part.
[0100] Dynamic Changes in Packet Processing
[0101] In the foregoing we have implicitly assumed that the packet processor part operates according to some relatively fixed set of instructions regarding redirection of packets to the application gateway part. Indeed, in simple embodiments of the invention such fixed instructions are given to the packet processor part at the time when an application gateway is installed or the operation of an installed application gateway is modified. However, the invention encompasses also embodiments where dynamic changes in packet processing are possible. Dynamic changes in this sense mean that at least one of the packet processor part and the application gateway part discovers something in the stream of packets that requires a different packet handling strategy to be implemented than before, and takes action in order to implement such a different packet handling strategy.
[0102] As an example we may consider a situation where an application gateway part is in general arranged to handle packets that pertain to ftp. Initially, however, a packet processor part is instructed to redirect only packets that contain ftp control channel signalling to the application gateway part. Packets that are related to an ftp data channel would have a different port number than those related to the ftp control channel signalling, and therefore it is possible that initially the packet processor part is not instructed to redirect them to the application gateway part. According to the principle of dynamic changing the application gateway part may respond to the arrival of certain ftp control channel signalling by asking the packet processor part to change its redirecting strategy so that also the ftp data channel packets will be redirected, for example in order to check for viruses that might come embedded in a file transferred over the ftp data channel.
[0103] Some protocols require two or more port numbers for themselves. An example is the Real Time Protocol or RTP, which is discussed in the known IETF document RFC 1889. It requires two consecutive port numbers of which one is for data and the other is for control. Dynamic changes can be utilized so that when an RTP application gateway part detects the arrival of RTP-related packets that have a certain port number, it instructs the packet processor part to add a new redirection rule according to which packets that have the immediately adjacent port number must also be redirected.
[0104] It is not necessarily the application gateway part that reacts to achieve dynamic changes in redirecting. At least in cases where a certain protocol requires two or more port numbers for itself and these port numbers are easy to deduce from each other (like in the case of two consecutive port numbers), the packet processor part can achieve dynamic changing for itself. When the packet processor part has detected a packet that has a certain port number, analysed the packet enough to find out that it contains data that pertains to a certain protocol, and consequently decided to redirect it to a certain application gateway part, the packet processor part may by itself deduce the other port number(s) that must necessarily mean pertinence to the same protocol. Thus the packet processor part may define new instructions for itself to redirect also packets that have such other port number to the application gateway part.
[0105] Dynamic changes may naturally involve more than one application gateway parts. Even if a certain first application gateway part was in one way or another involved in detecting the need for a dynamic change, the dynamic change may result in new redirecting instructions for the packet processor part that concern some second application gateway part.
[0106] Method Diagrams
[0107] [0107]FIGS. 6 a , 6 b and 6 c illustrate schematically the main features of the methods executed by the packet processor part according to the invention. FIG. 6 a pertains to the phase where a packet processor part that applies packet-level filtering rules receives a packet that it has not yet processed. At step 601 the packet processor part receives a packet and examines it enough to tell, whether the packet contains data that pertains to a certain known protocol. At step 602 the packet processor part checks, whether it knows about an application gateway part that is specialized in handling a protocol that was identified in the packet. We assumed that this packet processor part applies certain packet filtering rules, so the check that is performed at step 602 can be understood as applying at least one of these rules and arriving at a positive finding: the rule states (or: the rules state) that the packet in question is to be redirected to the appropriate application gateway part. A negative finding at step 602 causes the packet to be just processed at step 603 according to certain other (preferably stateful) packet filtering rules, followed by a jump back to step 601 . In a case where outgoing packets related to certain protocol X are not subjected to application gateway processing even if incoming packets related to protocol X are, receiving an outgoing packet results in a negative finding at step 602 because the data in the packet does not pertain to the combination of protocol X and the correct transmission direction.
[0108] A positive finding at step 602 means that the packet processor part should redirect the packet to the appropriate application gateway part. In order not to omit its signalling duties, the packet processor part checks at step 604 , whether the packet in question is the first packet of a TCP/IP connection. If it is, there follows a transition to step 605 in which the packet processor part stores the appropriate header information from the packet. Step 606 represents signalling in general; in case of push-type signalling the packet processor part takes spontaneous action to signal the appropriate header information to the application gateway part, and in case of pull-type signalling it prepares for responding to a query from the application gateway part (the actual querying and respnding round may take place later). Step 606 may even represent no action being taken at all, if the implemented embodiment of the invention is such where redirecting leaves the original source and destination information readable in the redirected packet. Either a negative finding at step 604 or the completion of step 606 lead to step 607 , where the packet is redirected to the application gateway part.
[0109] [0109]FIG. 6 b illustrates an alternative, more general situation where the assumption of using packet-level filtering rules for packet processing is not required. FIG. 6 b is applicable to e.g. connection-oriented of flow-oriented processing where a packet is regarded as belonging to a certain connection or flow if certain features in the packet match with the corresponding features of other, previously handled packets and possibly if some other constraints are met regarding e.g. time intervals between packets or maximum length of a connection or flow in time or number of packets. It is typical to connection or flow oriented processing that detailed considerations about how should a certain connection or flow be handled are only made when the first packet of a certain connection or flow arrives, and thereafter the rest of the packets that belong to the same connection or flow as the first one are handled the same way without every time going through the same detailed considerations again. Regarding the invention it is noted that if the packet processing part finds that the first packet of a certain connection or flow should be redirected to an application gateway part, it is evident that the subsequent packets of the same connection or flow should be handled in similar way, as long as the concept of connection or flow is defined accurately enough to exclude changes of protocol in the middle of a connection or flow.
[0110] At step 611 the packet processor part receives a packet. At step 612 it checks, whether the received packet belongs to a connection or flow that is already known and for which a packet-handling policy has been established. If not, i.e. if the received packet is the first packet of a new connection or flow, certain rules are applied at step 613 in order to determine, what is the appropriate way of handling packets that belong to such a new connection or flow. Without loss of generality we may say that at step 613 the packet processor part defines a policy for handling the newly received packet as well as all subsequent packets that will be found to belong to the same connection or flow. At step 615 it applies this policy; the part of step 615 that is important to the present invention is that if the connection or flow was found to contain packets that require processing at an application gateway part, step 615 means redirecting the packet thereto. In order to accommodate signalling to the method of FIG. 6 b a signalling initiation step 614 has been shown. When a new connection or flow has been discovered and the policy for handling its packets has been defined, some kind of signalling must also be initiated similarly as in the case of FIG. 6 a.
[0111] [0111]FIG. 6 c pertains to the phase where the packet processor part receives a packet that has already been subjected to application gateway processing. At step 621 the packet processor part notices that the source from which the packet was received is actually (one of) the known application gateway part(s), which means that there only remain the tasks of restoring the packet at step 622 and transmitting it further towards its original intended recipient at step 623 .
[0112] [0112]FIGS. 7 a and 7 b illustrate schematically the main features of the methods executed by the packet processor part according to the invention. FIG. 7 a pertains to the “blind track” embodiments of the invention where the application gateway part receives packets only from a packet processor part and returns processed packets through the same route. At step 701 the application gateway part receives a packet and examines, which TCP/IP connection the packet belongs to. At step 702 the application gateway part checks, whether it already knows the original source and destination information that describe the identified TCP/IP connection. A negative finding at step 702 causes a transition to step 703 , which again represents only generally all the signalling tasks that aim at determining the appropriate original source and destination information. In push-type signalling step 703 means checking, whether the packet processor part has already provided this information spontaneously. If not, step 703 means waiting for such information. In pull-type signalling step 703 means transmitting a query to the packet processor part. If the implemented embodiment of the invention is such where redirecting leaves the original source and destination information readable in the redirected packet, step 703 will not become actual because the application gateway part notes already at step 702 that it has already all necessary information.
[0113] After the application gateway part has all necessary source and destination information it can start the actual application gateway processing at step 704 . For those packets that pass the application gateway processing there comes step 705 , in which the source and destination values of the packet are exchanged. This facilitates easy returning of the packet to the packet processor part at step 706 . FIG. 7 b illustrates an alternative sequence of steps after steps 704 ; here the packet is restored at step 711 to ensure transparency of the application gateway processing, and transmitted further at step 712 . The sequence of FIG. 7 b is most pertinent to those embodiments of the invention where the application gateway part forwards incoming packets towards their intended recipients in an internal network without bothering the packet processor part any more with these packets.
[0114] Block Diagrams
[0115] [0115]FIG. 8 a illustrates schematically a firewall device 801 that has a first network interface 802 for communicating with a first network and a second network interface 803 for communicating with a second network. The first and second networks correspond to the previously mentioned external and internal networks respectively. The operating system kernel 804 is illustrated as communicating bidirectionally, i.e. transmitting and receiving packets, with both the first 802 and second 803 network interfaces. According to an important aspect of the invention the kernel 804 contains (preferably stateful) packet processor functionality that is arranged to execute the methods illustrated in FIGS. 6 a or 6 b and 6 c . There is also illustrated a user mode entity 805 that has a bidirectional communication connection for both exchanging packets and signalling with the kernel 804 . According to another important aspect of the invention the user mode entity 805 contains application gateway functionality that is arranged to execute the method illustrated in FIG. 7 a , or the modified method illustrated by replacing the appropriate steps of FIG. 7 a with those of FIG. 7 b . The optional bidirectional communication connection illustrated as a dashed line between blocks 803 and 805 represents the possibility of the application gateway functionality transmitting and receiving packets directly to and from the second network without routing them through the packet processor functionality.
[0116] [0116]FIG. 8 b illustrates schematically a firewall device 811 that has a first network interface 812 for communicating with a first network and a second network interface 813 for communicating with a second network. The first and second networks correspond to the previously mentioned external and internal networks respectively. The operating system kernel 814 is illustrated as communicating bidirectionally, i.e. transmitting and receiving packets, with both the first 812 and second 813 network interfaces. Also in FIG. 8 b the kernel 814 contains (preferably stateful) packet processor functionality that is arranged to execute the methods illustrated in FIGS. 6 a or 6 b and 6 c . Also in FIG. 8 b there is illustrated an exemplary user mode entity 815 that has a bidirectional communication connection with the kernel 814 , but this user mode entity is there just for running various control applications of the packet processor functionality and has no significance to the scope of the present invention.
[0117] On the other hand there is another computer device 821 that has a communications connection with the firewall device 811 so that a third network interface 816 at the firewall device 811 is arranged to communicate with a network interface 822 at the other computer device 821 . The other computer device 821 comprises typically also an operating system kernel 823 , but it has minor importance to the present invention. Much more importantly in a bidirectional communications connection with the kernel 823 there is a user mode entity 824 that contains application gateway functionality that is arranged to execute the method illustrated in FIG. 7 a , or the modified method illustrated by replacing the appropriate steps of FIG. 7 a with those of FIG. 7 b . In order to potentially bypass the firewall device 811 in exchanging packets with the second network the other computer device may contain another network interface 825 that offers it a bidirectional communications connection to the second network; the optionality of such an arrangement is illustrated in FIG. 8 b through using dashed lines. The communications connection between the firewall device 811 and the other computer device 821 can also go through the second network, in which case blocks 813 and 825 are unnecessary and the coupling between blocks 816 and 822 is through the second network.
[0118] The kernel 823 or a suitable user mode process at its command can be used to implement the deNATting/reNATting layer that was discussed previously.
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A method and apparatuses are disclosed for handling digital data packets at a logical borderline that separates an untrusted packet-switched information network from a protected domain. A packet processor part intercepts a packet that is in transit between the untrusted packet-switched information network and the protected domain. The packet is examined at the packet processor part in order to determine, whether the packet contains digital data that pertains to a certain protocol. If the packet is not found to contain such digital data, it is processed at the packet processor part. If the packet is found to contain digital data that pertains to said certain protocol, it gets redirected to an application gateway part that processes the packet according to a set of processing rules based on obedience to said certain protocol. The packet processor part is a kernel mode process running in a computer device and the application gateway part is a user mode process running in a computer device.
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CROSS-REFERENCE STATEMENT
This application is a divisional of and claims the benefit of U.S. Utility application Ser. No. 09/876,633, filed Jun. 7, 2001 (now issued as U.S. Pat. No. 6,592,962), and further claims the benefit of U.S. Provisional Application No. 60/233,879, filed Sep. 20, 2000 and U.S. Provisional Application No. 60/210566, filed Jun. 9, 2000.
BACKGROUND OF THE INVENTION
The present invention relates to wood that is reinforced with a fiber-reinforced thermoplastic composite.
As a result of dwindling stocks of high quality lumber, wood product engineers have had to adopt innovative designs to enhance the structural properties and reduce the cost of wood products. Examples of these designs include glue laminated wood beams, laminated veneer lumber, parallel strand lumber laminated wood columns, wood I-beams, and wood trusses. However, merely redesigning the lumber products has not proved adequate. Therefore, efforts have continued to combine low quality, low cost lumber with structurally reinforcing composites to achieve the same performance as achieved with higher cost, higher quality wood products.
For example, O'Brien in U.S. Pat. No. 5,026,593 discloses the use of a thin flat aluminum strip to reinforce a laminated beam. O'Brien teaches that the aluminum strip must be continuous across the width and length of the beam and that the reinforcing strip may be affixed to the lowermost lamina to improve tensile strength or to theuppermost lamina to improve compression strength of the beam.
In U.S. Pat. No. 5,362,545, Tingley (hereinafter “Tingley '545”) discloses the use of reinforced plastics in glue laminated wood beams (glulams). More particularly, Tingley '545 discloses the use of pultruded composites as materials. These composites are prepared by impregnating thermoset or thermoplastic resins into a continuous fiber bundle. The disclosed thermoset resins include epoxy resins, polyesters, vinyl esters, phenolic resins, polyimides, and polystyrylpyridine while the thermoplastic resins include polyethylene terephthalate and nylon-66. The preferred fibers are disclosed as being aramid or carbon fibers or high modulus polyethylene fibers. Tingley '545 discloses that it is necessary to “hair up” the surface of the fiber-reinforced composite so that fibers protrude, thereby providing a means of adhering the wood to the composite without having to use expensive epoxy adhesives.
In U.S. Pat. No. 5,498,460, Tingley discloses improved adhesion of the fiber-reinforced composite to the wood by creating multiple recesses distributed over the opposed major surfaces of the composite.
In U.S. Pat. No. 5,547,729, Tingley discloses abraded or haired up synthetic tension and compression reinforcements to provide enhanced tensile and compression strength.
In U.S. Pat. No. 5,641,553, Tingley discloses a reinforcing panel comprising a plurality of substantially continuous and parallel synthetic fibers, affixed to at least one cellulose surface material, which improves adhesion of the panel to a wood structure.
In U.S. Pat. No. 5,885,685, Tingley discloses an aramid fiber mat encased in resin along with the fiber-reinforced composite to reduce interlaminar shear failure when nonepoxy resins are used for encasement.
In U.S. Pat. No. 6,037,049, Tingley discloses a composite that comprises two types of fiber strands encased in a resin matrix, a high strength fiber for the central portion of the composite and a lower strength fiber for the edges. The use of lower cost fibers along the edges reduces waste during a planing process.
In each instance, the prior art requires some kind of modification to the surface of the composite to enhance adhesion to the wood member. It would therefore be desirable to prepare a glue-laminated wood structural member that is reinforced with a composite that adhered to wood either with reduced or no adhesive and without surface modification of the composite.
SUMMARY OF THE INVENTION
The present invention addresses a problem in the art by providing a reinforced wood structure comprising an a) elongated multilamellar wood member having an uppermost lamina with an outer surface, a lowermost lamina with an outer surface, a longitudinal center, and a transverse center; and b) a first elongated fiber-reinforced thermoplastic composite layer disposed 1) through the longitudinal center of the wood member; and 2) between and adherent to the major surfaces of two of the laminae, or adherent to the outer surface of the uppermost or the lowermost lamina; wherein the composite contains a plurality of substantially parallel continuous fibers impregnated with a thermoplastic polymer having the following structural units:
where Z is S or O, and Z′ is S, O, N-alkyl or NH.
In a second aspect, the present invention is a reinforced wood structure comprising a) an elongated multilamellar wood member having an uppermost lamina with an outer surface, a lamina adjacent to the uppermost lamina, a lowermost lamina with an outer surface, and a lamina adjacent to the lowermost lamina; b) a first elongated fiber-reinforced thermoplastic composite layer disposed through the length of the wood member and between and adherent to the uppermost lamina and the lamina adjacent to the uppermost lamina; c) a second elongated fiber-reinforced thermoplastic composite layer disposed through the longitudinal center of the wood member and between and adherent to the lowermost lamina and the lamina adjacent to the lowermost lamina, wherein the composite layers each contain a plurality of substantially parallel continuous fibers impregnated with a thermoplastic polyurethane.
In a third aspect, the present invention is a reinforced wood structure comprising a fiber reinforced thermoplastic composite layer disposed onto wood or dispersed into wood particles, wherein the thermoplastic composite layer contains a plurality of substantially parallel continuous fibers impregnated with a thermoplastic polymer having; the following structural units:
where Z is S or O, and Z′ is S, O, N-alkyl or NH.
In a fourth aspect, the present invention is a reinforced wood structure comprising a first fiber-reinforced thermoplastic composite flange and a second fiber-reinforced thermoplastic composite flange, each flange being bonded to a web to form a reinforced I-beam, wherein the fiber-reinforced thermoplastic composite flanges contain a plurality of substantially parallel continuous fibers impregnated with a thermoplastic polymer having the following structural units:
where Z is S or O, and Z′ is S, O, N-alkyl or NH.
In a fifth aspect, the present invention is a reinforced wood structure comprising an elongated multilamellar wood member having a longitudinal center, a transverse center, a width center, and a plurality of elongated fiber-reinforced thermoplastic composite rods, at least two of which rods are tension reinforcement rods and at least two of which rods are compression reinforcement rods, wherein the tension reinforcement rods are disposed through the longitudinal center, and distal on either side of the width center and imbedded into and adhering to a lamina distal from the transverse center and proximal to the lowermost lamina of the multilamellar structure, and wherein the compression reinforcement rods are disposed through the longitudinal center, and distal from either side of the width center and imbedded into and adhering to a lamina distal from the transverse center and proximal to the uppermost lamina of the multilamellar structure.
In a sixth aspect, the present invention is a reinforced wood structure comprising a wood member having slots or bores and a plurality of elongated fiber-reinforced thermoplastic composite rods incorporated into the slots or bores of the wood member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is an illustration of a reinforced glue-laminated or laminated veneer lumber structure.
FIG. 1 b is an illustration of a glue-laminated or laminated veneer lumber structure that is reinforced with a plurality of composite rods.
FIG. 1 c is an illustration of reinforcing composite rods disposed in the slots of a slotted lamina.
FIG. 1 d is an illustration of reinforcing composite rods disposed in the bores of a bored lamina.
FIG. 2 is an illustration of a reinforced I-beam.
FIG. 3 is an illustration of an I-beam reinforced with purely synthetically reinforced flanges.
FIG. 4 is an illustration of particle board reinforced with strands of synthetic reinforcement.
FIG. 5 is an illustration of a wood particle structure reinforced with sheets of synthetic reinforcement.
FIG. 6 is an illustration of a glum lam reinforced with sheets of synthetic reinforcement in a zig zag pattern.
DETAILED DESCRIPTION OF THE INVENTION
In a preferred embodiment of the present invention, FIG. 1 a shows an elongated glue laminated wood structural member 10 having multiple wood laminae 12 that are bonded together as elongated boards. The wood structural member 10 is shown with its ends supported by a pair of blocks 14 and bearing a point load 16 midway between the blocks 14 . It will be appreciated that the glue laminated wood member 10 could also bear loads distributed in other ways (for example, cantilevered) or be used as a truss, joist, or column. It will also be appreciated that the wood member 10 can be in the form of laminated veneer lumber (LVL).
Under the conditions represented in FIG. 1 a , the lowermost lamina 12 a is subjected to a substantially pure tensile stress and the uppermost lamina 12 d is subjected to a substantially pure compressive stress. To increase the tensile load-bearing capacity of the glue laminated wood member 10 , at least one layer of synthetic tension reinforcement 24 is offset from the transverse center 25 and adhered between lamina proximal to the lowermost lamina 12 a , preferably between the lowermost lamina 12 a and the adjacent lamina 12 b . Alternatively, the synthetic tension reinforcement 24 may be adhered to the outer surface 28 of the lowermost lamina 12 a.
To increase the compressive load-bearing capacity of the glue laminated wood member 10 , at least one layer of synthetic compression reinforcement 30 is distal from the transverse center 25 and adhered between lamina proximal to the uppermost lamina 12 d , preferably between the uppermost lamina 12 d and the adjacent lamina 12 c . Alternatively, the synthetic compression reinforcement 30 may be adhered to the outer surface 34 of the uppermost lamina 12 d.
Synthetic tension reinforcement 24 and synthetic compression reinforcement 30 are generally positioned through the longitudinal center 16 and preferably extend along from about 20% to about 100% of the length of the wood structural member 10 . If the length of the synthetic tension reinforcement 24 is less than the length of the wood structural member, a pair of spacers 35 , preferably wood spacers, are advantageously positioned at opposite ends of synthetic tension reinforcement 24 between laminae 12 a and 12 b to maintain a uniform separation therebetween. Similarly, a pair of spacers 35 are advantageously positioned at opposite ends of synthetic compression reinforcement 30 between laminae 12 c and 12 d to maintain a uniform separation therebetween.
The widths x of the synthetic reinforcements 24 and 30 are preferably matched to the finished width x′ of wood member 10 by methods such as those described in U.S. Pat. No. 5,456,781, column 4, lines 8-35, which teachings are incorporated herein by reference. The thicknesses z of the reinforcements 24 and 30 are application dependent but are preferably in the range of from about 0.01 cm, more preferably from about 0.1 cm, to preferably about 1 cm, more preferably to about 0.5 cm.
FIG. 1 b illustrates a modification of the embodiment illustrated in FIG. 1 a , wherein the multi-lamellar structure 10 is reinforced with a plurality of synthetic reinforcement rods incorporated into two of the lamina of the multi-lamellar structure 10 and along the grain of the structure 10 . Although FIG. 1 b illustrates a composite with two synthetic tension reinforcement rods 24 a , and two synthetic compression reinforcement rods 30 a , it is possible, and may be desirable, to incorporate a multitude of synthetic tension and compression reinforcement rods into the composite. Synthetic reinforcing sheets can be used in place of or in addition to reinforcing rods and the synthetic reinforcement rods ( 24 a , 30 a ) may be mechanically or adhesively bonded or mechanically and adhesively bonded to the lamellae.
The synthetic tension reinforcement rods 24 a are disposed through the longitudinal center 16 of the structure and may, but do not necessarily, extend through the length of the structure 10 . The rods 24 a are distal from either side of the width center 31 and embedded into and bonded to a lamina distal from the transverse center and proximal to the lowermost lamina 12 a , preferably imbedded into and bonded to the lowermost lamina 12 a , which may be slotted or bored to accommodate to the tension reinforcement rods 24 a.
Similarly the two synthetic compression reinforcement rods 30 a are disposed through the longitudinal center 16 of the structure 10 , and may extend through the length of the structure 10 . The rods 30 a are distal from either side of the width center 31 and imbedded into and bonded to a lamina distal from the transverse center 25 and proximal to the uppermost lamina 12 d , preferably imbedded into and bonded to the uppermost lamina 12 d , which may be slotted or bored to accommodate to the compression reinforcement rods 30 a . FIG. 1 c illustrates a portion of an individual slotted lamina 12 a with the rods 24 a disposed in the slots. FIG. 1 d illustrates a portion of an individual bored lamina 12 a with the rods 24 a disposed in the bores.
The reinforced multilamellar structure represented by FIG. 1 b is especially advantageous for applications requiring repairing or reinforcing existing structures such as bridges and utility poles, or upgrading beams in houses, because of the ease of incorporating the rods into these structures. Other structures suitable for reinforcement using this embodiment include home and office furniture such as bookshelves, kitchen cabinet shelves, work surfaces, and desks. To simplify manufacture of structures such as glulam beams, a separate lamstock consisting of only the layer of a glulam containing reinforcement, or a lamstock consisting of a layer of LVL containing reinforcement can be made and supplied separately.
The composite rods can have any desirable cross-sectional shape such as circular, oval, rectangular, and star-shaped, and the rods may be hollow, C-shaped, Z-shaped, and the like. The rods are desirably incorporated through the longitudinal center of the multilamellar structure, and preferably along the entire length of the structure.
Another example of a use for the reinforced wood structures illustrated in FIGS. 1 and 2 is wood ladders containing linear veneer lumber rails that are reinforced with composite rods or sheets.
FIG. 2 represents another embodiment of the reinforced wood structure 10 of the present invention which is generally in the shape of an I-beam. The embodiment depicts a compression reinforcement portion 40 (also known as a compression flange) at the top of the wood structure 10 and a tension reinforcement portion 42 (also know as a tension flange) at the bottom of the wood structure 10 . The compression flange 40 comprises a synthetic compression reinforcement 30 bonded between the uppermost lamina 12 d and the adjacent Laconia 12 c . The tension reinforcement flange 42 comprises the synthetic tension reinforcement 24 bonded between the lowermost lamina 12 a and the adjacent lamina 12 b . A web 44 is centrally disposed between the reinforcement flanges 40 and 42 at their major surfaces 50 and 54 to form the “I” beam shape. The web 44 , which can be any suitable material, but is preferably made of oriented strand board or plywood. The web 44 has substantially the same length as the laminae 12 a , 12 b , 12 c , and 12 d , but is narrower in width. The ratio of the width x of the reinforcement flanges 40 and 42 to the width y of the aligned web 44 is application dependent but generally varies from about 4:1 to about 10:1. It is to be understood that the reinforcement flanges 40 and 42 may contain several wood laminae. In this case, the synthetic reinforcements 24 and 30 can be bonded between any two laminae. Alternatively, the synthetic reinforcements can be bonded to a major surface 50 , 52 , 54 , or 56 of the reinforcement flanges 40 and 42 . In this case, the reinforcement portions may contain a single lamina or multiple laminae.
Reinforcement of wood can also be accomplished by shaping the synthetic reinforcements in the form of flanges to adhere to the web without wood laminae. FIG. 3 illustrates such a reinforcement. In FIG. 3A a synthetic compression reinforcement flange 31 is depicted as adhering to the top 45 and major surfaces 47 and 49 of the aligned web 44 while a synthetic tension reinforcement flange 25 is depicted as adhering to the bottom 51 and the major surfaces 47 and 49 of the web 44 . Alternatively, as illustrated, in FIG. 3B, the tension reinforcement flange 25 can be adhered to the major surfaces 47 and 49 of web 44 without being adhered to the bottom 51 , while the compression reinforcement flange 31 can be adhered to the major surfaces 47 and 49 of the web 44 without being adhered to the top.
Synthetic reinforcement can also be used to improve the physical properties of adherent wood particles such as particle board, oriented strand board, oriented strand lumber, fiberboard, and chipboard. As illustrated in FIG. 4, particle board 60 is reinforced with strands of synthetic reinforcement 62 dispersed in an aligned or random fashion in the particle board 60 . The dimensions of the synthetic reinforcement strands 62 can vary widely, but are typically in the order of 0.01 cm×01 cm×1 cm to about 0.1×0.5×10 cm. Because of the unique properties of the synthetic reinforcement material, discussed herein, this reinforced particle board is recyclable and reusable. Indeed, the reinforced structural lumber illustrated in FIGS. 1-3 can all be recycled to make reinforced particle board 60 . To our knowledge, no other synthetic reinforcement is suitable for this purpose.
FIG. 5 illustrates another embodiment of the present invention. In this embodiment, a reinforced wood particle structure 61 can be made by superposing sheets of synthetic reinforcement 63 onto one major surface of elongated particle board beam 65 and preferably opposing major surfaces of elongated particle board beam 65 . The reinforcing fibers 67 are longitudinally aligned and extend continuously through the length of the reinforced wood particle structure 61 . This reinforced wood particle structure 61 , which is similar in strength and stiffness to LVL or solid lumber, can be manufactured in a single stage because the adhesive used to bind the particles together to make the particle board (typically MDI) can also adhere the composite to the particle board as it is being manufactured. The reinforced wood particle structure 61 can also be in the shape of a panel, or an I-beam, wherein the synthetic reinforcement superposes outer major surfaces of flanges made from particle board.
In another embodiment of the present invention, strands of the synthetic reinforcement material can be incorporated into parallel strand lumber (PSL) in which strands of lumber are aligned along an axis. In this embodiment, the synthetic reinforcement material is aligned along the same axis as the lumber strands and dispersed through the PSL structure.
FIG. 6 illustrates another embodiment of the invention. In this embodiment, sheets of the synthetic reinforcement 40 are incorporated in a zig-zag fashion across the grain of the multilamellar structure 10 . The sheets can be inserted into an appropriately slotted structure.
The preferred synthetic reinforcements and flanges depicted in FIGS. 1-6 are fiber-reinforced thermoplastic composites described by Edwards et al. in U.S. Pat. No. 5,891,560, column 3, lines 8-37 to column 4, lines 1-35, which description is incorporated herein by reference. The preferred fiber-reinforced composite comprises a depolymerizable and repolymerizable thermoplastic polymer resin, and at least 30 percent, more preferably at least 50 percent, and most preferably at least 65 percent by volume of substantially parallel reinforcing fibers that are impregnated by the polymer resin and extend substantially through the length of the resin. The composite is preferably prepared by pultrusion as described by Edwards et al. to form the synthetic reinforcement of the desired length, width, thickness, and shape.
The preferred class of polymers for the fiber-reinforced composite are depolymerizable and repolymerizable polymers (DRTPs) having the following structural units:
where Z is S or O, preferably O, and Z′ is S, O, N-alkyl or NH, preferably O or NH, most preferably O. As used herein, the term depolymerizable and repolymerizable refers to a polymer the undergoes some degree of molecular weight reduction upon application of a sufficient amount of heat, and some degree of molecular weight rebuilding when the polymer is cooled.
The reinforcing fibers are not critical to the practice of the present invention and may include glass, carbon, aramid fibers, ceramic, and various metals. The DRTP is a single- or two-phase polymer that can be prepared by the reaction of: a) a diisocyanate or a diisothiocyanate, preferably a diisocyanate; b) a low molecular weight compound (not more than 300 Daltons) having two active hydrogen groups; and c) optionally a high molecular weight compound (molecular weight in the range of from about 500 to about 8000 Daltons) with two active hydrogen groups. The low molecular weight compound, in combination with the diisocyanate or diisothiocyanate group, contributes to what is known as the “hard segment” content. Similarly, the high molecular weight compound, in combination with the diisocyanate or diisothiocyanate group, contributes to what is known as the “soft segment” content. Either a stoichiometric amount or a stoichiometric excess of the diisocyanate can be reacted with the low molecular weight compound and optionally the high molecular weight compound. Preferred DRTPs are thermoplastic polyurethanes and thermoplastic polyureas, preferably thermoplastic polyurethanes.
As used herein, the term “active hydrogen group” refers to a group that reacts with an isocyanate or isothiocyanate group as shown:
where Z and Z′ are previously defined, and R and R′ are connecting groups, which may be aliphatic, aromatic, or cycloaliphatic, or combinations thereof. Examples of, compounds with two active hydrogen groups include diols, diamine, dithiols, hydroxyamines, thiolamines, or hydroxythiols. Preferred compounds with two active hydrogen groups are diols.
A preferred class of thermoplastic polyurethanes is polyurethane engineering thermoplastic resins, also known as rigid thermoplastic polyurethanes (RTPUs). RTPUs are characterized by having a glass transition temperature (T g ) of not less than 50° C. RTPUs preferably have a hard segment not less than about 75 percent by weight, more preferably not less than 90 percent by weight, to about 100 percent by weight, based on the weight of the RTPU. The disclosure and preparation of polyurethane engineering thermoplastic resins is described, for example, in Goldwasser et al. in U.S. Pat. No. 4,376,834, and Oriani in U.S. Pat. No. 5,627,254, which teachings are incorporated herein by reference. Such resins are commercially available under the trade name ISOPLAST™ engineering thermoplastic polyurethanes (a trademark of The Dow Chemical Company).
Another preferred class of thermoplastic polyurethanes is soft thermoplastic polyurethane resins (STPUs). STPUs are characterized by having a T g of less than 25° C. Preferably, the STPU has a hard segment of not less than 15 and not more than 50 weight percent, and a soft segment of not more than 85, and not less than 50 weight percent, based on the weight of the STPU. STPUs are commercially available under the trade name PELLETHANE™ resins. It is to be understood that blends of STPUs and RTPUs can also be used as a resin for the fiber-reinforced thermoplastic composite.
Processes for the manufacture of glue-laminated structural wood members, LVL, I-joists and PSL are well known in the art. See, for example, U.S. Pat. No. 5,4556,781, column 3, lines 27-49, incorporated herein by reference. The conventional processes can be modified to incorporate synthetic tension reinforcement or synthetic compression reinforcement or both.
One of the advantages of using pultruded fiber-reinforced composites made using thermoplastic polyurethanes is that the formation of diisocyanates in the depolymerization process provides a mechanism for adhesion to wood without surface modification of the wood laminae, without the use of an ancillary adhesive, and without modification of the surface of the fiber-reinforced composite. This natural ability of the composite to adhere to wood is due presumably to the presence of active hydrogens in the wood. Thus, the thermoplastic composite part can be bonded to wood, or affixed between two lamina to provide synthetic tension or compression reinforcement or both by heat bonding the part to the surfaces of the wood laminae. An alternative or additional explanation for the propensity of the thermoplastic matrix to bond to the wood is that under melt producing conditions, the matrix can flow into the cracks and pores of the wood, thereby producing mechanical bonding.
Nevertheless, it may be desirable and preferable in some instances to use an ancillary adhesive such as those generally used in the wood industry, for example, phenol formaldehyde, phenol resorcinol formaldehyde, or MDI, to promote adhesion between the wood laminae and the thermoplastic composite part. Generally, the amount of adhesive required is less than the amount required for typical matrix resins due to the natural tendency of the thermoplastic polyurethane to chemically and/or mechanically bond to wood.
Alternatively, or additionally, it may be desirable to react the compound or compounds having two active hydrogen groups with a stoichiometric excess of the diisocyanate or diisothiocyanate to create an “overindexed” DRTP, which more readily reacts with the active hydrogens in the wood.
The reinforced lumber of the present invention shows surprising advantages in hygrothermal cycling due to perpendicular compliance, and improved toughness for handling in lamination mills due to the unique nature of the resin used to make the fiber-reinforced thermoplastic composite. This composite does not produce undesirable VOCs during manufacture, and it can be prepared at rapid line speeds as compared to the pultruded composites that do not use these unique resins. Furthermore, the depolymerizable/repolymerizable nature of the engineering thermoplastic polyurethane resin provides extremely high modulus composites (greater than 40 GPa) as compared to other fiber-reinforced thermoplastic composites, thus resulting in superior reinforcement of the wood. Moreover, the thermoplastic nature of the composite provides an avenue for the shaping of and hammering nails into the composite, which are not possible using fiber-reinforced thermoset composites due to their brittleness. Finally, the unique nature of this composite provides a means to recycle and reuse the reinforced lumber, which is not possible using conventional fiber-reinforced thermoset or thermoplastic composites.
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The present invention relates to wood that is reinforced with a fiber-reinforced thermoplastic composite that contains a plurality of substantially parallel continuous fibers impregnated with thermoplastic polymer having the following structural units:
where Z is S or O, and Z′ is S, O, N-alkyl or NH The invention is useful in a variety of applications including glue-laminated structures, laminated veneer lumber, reinforced I-beams, parallel strand lumber, reinforced particle board, and ladders. The use of a thermoplastic polyurethane, particularly the high Tg thermoplastic polyurethane as the impregnating resin provides a means of recycling and reusing the reinforced lumber, as well as shaping the composite in ways that would be impossible using conventional fibe-reinforced thermoset composites.
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FIELD OF THE INVENTION
[0001] The field of the invention is irrigation controllers.
BACKGROUND OF THE INVENTION
[0002] Considerable resources have been invested over the years to improve irrigation controllers, especially with respect to increasing sophistication of the watering schedules. Modern controllers, for example, may manipulate half a dozen or more valves, may have multiple on/off periods during the day, may have different watering schedules from day to day during the week.
[0003] One undesirable side effect of the trend towards increasingly sophisticated controllers is that the inputs needed to drive such controllers are also becoming more complex. Typical modem controllers require a user to separately specify start times and durations for irrigation intervals for each zone and possibly for each day of the week. Modem controllers may also take into account inputs from external sensors, such as temperature, wind, precipitation and soil moisture sensors. Still further, systems are also known which receive input from a local or distal signal source, such as a radio transmitter. Exemplary disclosures are U.S. Pat. No. 4,962,522, issued October 1990, and U.S. Pat. No. 5,208,855, issued May 1993, both to Marian, and each of which is incorporated by reference herein in its totality. Such systems offer considerable advantages, including the ability to integrate historical rainfall and other data with current reference evapotranspiration (ETo) rates.
[0004] The large quantity of external data makes irrigation controllers relatively complicated to use and even systems touting automatic adjustment of irrigation flow still require relatively complicated input. Systems discussed in U.S. Pat. No. 5,208,855, for example, merely update an interval used for preset irrigation control timings, rather than determine an entirely new irrigation schedule. Similarly, systems discussed in U.S. Pat. No. 5,444,611 issued to Woytowitz et al. (August, 1995) are said to automatically calculate and execute a new schedule, but the new schedule is still based upon programming of a start time. Systems disclosed in U.S. Pat. No. 4,646,224 issued to Ransburg et al. (February, 1987) automatically determine the number of cycles and length of time of each cycle that water is to be applied, but still requires the operator to provide data concerning desired sprinkling days, soil type, the type of sprinkler for each zone, and so forth.
[0005] The trend towards increasingly sophisticated controllers is accompanied by a trend towards having ever fewer input controls accessible to the user. Decreasing the number of input controls may reduce the cost and size of a controller unit but it also adds to the complexity of using the unit. The whole process of adjusting a modem irrigation controller can be compared to programming a VCR. It may be advantageous to have available a large number of different functions but controlling all of those functions using only half a dozen or so buttons is extremely difficult for many individuals. This problem has been resolved to some extent in VCR controllers by utilizing the TV screen as an interactive display but that approach is not readily adaptable to irrigation controllers, where a relatively small, inexpensive display screen is employed to reduce costs.
[0006] Even if the process of modifying controller parameters were not complex, determining appropriate values for the required input parameters may be exceedingly complex. As an example, modifying a watering duration value to provide more water to a particular irrigation zone might involve all of the following steps: (1) determining the total of all the watering durations currently programmed for the zone over the course of a week; (2) estimating an appropriate change in the amount of water to be applied to the zone; (3) translating that amount into a percentage increase over the presently programmed total; (4) translating such percentages into changes in durations and deciding how such changes in durations should be distributed over the existing schedule; and (5) entering the scheduling changes. Step 4 is particularly difficult for many individuals because there are often no established guidelines for deciding among various options. Thus, a user may have insufficient knowledge to decide between reducing the watering for each day by 10 minutes, or eliminating watering entirely two days per week.
[0007] In short, the steadily increasing sophistication of irrigation controller outputs, coupled with the steadily increasing difficulty of operating such controllers, is a significant problem for users. Thus, there is a continuing need to provide sophisticated irrigation control, while providing simple operator input.
SUMMARY OF THE INVENTION
[0008] Methods and apparatus are provided herein for controlling irrigation to irrigated zones, comprising: providing water to be applied to more than one irrigated zone at an irrigated site; providing an irrigation controller that controls the application of the water to the irrigated zones; and operating a more/less adjustment mechanism, on the irrigation controller, that modifies the amount of water applied to at least one irrigated zone in an inverse relationship to the amount of water applied to the remaining irrigated zones at the irrigated site.
[0009] In a preferred embodiment of the present invention, the irrigation controller will execute an irrigation schedule to the irrigated site and then the irrigated site will be examined to determine the effect of irrigating according to the irrigation schedule.
[0010] It is contemplated that if a change is required to the amount of water that is applied to one or more irrigated zones that the user can operate a more/less adjustment mechanism to modify the irrigation schedule to arrive at a new irrigation schedule. The new irrigation schedule is then executed to the irrigated site by the irrigation controller. Preferably, the operating of the more/less adjustment mechanism comprises operating a first button corresponding to increasing the amount of water provided to at least one irrigated zone and a second button corresponding to decreasing the amount of water provided to at least one irrigated zone. Alternatively, the operating of the more/less adjustment mechanism may comprise operating a slide control, a rotating control knob or any other device that will provide for the increasing or decreasing of the water applied to at least one irrigated zone.
[0011] In a preferred embodiment of the present invention the irrigation controller derives irrigation schedules, which may be at least partly, from reference evapotranspiration (ETo) data.
[0012] Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic of an irrigation controller according to the present invention.
[0014] FIG. 2 is a schematic of a method embodying an irrigation controller, according to the present invention.
DETAILED DESCRIPTION
[0015] Referring to FIG. 1 , an irrigation controller 200 according to the present invention generally includes a microprocessor 220 , an on-board memory 210 , some manual input devices 230 through 232 (buttons and/or knobs), an input/output (I/O) circuitry 221 connected in a conventional manner, a display screen 250 , a communications port 240 , a serial, parallel or other communications connection 241 coupling the irrigation controller to one or more communication sources, electrical connectors 260 which are connected to a plurality of irrigation stations 270 and a power supply 280 . Additionally, the irrigation controller may be connected to a rain detection device 291 , a flow sensor 292 , a pressure sensor 293 and/or a temperature sensor 294 . Each of these components by itself is well known in the electronic industry, with the exception of the programming of the microprocessor in accordance with the functionality set forth herein. There are hundreds of suitable chips that can be used for this purpose. At present, experimental versions have been made using a generic Intel 80C54 chip, and it is contemplated that such a chip would be satisfactory for production models.
[0016] In a preferred embodiment, the controller has one or more common communication internal bus(es). The bus can use a common or custom protocol to communicate between devices. There are several suitable communication protocols, which can be used for this purpose. At present, experimental versions have been made using an I 2 C serial data communication, and it is contemplated that this communication method would be satisfactory for production models. This bus is used for internal data transfer to and from the EEPROM memory, and is used for communication with personal computers, peripheral devices, and measurement equipment including but not limited to a rain detection device, a flow sensor, a water pressure sensor and a temperature sensor.
[0017] It is contemplated that the microprocessor will be disposed in an irrigation controller. Alternatively, the microprocessor may be disposed in a personal computer or other device that provides control of an irrigation system.
[0018] FIG. 2 is a method embodying an irrigation controller according to the present invention. An irrigation controller is provided (step 100 ) in which a user initially sets run-time durations for each irrigated zone to arrive at a first irrigation schedule (step 110 ). In step 120 the irrigation controller executes the first irrigation schedule to an irrigated site, during which time the flow rate of each station or irrigated zone is measured and the total amount of water, applied to the irrigated site, is calculated. Preferably, the measurement of the water flow to the irrigated site is accomplished with a single flow meter located at the irrigated site that is used for measuring the total water used at the residential, commercial, etc. site (See pending U.S. patent application Ser. No. 10/297,146). Alternatively, the measurement of the water flow to the irrigated site is accomplished with a separate, dedicated flow meter.
[0019] In a preferred embodiment of the present invention, a water district, government agency or other entity may provide the user with an allotment of water. Alternatively, it can be appreciated that the user may choose to reduce the water applied to his/her landscape because of conservation pricing and the savings they could obtain by applying an amount of water that allows them to be in the lower tier of a conservation pricing scheme. Preferably, the allotment, provided the user, will be based on a percent of ETo (step 130 ). However, it can be appreciated that the allotment could be a volume of water, set number of minutes of watering or any other appropriate measurement that could indicate a volume of water that could be applied, during a specific time period, to a specific irrigated site.
[0020] The total amount of water to be applied to the irrigated site is determined in step 140 . If the allotment of water is based on a percent of ETo then the allotment, in gallons of water, is determined by the following formula: percent ETo times ETo times the total irrigated site area, measured in square feet, times 7.5 gallons per cubic foot, which is then divided by 12 inches per foot. Assume that the percent ETo is set at 90%, the ETo value for a given day is 0.25 inches and the total square feet of the irrigated area is 5000 square feet. Then, using the formula above, we arrive at an allotment of approximately 700 gallons of water that can be applied the following day to the irrigated site (Generally, a specific days irrigation application will be based on the previous days ETo value). It should be appreciated that the allotment of water can be determined on a basis other than daily, such as weekly, monthly, and so forth.
[0021] In a preferred embodiment of the present invention, the irrigation controller will automatically derive a second irrigation schedule by proportionately increasing or decreasing the amount of water applied to each irrigated zone at the irrigated site, based on the allotment of water for the irrigated site and the actual amount of water applied, with the first irrigation to the irrigated site (step 150 ). Assume that 777 gallons was the actual amount of water that was applied with the first irrigation schedule to the irrigated site. To apply the allocated amount of water or 700 gallons of water to the irrigated site, the actual amount of water, applied to the irrigated site, will have to be reduced by 77 gallons or approximately by 10%. As mentioned earlier, preferably this will be accomplished by proportionately reducing the run-time durations for each of the irrigated zones by 10%. However, it can be appreciated that the run-time durations may be reduced for some irrigated zones differently than for other irrigated zones, as long as the total reduction in water, actually applied to the irrigated site, is reduced by 77 gallons so that the 700 gallon allocation amount is not exceeded.
[0022] In step 160 , the irrigation controller will execute the second irrigation schedule to the irrigated site. In step 170 the irrigated site is examined to determine the effect of irrigating according to the executed irrigation schedule. The examination is preferably visual, but may be accomplished by any suitable means, such as using a soil moisture sensor, which may be inserted into one or more sites in the soil of an irrigated zone. The examination is preferably carried out after step 160 has been ongoing for a substantial period of time, such as several days of watering using the second irrigation schedule. This provides a good baseline from which reasonable decisions regarding changes in the irrigation schedule can be made. Alternatively, however, inspection can take place after or even during a single watering.
[0023] After one or more inspections (step 170 ), it is contemplated that the user may desire to modify the water applied to one or more irrigated zones. Preferably the user will operate the more/less adjustment mechanism to modify the second irrigation schedule to arrive at a third irrigation schedule that is at least partly based on the examination of the irrigated site and wherein the amount of water applied, to at least one irrigated zone, is modified in an inverse relationship to the amount of water applied to the remaining irrigated zones at the irrigated site (step 180 ). For example, it may be desirable to increase the watering of irrigated zones 2 and 4 relative to the then-existing irrigation schedule. To accomplish this the user might press a button to access irrigated zone 2 and then press a “more” button to increase the water applied to irrigated zone 2 and follow the same procedure for irrigated zone 4 . In a preferred embodiment of the present invention, the increase in the amount of water applied to irrigated zones 2 and 4 will result in a like decrease in the water applied to at least one other irrigated zone at the irrigated site.
[0024] The actual strategy by which an irrigation controller modifies the watering schedule for one or more irrigated zones, as disclosed herein, may vary among different embodiments of the controllers. It may be, for example, that each pressing of the “more” button increases the watering of that zone by 5% and that each pressing of the “less” button decreases the watering of that zone by 5%. That change may be reflected in an across the board change in all watering durations, and/or perhaps in the addition or subtraction of an entire watering day.
[0025] In the following example, the same assumption is made, as in the above example, where the allotment of water was 700 gallons per day to be applied to the irrigated site. Further assume that on a specific day 180, 150, 210 and 160 gallons of water are applied to zones 1 , 2 , 3 and 4 , respectively, which is equal to the 700 gallon water allotment for that day. Further, assume that the more adjustment modification to irrigated zones 2 and 4 , mentioned above, would result in an increase in the gallons applied to irrigated zones 2 and 4 of 40 and 37 gallons, respectively. The total gallons that would be applied to irrigated zones 1 , 2 , 3 and 4 would now be 180, 190, 210 and 197 gallons, respectively. This would result in a total gallons of 777 gallons being applied to the irrigated site, which would be 77 gallons over the 700 gallon allotment for the site. As mentioned earlier, preferably the irrigation controller will automatically maintain the allotment of water by proportionately decreasing the amount of water applied to each irrigated zone at the irrigated site. Therefore, there would be an approximate 10% decrease in the water applied to each irrigated zone. A 10% decrease in the water applied to each irrigated zone will result in approximately 162, 171, 189 and 178 gallons of water being applied to irrigated zones 1 , 2 , 3 and 4 , respectively. This would result in 700 gallons being applied to the irrigated site, which is equal to the allotment of water for the irrigated site.
[0026] As mentioned earlier, it is contemplated that to achieve actual water applications that do not exceed the allotment, the run-time durations may not always be reduced proportionately for all the irrigated zones at an irrigated site. In some situations, to achieve actual water applications that do not exceed the allotment, it may be advantageous for run-time durations for some irrigated zones to be reduced differently than for other irrigated zones at the irrigated site. For example, if irrigated zones 2 and 4 involve turf areas and irrigated zones 1 and 3 involve ornamental plantings, then it might be advantageous to have the decrease in water occur entirely in irrigated zones 1 and 3 with no change in the watering of the turf areas or in irrigated zones 2 and 4 . It can be appreciated, that when the operation of the more/less adjustment mechanism results in an increase in the water applied to one or more irrigated zones that the inverse relationship or decrease in the water applied to the remaining irrigated zones can be accomplished by various means. The opposite would occur, when a more/less adjustment would provide a decrease in the water applied to one or more irrigated zones and with an inverse relationship there would be an increase in the water applied to the remaining zones.
[0027] In step 190 , the irrigation controller will execute the third irrigation schedule to an irrigated site. Then the irrigated site will be examined to determine the effect of irrigating according to the execution of the irrigation schedule (step 170 ) and if need be, additional adjustments, with the more/less adjustment mechanism, will be made to the irrigation schedule (step 180 ).
[0028] FIG. 2 discloses that the first irrigation schedule was derived from the user setting run-time durations. Furthermore, the second and third irrigation schedules resulted from the irrigation controller automatically modifying irrigation schedules to prevent the amount of water, applied to the irrigated site, from exceeding the allotment after initially setting the run-time durations and after the operation of the more/less adjustment mechanism, respectively. However, it can be appreciated that the more/less adjustments, contemplated herein, may only indirectly control the amount of water provided to an irrigation zone. This is because the contemplated irrigation controller may advantageously determine irrigation schedules based upon one or more algorithms involving many parameters. For example, in addition to the irrigation schedule change that will have occurred from the operation of the more/less adjustment mechanism in step 180 , the irrigation controller may use ETo data, crop coefficient values, irrigation efficiency values, rainfall data, soil characteristics, topography and other data in the derivation of irrigation schedules executed by the irrigation controller. In a preferred embodiment of the present invention the irrigation controller derives irrigation schedules at least partly from ETo data. The ETo data used may advantageously comprise current ETo data (i.e., ETo data within the last week, three days, or most preferably within the last 24 hours). Preferably the ETo value is derived from a calculation involving the following four weather factors; solar radiation, temperature, wind and relative humidity. Alternatively, the ETo data may be based on a regression model using one or more of the factors used in calculating the above ETo value (as for example that described in U.S. patent application Ser. No. 10/009,867) or the ETo data may be based on historical ETo data.
[0029] Thus, specific embodiments and applications of methods of controlling irrigation have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. For example, the more/less adjustment might affect all controlled valves at once, or might be limited to a subset of the controlled valves with additional more/less adjustments being provided for each subset. Similarly, it is possible to utilize various types of more/less controls such as buttons, sliders, rotating knobs, touch screens, and similar devices, which affects more or less water, and/or some other watering parameter such as frequency or duration. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.
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An irrigation controller modifies sophisticated irrigation protocols using an extremely simple user control. In one aspect of a particularly preferred class of embodiments, the user control includes a simple “more/less” (increase/decrease) adjustment. In another aspect of preferred embodiments, the controller automatically determines appropriate irrigation amounts, start times, durations, and frequencies. Such automatic determination may advantageously be based in part on the more/less adjustment.
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus and method for positioning and joining fabric sections. More particularly, this invention relates to an apparatus and method for positioning and joining hook and eye tabs to the back strap portions of a brassiere.
Manual methods and apparatuses for the fabrication of brassiere type garments are well known in the art. Additionally, automatic devices for performing the positioning and joining of the hook and eye tape to the back strap portion are known. For example, in one particular method hook tape and eye tape sections are employed which each have a pair of separated end flaps. The desired tape section is secured in a clamp or held by hand and the back strap portion is inserted between the two flaps. The assemblage is then sewn securely together. For the most part, the hook tape, eye tape and back strap portion are of the same width which facilitates the alignment. However, the respective lengths of the hook tape and eye tape vary as does the stitch pattern which is employed therewith in the securement to the back strap portion. Thus, with a prior art automated apparatus for performing the operations hereunder consideration, it may be possible to secure both the hook tape and eye tape portions with the same clamping system, however, difficulty would be experienced in the performance of the sewing operation. That is, the sewing operation in prior art devices has been controlled through the use of a cam assembly. As is apparent, problems are created thereby if the stitch pattern for joining the hook tape is different from that employed in joining the eye portion. For the most part, the prior art combinations even with respect to automated mechanisms suffer from this lack of versatility in that cams must be changed in order to change stitch patterns.
SUMMARY OF THE INVENTION
According to the present invention, a system is provided in combination with a programmed sewing machine which can employ any of a number of programmed devices, for example: core memory, semiconductor or solid state, to name a few. The memory or programmed device contains at least two stitching patterns, the information from which is employed to drive a fabric positioning holder through a predetermined path with respect to the needle of the sewing machine. The location of the hook tape or eye tape member is achieved by the cooperation of horizontally movable positioning levers and a front stop plate, located respectively on either side of an in front of jaw means that are carried by the fabric positioning holder means. At the inception of the cycle, a preliminary clamp is employed to secure the tape and related elements between the horizontally movable positioning levers and the front stop plate. Thereafter, engagement by the jaw means occurs. Upon engagement of the jaw means, the horizontally movable lever means is moved into a non-engaging position and the jaw means are driven through a predetermined work cycle with respect to the needle, to effect the desired stitch pattern.
It is, therefore, an object of this invention to provide an apparatus for positioning and joining the hook and eye tape portions to a brassiere body in combination with, a semiconductor controlled sewing system which is capable of storing a substantial number of different stitch patterns. Yet another object of this invention is to provide a positioning and joining system which is capable of dealing with a hook tape portion in combination with a back strap portion of a brassiere and then the eye tape portion in combination with a back strap portion of a brassiere without the changing of mechanical elements. Yet another object of this invention is to provide a system for the construction of brassieres which is self-compensating to facilitate the width of either a hook tape or an eye tape in combination with a semiconductor control sewing system which has at least two different sewing patterns stored within its memory means. Yet another object of this invention is to provide a method for the joining of hook tape and eye tape portions to the back strap portion of a brassiere.
BRIEF DESCRIPTION OF THE DRAWINGS
The above description, as well as further objects, features and advantages of the present invention, will be more fully appreciated by reference to the following detailed description of a presently preferred, but nevertheless, illustrative embodiment in accordance with the accompanying drawings wherein:
FIG. 1 is a partial side view of the semiconductor controlled positioning and joining system;
FIG. 2 is a front elevational view of the sewing machine incorporating the present invention;
FIG. 3 is a top view of FIG. 1 taken generally along the line 3--3;
FIG. 4 is a partial broken away view showing the various elements involved in the positioning and joining system; and
FIGS. 5-7 are views showing the various steps involved in the location of the various mechanical elements as the positioning and joining system moves through a partial work cycle; and
FIGS. 8-11 show various views of the hook and eye tape portions and the back strap portion.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings and, more particularly, to FIG. 1, there is shown in combination with a programmed sewing machine system 10 the positioning and joining means 12. The programmed sewing system 10 includes a sewing machine 14 having an overhanging arm portion 16 which carries a vertically reciprocating needle means 18. The lower arm portion 20 supports the fabric positioning holder means 22 which, as previously stated, is driven through a predetermined cycle determined by the information stored in the memory of the programmed sewing system. For a complete discussion of the fabric positioning holder means hereunder consideration, reference should be made to U.S. Pat. No. 3,974,787, issued Aug. 17, 1976 to Kraatz et al and U.S. Pat. No. 3,970,016, issued July 20, 1976 to Yanikoski. For a complete discussion of one embodiment of a programmed sewing machine system, reference should be made to U.S. Pat. No. 3,982,491, issued Sept. 28, 1976 to Herzer et al.
Included within fabric positioning holder means 22 is a generally U-shaped elongated lever or channel means 24 that is pivotally carried on the sliding plate means 26 at a first end 28. A support member 30 that is secured to the plate means 26 provides support for cylinder means 32 such that by the reciprocation of the piston thereof force can be exerted on or removed from the U-shaped lever means 24, the U-shaped channel means 24 then pivoting around the end means 28. Carried adjacent a second end means 34 of the elongated lever means 24 is jaw means 36. The jaw means 36 include an upper jaw means 38 and a lower jaw means 40. As is appreciated, the upper jaw 38 is connected to the U-shaped elongated bar means 24 and the lower jaw means 40 is connected to the sliding feed plate means 26. The two jaw means 38 and 40 are additionally pivotally mounted with respect to each other. These jaw means work in combination to securing the work pieces during the work cycle.
Secured to the front section 15 of the upper arm means 16 by a suitable means such as bracket means 42 is a pneumatic cylinder means 44. Attached to the rod portion 46 of the pneumatic cylinder means 44 is a high friction fabric engaging means 48. These elements in combination make up a preliminary clamp means 50 employed to engage the fabric in the initial stages of the work cycle as will hereafter be more fully explained.
Referring now to FIGS. 2 and 3, the joining and securing apparatus for the hook and eye tape sections will be further discussed. Included within the positioning and joining apparatus 12 as previously discussed is the preliminary clamp means 50 and the jaw assembly means 36. These means work in combination with horizontally movable positioning lever means 52, a front stop means or stationary fabric aligning means 54, and first and second microswitch means 56 and 58. The horizontally movable lever means 52 includes a first lever 60 and a second lever 62 each of which has first front ends 64 and 66 and second rear ends 68 and 70. Secured to the rear end 68 and 70 is an actuating device 72 which in the preferred embodiment is a rack and pinion assembly. Upon the actuation thereof the arms can be driven between the positions as shown in FIGS. 3 and 4. Secured to the leading extremities of first front ends 64 and 66 are fabric centering means 74 and 76 (See FIG. 2) which in a preferred embodiment have abutting portions 67 and 69 and fabric contacting means 71 and 73 (See FIG. 3). The rack and pinion means 72 drives the abutting portions into the outer edges 78 and 80 of the lower jaw means 40 as is shown in FIG. 4. In practice, the rack and pinion assembly means 72 is driven by a pneumatic cylinder means for example 82 until this abutting relationship is achieved. Thus, it is apparent that by changing the width of the lower jaw support means different width tapes can be accomodated thereabove. Wings or stabilizing means 84 and 86 are provided in the area of abuttment to further stabilize the engagement.
The point of abutment of the outer edges 78 and 80 and abutting portion 67 and 69 is such that a gap is created between the fabric contacting the fabric engaging means 71 and 73 and the upper jaw means 38. Thus, from a consideration of FIGS. 3 and 4, it is apparent that a given amount of fabric will be exposed around the three sides of the jaw means. In practice, the jaw means 38 and 40 are selected such that they will allow this predetermined amount of fabric to extend out therefrom. The outer edges 78 and 80 are adjustable in a predetermined manner with respect thereto such that the abutting portions 67 and 69 achieve an abutting relationship while at the same time fabric contacting means 71 and 73 just contact the outer edges 90 and 92 of the fabric 131. The result being that the fabric, which comprises the hook tape and related bra portion or eye tape and related bra portion, is centered in a predetermined manner with respect to the upper and lower jaws 38 and 40. In effect, the fabric centering means 74 and 76 function as guide means for centering the fabric means therein with the necessary predetermined amount of fabric extending out therefrom along the three sides of the jaw means. The necessity of having the fabric exnteing out an exact predetermined amount becomes apparent where it is appreciated that it is in these regions that the particular sewing pattern is effected. It must also be appreciated that if for some reason the fabric is not properly aligned a substandard stitch pattern will result and may cause the resultant brassiere to be classified as a second.
Referring now to FIGS. 8-11, wherein are shown representative samples of a hook tape 96, an eye tape 98, each of which has been joined to the back strap portion of a brassiere 100 and 100a.
An unsecured eye tape 98a and unsecured brassiere portion 100b are shown in FIGS. 10 and 11. The unsecured eye tape 98a shows the wing or flap portion means 102 which are folded around the leading edge 104 of the brassiere.
The samples shown in FIGS. 8 and 9 are secured with stitch runs 106a and b and 108a-d. It should be appreciated that the sections 110 and 112, for example, of stitch run 108a and b are sewn to close the outside open edge of the eye tape 98. Only the upper section 114 actually secures the two fabric portions. As is apparent, the area wherein the stitches are sewn is that which extends out along the three sides of the fabric engaging jaw means 38 and 40. The sections 110 and 112 being most critical in this regard since displacement of the thread into or out of the body of the fabric will result in improper stitch formation. For example, if the fabric is not engaged or just barely engaged, the stitch may not be formed at all.
In operation, the operator manually positions the end 104 of the bra section between the two flap means 102 of the eye portion 98a. The same assembly would be repeated of course for the sewing of the hook portion and the same clamp and procedural steps being employed as well. Returning now to the attachment of the eye portion 98a to the bra section 104, the operator, once having positioned them correctly with respect to each other, inserts the leading edge 118 between the jaw means 38 and 40. During this point in the cycle, the arm means 60 and 62 have assumed the position shown in FIGS. 4 and 5. Thus, the fabric engaging portion 71 and 73 serve to align the fabric combination such that seams 110 and 112 as shown in FIG. 9 can be placed in the proper location. Once the garment is properly positioned with respect to the fabric contacting means 71 and 73, the operator slides the assemblage in a direction out of the jaws until the leading edge 121 of one of the wings 102 just contacts the leading edge 115 of the front stop plate means 54. When all of these parameters have been achieved it can be said that the garment is properly positioned to begin the sewing cycle. An alternate procedure would be to first locate the eye tape 98a properly within the clamp jaws 38 and 40 and front stop 54 and then insert the leading edge 104 of the bra section between the flaps 102. In either procedure, the same result will be achieved.
The relationship of the various elements is now substantially that shown in FIG. 5. In order to initiate the automatic cycle, the operator need only actuate a multiposition switch, for example a treadle switch 120, as is well known in the art. Upon the actuation of the treadle switch to a first position, the preliminary clamp 50 moves into the position represented in FIG. 6. That is, the preliminary clamp means 50 is actuated such that the high friction fabric engaging means 48 passes through the aperture 122 in the top jaw 38 to preliminarily secure the fabric elements. The operator then checks all of the fabric elements for proper alignment. If any of the elements are misaligned, the operator returns the foot switch to a neutral position causing the friction fabric engaging portion 48 to return to its original non-fabric engaging position. An operator can then properly realign the fabric elements and again actuate the treadle to the first position as previously described. In the event that all elements are properly aligned, the operator pushes the foot pedal to a second position which triggers or actuates the pneumatic cylinder 32 to clamp the top jaw 38 against the bottom jaw 40. As the elongated U-shaped member 24 moves down into a clamping position a micro-switch 56 (FIG. 1) is actuated. The actuation thereof in turn causes the arm means 60 and 62 to move into the position as shown in FIG. 3 and the preliminary clamp 50 to return to its neutral position as shown for example in FIG. 1. The action of the arm means 60 and 62 is employed to trigger a second micro-switch means 58 at a point just prior to their maximum spread distance. This point coming after the preliminary clamp and, more specifically, the high friction fabric engaging portion 48 has cleared the aperture 122. The actuation of the micro-switch means 58 in turn triggers or initiates the beginning of the predetermined sewing cycle whereby a sewing pattern such as that shown in FIG. 9 is achieved. During the time that this sewing cycle is taking place, the operator can be manually arranging the strap portion of the other end of the same brassiere portion for the attachment thereto of a hook portion such as that shown in FIG. 8.
Upon completion of the sewing cycle, the logic system of the programmable sewing machine actuates the pneumatic cylinder 32 such that the jaws are opened. As is apparent, upon opening of the jaw means 40 and 38, the first micro-switch 56 will be actuated. This actuation in turn causes the arm means 60 and 62 to return to the position shown in FIG. 4 such that the next sewing cycle can be undertaken.
An additional feature of the apparatus and method as has been described relates to the simplicity with which the apparatus can be converted to handle garment elements of different widths. That is, the width as represented by the stitch line 114 in FIG. 9. Depending upon this width, it becomes only necessary to change the upper and lower jaws 38 and 40. Built into each set of jaws is the relationship to determine the amount of material or fabric which will protrude out from around the edges of the jaws. In the example, as has been described, this relationship is determined by the point at which edges 78 and 80 abutt portions 67 and 69. That is, because the arm means 60 and 62 will be driven inwardly until the portions 67 and 69 abut the edges 78 and 80, the pneumatic cylinder 82 is simply being driven through a shorter or a longer stroke. Thus, the overall apparatus can be very easily and simply converted to accomodate the sewing of different width fabric elements.
In summation, an apparatus which is employed in the joining of hook and eye tape to a brassiere. Included in the apparatus are first and second fabric aligning means. In the embodiment described, these are the horizontally movable positioning lower means and the front stop means secured to the throat plate of the sewing machine. The jaws of the fabric positioning holder are in the raised position and the first and second fabric aligning means generally positioned therearound. The first fabric aligning means having moved in to the position in response to a switching signal.
The fabric is inserted between the jaw means and the treadle moved to a predetermined position whereby the preliminary clamp secures the fabric. Actuation of the switch to the next position causes the jaws to shut which in turn trigger a switch that retracks the preliminary clamp and moves the fabric contacting end means of the first aligning means from engagement with the fabric. As the rack and pinion driving assembly moves arms of the first alignments, yet another switch is activated which begins the actual sewing cycle. The jaws being opened at the completion thereof, which causes the first aligning means to be returned to its initial position.
Thus, it is apparent that there has been provided, in accordance with the present invention, an apparatus for use in combination with an automatic sewing machine for attaching hook and eye tape portions to a brassiere that fully satisfies 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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An apparatus which aligns, preliminarily clamps, clamps and then sews hook or eye tape portions to a brassiere, in combination with a computer controlled sewing machine.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from German Application No. 102 40 508.5-45, filed Sep. 3, 2002, which is incorporated herein by reference as if fully set forth.
BACKGROUND
The invention relates to a process for producing leached fiber bundles (LFBs), and to an improved LFB.
LFBs are used in particular as image light guides for the transmission of optical information, for example in endoscopes. LFBs generally include a multiplicity of optical fibers which are arranged in defined fashion. The diameter of the optical fibers is typically 8 to 120 μm. The optical fibers themselves often comprise a light-conducting core and a sheath, for example a glass or plastic, with a lower refractive index.
Processes for producing LFBs are known, for example from WO 02/40416 A1 and U.S. Pat. No. 4,389,089. To obtain an ordered fiber arrangement, LFBs are produced by drawing out correspondingly arranged fiber bundle preforms, for example glass rods or tubes, which additionally include at least a few spacers made from etching glass, i.e. a glass which can be partially dissolved by treatment with acids, bases or deionized water. The spacer preforms are generally in the form of tubes or rods. The distance between and arrangement of the optical fibers with respect to one another can be defined by a suitable arrangement of the etchable spacers.
The fiber bundle preforms obtained in this way are then drawn out under the action of heat using known processes until the desired fiber or fiber bundle cross section is reached. In the process, the spacers are fused to the optical fibers and fill the space between the individual optical fibers.
To produce an image light guide, the ends of the fused fiber bundles are provided with a protective layer which is resistant to acids and/or lyes, and the spacers located in the unprotected regions are removed in hot acid or lye baths or baths in deionized water. In this way, the optical fibers are uncovered or separated from the spacers again and the fiber bundle becomes flexible at these locations. The ends remain connected to one another and therefore rigid and fixed. The end faces are also usually polished in order to increase the optical quality.
In many applications, for the optical quality it is also important for the light outlet points, i.e. the end faces of the optical waveguides to adopt an accurately defined position in the matrix of the end faces of optical fibers and spacers.
The production process described has the drawback that, on account of the optical fibers and the etching glass fusing together in the end region of the fiber bundle, the fibers are shifted out of their original geometric position, and consequently an accurate position of the light outlet points at the end of the optical fiber bundle is lost. For applications which require a high image or light transmission quality, for example connecting units for optical data transmission (optical interconnects), therefore, it is not possible to use this process for producing optical fiber bundles.
A general problem with optical fiber bundles is the fact that their ability to withstand mechanical loads is often low. If fiber bundles are bent, the individual fibers rub against one another, which leads to an increased mechanical stress which can ultimately cause fibers to break. If dirt particles are present between the individual fibers, the stresses are increased further. Each broken optical fiber leads to the associated light point failing, so that if a corresponding number of fibers have broken, the entire fiber bundle has to be exchanged. To extend the service life of the optical fiber bundle, WO 02/40416 A1 proposes introducing a special powder between the individual fibers of the bundle and placing a protective mesh around the flexible region of the optical fiber bundle. However, even these measures are for certain applications not sufficient to effect sufficient durability of the fiber bundles.
SUMMARY
The invention is based on the object of providing a process for producing a leached fiber bundle with the position of the light outlet points defined as accurately as possible, and a leached fiber bundle which has the light outlet points in a position which is as accurately defined as possible.
The object is achieved by the process according to the invention for producing leached fiber bundles and by the leached fiber bundle in accordance with the independent claims. Preferred embodiments will emerge from the subclaims.
The desired position of the optical fibers results, as described in the introduction, from the arrangement of the fiber preforms and the spacer preforms before they are drawn out to form fibers. The drawing process merely influences the absolute size of the fiber diameters and therefore the absolute spatial position of the light outlet points, but does not influence the relative position of these points with respect to one another. To ensure that this relative position is not shifted by the conventional fusing of the end region or regions, according to the process according to the invention the arranged fiber preforms together with the spacer preforms made from etching glass are drawn out in such a way that the individual fibers and spacers, at least at one end, are not completely fused together, but rather are fused together only at their contact surfaces. In this way, spaces are formed between the individual fibers and the spacers, referred to below as “interstices”.
The distance between the light outlet points, referred to below as the “pitch” is determined by the diameter of the spacers. The size of the interstices is in turn dependent on the ratio of the optical fiber diameter to the spacer diameter. In general, the diameters of the optical fibers and of the spacers are matched to one another in such a way that the interstices have the minimum possible size.
Before the next process steps, namely the polishing of the end face and removal of the drawn-out spacers in the region of the fiber bundle which is to be flexibilized, the interstices have to be filled. Without the interstices being filled, it would be impossible to obtain an end region of high optical quality, since during removal of the spacers the baths used (e.g. acid or lye baths or baths in deionized water) would penetrate into the interstices and would also dissolve or at least attack the spacers in the end region, so that it would once again be impossible to obtain an accurate position of the light outlet points. Furthermore, during the polishing of the end faces, abraded material would pass through the interstices into the region of the fiber bundle which is subsequently to become flexible or has already been flexibilized, where this material, on account of friction, would lead to an increased mechanical load on the optical fibers and therefore to a reduced service life on the part of the fiber bundle.
Surprisingly, it has been found that the required filling of the interstices can be effected in a simple way using adhesives. Certain demands, which will be explained below, are to be placed on the adhesives. Examples of adhesives which are to be used are cited in the exemplary embodiments. If the adhesives do not cure of their own accord in the interstices, it is possible to take suitable curing measures after the adhesives have been introduced into the interstices. Depending on the particular adhesive, these measures may, for example, comprise thermal curing, curing with the aid of gaseous catalysts or irradiation with UV or visible light. Combinations of curing methods are also possible.
After the interstices have been filled and the adhesives have been at least partially cured, the at least one unfused end of the fiber bundle is provided with a protective layer, for example an acid-resistant or lye-resistant wax, and the spacers are removed in an etching bath or by means of other suitable measures. The protective layer at the end region(s) prevents the means used to remove the spacers from advancing into the end regions and then attacking the spacers.
The region of the fiber bundle in which the spacers have been removed, generally the central region, is flexible, while the end region or regions remain rigid. The adhesives can be introduced into the interstices in various ways. One possible option in this respect is, for example, the adhesives being introduced with the aid of capillary forces in the interstices. For this purpose, the end region of the fiber bundle is generally immersed in the adhesive, whereupon the adhesive is sucked into the interstices up to a certain height as a result of the capillary forces. However, a problem in this respect is that relatively great filling heights are difficult to achieve and that the capillary forces can only be exploited when filling a single end of the fiber bundle, since the counterpressure of the gas volumes located in the interstices makes it more difficult to fill the second end of the fiber bundle.
The invention is based on the idea that the introduction of the adhesives into the interstices can be effected with the aid of a pressure difference between the atmosphere outside the fiber bundle and the gas volumes located in the interstices; a pressure reduction should be present in the interstices. The pressure reduction can be generated by a vacuum pump. This method is extremely simple to employ if it is only intended to fill the interstices at one end of the fiber bundle. Then, the end which is to be filled can be immersed in the adhesives, while a pressure reduction can be applied to the other end. In this way, adhesive is sucked into the interstices from the immersed end. If the other end of the fiber bundle is also to be filled with adhesive, it is necessary to take measures to allow the pressure reduction also to be applied in the region which is subsequently to be flexibilized, generally the central region, of the fiber bundle.
Another possible way of generating the pressure reduction and of introducing the adhesives is heating and then cooling the gas volumes in the interstices. If the gas volumes located in the intersticies are first all heated, for example by heating the fiber bundle or regions thereof, the heated gas volumes expand. If the end or ends of the fiber bundle are immersed in the adhesives in good time, the gas volumes suck the adhesives into the interstices as they contract through cooling. In this way, it is also possible for both ends of the fiber bundle to be filled in an extremely simple way.
The use of a pressure reduction generally has the advantage that in this way it is possible to accurately set the filling height of adhesives in the interstices. Furthermore, it is possible to achieve higher filling heights than with the methods based on capillary forces. Furthermore, it is possible to use adhesives from a higher viscosity range. Of course, it is in general terms possible to use combinations of a plurality of adhesives instead of a single adhesive.
It is preferable for the interstices in two rigid end regions of an LFB to be filled with at least one adhesive to a filling height of at least 0.5 cm with the aid of a pressure reduction. In a further preferred embodiment, the interstices are filled with at least one adhesive to a filling height of 0.5 cm to 5 cm, particularly preferably of 1.5 cm to 2.5 cm. The filling height is in each case measured from the end face of the end region towards the flexible region. In a most preferred embodiment the interstices in two rigid end regions are completely filled with at least one adhesive. This comprises the filling height of the adhesives amounting to the same height as the height of the rigid end regions or the filling height even exceeding the height of the rigid end regions.
After the interstices have been filled, it may be necessary to cure the adhesives, if this does not occur automatically. For this purpose, it is preferable to use thermal methods or methods which are based on irradiation with light. Combinations of the two options are also conceivable. It is particularly preferable to use adhesives which can be cured with the aid of UV irradiation. The UV light can be radiated into the optical fibers and spacers and thereby promotes the curing of the adhesives.
Certain properties must be borne in mind when selecting the adhesives to fill the interstices. Firstly, in the uncured state their flow properties must be sufficient to enable them to penetrate into the interstices. Therefore, it is preferable to use adhesives with a viscosity of 5·10 −2 Pa·s to 5 Pa·s at 25° C. Furthermore, the adhesives must have the following properties: their volumetric contraction during curing must not be too great, they must have a low coefficient of thermal expansion (preferably <100 ppm/K), good durability under climatic tests and long-term heating to 120° C., no release of components in gas form during the removal of the spacers and heating to 150° C. for a period of 5 minutes, a high ability to withstand hot acids, lyes and/or deionized water, in particular the agents which are used to remove the spacers, and good bonding to glass. Furthermore, preferred adhesives have the minimum possible polishability, i.e. when the end surfaces are being polished they are not abraded to any significantly greater extent than the glass material, so that no pits are formed in the filled interstices between optical fibers and spacers which run to a depth of deeper than 3 μm for a interstice size of 45 μm. The interstice size is to be understood as meaning the height of the substantially triangular shape formed by the interstice. In this way, it is possible to obtain a high-quality, i.e. substantially planar surface. It has been found that adhesives which are based on epoxy satisfy the above properties. In particular adhesives which contain nanoparticles have revealed only a slight tendency to be polished out.
After the spacers have been removed, the fiber bundle is generally present in the form of a fiber bundle with a flexible central region and rigid, fixed end regions. The spacers are retained in the end regions but removed in the flexible region. This means that in the flexible region substantially only the optical fibers remain, at defined distances from one another. Unlike with individual fibers, which are likewise used for data transmission, the optical fibers which remain in the flexible region of the fiber bundles do not have any significant protection from additional sheaths, for example thick plastic sheaths. The individual fibers in the flexible middle region may, as described in WO 02/40416 A1, be protected from mechanical loads. However, it has been found that in particular the transition regions between fixed end regions and flexible middle region are particularly sensitive to mechanical loads which can be caused, for example, by the considerable distance between the fibers and therefore the considerable angle of inclination of the individual fibers. This leads to high levels of fiber fractures. Therefore, in a preferred embodiment, the transition regions are provided with additional protection. This is achieved in a surprisingly simple way through adhesives being introduced at least partially between the exposed optical fibers in the transition regions. Different demands may be imposed on these adhesives from the demands imposed on the adhesives used to fill the interstices, since they do not have to withstand the removal of the spacers and a machining treatment. Instead, their purpose is to reduce the mechanical load on the optical fibers in the transition region.
It has been found that optimum results are obtained with adhesives which in the cured state still surround the optical fibers with sufficient flexibility for the pressure involved in a bending load on the transition regions to be absorbed by the optical fibers by deformation of the adhesives and if appropriate dissipated to the rigid end regions, but without being so soft that they are cut into by the optical fibers. For the adhesives of the transition regions, it is also important for no stresses induced by the adhesives to be transmitted to the individual fibers. What this means is that the softer the adhesives, the more feasible it is for a high level of shrinkage or high coefficient of thermal expansion of the adhesives to be directly absorbed therein, so that the loads which are thereby generated are not transmitted to the fibers. Fibers which are exposed to a high level of stress continue to have high attenuation rates during transmission of light. In general, it is preferred to use adhesives which have low levels of thermal expansion, high elongations at break, a good durability in climatic tests and during long-term heating to 120° C., as well as good adhesion to glass. The protection for the transition regions can be used not only for LFBs with filled interstices but also for conventional LFBs with fused end regions.
It has been found that adhesives which are based on silicone or acrylate fulfill the above requirements. In the case of the adhesives based on acrylate, it is particularly preferable to use adhesives which contain copolymers, e.g. polyurethane. The introduction of the adhesives into the transition region or regions can preferably be effected by injection, either manually or automatically with the aid of syringes with thin needles.
As a further step, the rigid end or ends of the fiber bundle can be provided with sleeves which may be formed, for example, of metal, glass, plastic, ceramic or composites. The sleeves on the one hand protect the rigid ends of the fiber bundle, and on the other hand make it possible to produce the connection to other optical or optoelectronic components.
To minimize the working steps required to be carried out on the drawn-out fiber bundle which is not protected with adhesives, it is possible for the abovementioned sleeve to be fitted to the end or ends of the fiber bundle before the spacers are removed or even before the interstices are filled.
The invention also relates to the provision of a leached fiber bundle which has the image outlet points positioned as accurately as possible. Its end regions are not completely fused, but rather have interstices. A fiber bundle according to the invention has at least two rigid end regions with interstices which are filled with at least one adhesive up to a filling height of at least 0.5 cm, preferably of 0.5 cm to 5 cm, particularly preferably of 1.5 cm to 2.5 cm. In a most preferred embodiment the interstices are completely filled with at least one adhesive.
A further leached fiber bundle according to the invention has at least one rigid end region with interstices which are filled with at least one adhesive whose viscosity in the uncured state is 5·10 −2 Pa·s to 5 Pa·s at a temperature of 25° C.
In a preferred embodiment of the leached fiber bundle, the adhesives which have been introduced into the interstices are able to withstand hot etching acids and/or hot etching lyes and/or deionized water. Furthermore, the filled adhesives preferably have the lowest possible polishability.
In a preferred embodiment, the fiber bundle has at least one transition region between at least one rigid end region and the flexible regions, and this transition region is protected with at least one adhesive.
The distribution and selection of the adhesives used to protect the transition regions have likewise been described above. On account of the protected transition regions, the fiber bundle according to the invention proves to be surprisingly resistant to mechanical loads.
In a particularly preferred embodiment, the fiber bundle according to the invention is provided with a sleeve at at least one end. The sleeve may be formed of metal, glass, plastic, ceramic or composite.
The fiber bundle according to the invention can be used as an image light guide for the transmission of image information. In this case, it is of course possible for only part of the overall image which is to be represented to be transmitted, given a corresponding arrangement of the optical fiber bundles.
The fiber bundle according to the invention is preferably used in endoscopy.
It is also possible for the fiber bundle according to the invention to be used for optical data transmission. This application is to be understood as encompassing, for example, digital and analogue optical data transmission. The fiber bundle according to the invention is particularly preferably used as an optical interconnect, i.e. as an optical element which transmits and/or converts, in a targeted manner, data, image or general light information between optical functional units.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail below on the basis of the drawings and exemplary embodiments.
FIG. 1 is an enlarged cross-sectional view through an end region of a drawn out and leached fiber bundle.
FIG. 2 is a longitudinal section view through the end region of the fiber bundle.
FIG. 3 is an enlarged view of a portion of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a plan view of an end region of a drawn out leached fiber bundle. The optical fibers 2 and spacers 1 are not completely fused together, so that interstices 3 are located between them. The figure does not illustrate the fact that the optical fibers 2 usually comprise a light-conducting core and a sheath. The interstices 3 are subsequently filled with at least one adhesive.
The pitch 4 between the optical fiber ends 2 is determined by the diameter of the spacers 1 , if the diameter 5 of the optical fibers 2 is less than or equal to the smallest interstice diameter. If the diameter 5 is smaller than the smallest interstice diameter, it can be adapted by a spacer tube around the optical fibers 2 .
FIG. 2 shows the longitudinal section through the end region of a drawn-out optical fiber bundle with end faces which are not completely fused. The rigid end region 11 is provided with a sleeve 10 made, for example, from metal, glass, plastic, ceramic or composite. In the rigid end region 11 there are optical fibers and spacers, and the interstices are filled with adhesive. An interlayer 12 , which protects the sensitive end region from damage caused be mechanical loads and/or forms a positively locking connection between end region 11 and sleeve 10 , may be introduced between sleeve 10 and end region 11 . This interlayer 12 may, for example, be formed of a wax.
The rigid end region 11 is filled with at least one adhesive up to a filling height (h). Of course, it is possible for the end region to be completely filled.
The filling height (h) is measured from the end face of the rigid end region 11 towards the flexible region 13 .
The end region 11 is adjoined by the transition region 14 between rigid end region 11 and flexible region 13 . According to the invention, at the transition region the adhesive or adhesives for protection of the transition region are introduced.
FIG. 3 shows the transition region 14 from FIG. 2 on a larger scale. In this region, the flexible optical fibers 21 meet the rigid region 20 , not all of which is shown. The rigid region 20 includes both optical fibers and spacers. Adhesive 22 which protects the transition region from mechanical loads has been introduced into the spaces between the optical fibers 21 .
In the following exemplary embodiments, optical fiber bundles with a pitch of 250 μm were produced using the process according to the invention.
In tests, adhesives from the VITRALIT® series produced by Panacol-Elosol have proven particularly suitable for filling the interstices, in this case in particular VITRALIT® 1508 containing 15% of nanoparticles and VITRALIT® 1605 (viscosity: 0.3-0.75 Pa·s at 25° C.). The adhesives from the ARALDITE® series from Ciba Specialty Chemicals can also advantageously be used, in this case in particular AY 103 and HY 956 (viscosity: 3 Pa·s at 25° C.). VITRALIT® is based on one component epoxy, and ARALDITE® is based on two component epoxy.
The abovementioned adhesives were used to produce fiber bundles according to the invention using the process of the invention. All the adhesives mentioned had only a very low polishability and also had a very good resistance to the production process described above. In particular during the application of a wax layer 12 at 150° C. to protect the end region 11 from the removal of the spacers and the subsequent etching for removal of the spacers using hot acids, lyes and deionized water, no changes occurred to the mechanical strength of the adhesives, and also no gaseous components were released.
At the pitch 4 of 250 μm used and an optical fiber diameter 5 of 100 μm, the interstices 3 were filled by first of all applying a pressure reduction, generated by a vacuum pump, to one end of the fiber bundle and filling the other end with adhesive to a filling height (h) of 2 cm. Then, the drawn-out, still rigid fiber bundle was heated with the aid of a hot-air drier (setting: 450° C. for 60 s), and the as yet unfilled end was immersed in the adhesive and then cooled. The contracting gas volumes in the interstices 3 ensured that the adhesive was drawn into the rigid fiber bundle ends to a filling height (h) of 2 cm.
It is also possible, instead of filling the interstices of the first end region with the aid of a vacuum pump, for the first end region also to be filled with adhesives by exploiting the contraction of preheated gas volumes, if the other end is at least temporarily closed, for example using a Teflon film, before the end region is immersed in the adhesives.
Of course, it is also possible for the interstices of one rigid end of the fiber bundle first of all to be filled with adhesives using the capillary forces. In this case, however, the introduction of the adhesives into the other end has to be effected with the aid of a pressure reduction as described.
The fiber bundle ends which had previously been filled with adhesive were then provided with end sleeves made from metal, polished, the end regions were protected with wax and the spacers were removed as described, so that the middle region was flexibilized. In bending tests with a bending radius of 25 mm, 24,000 bends and a lower end load weighing 20 g, it was found that even with the pitch 4 of 250 μm and an optical fiber diameter 5 of 100 μm, more than half of all the optical fibers 21 broke in the transition region 14 . This means a high scrap rate in the production process or a low service life for optical fiber bundles in use. To protect the optical fibers 21 in the transition region 14 , additional adhesives 22 were introduced with the aid of syringes with thin needles. To ensure sufficient distribution of the adhesives, they were introduced dropwise from a plurality of locations in the transition region 14 of the fiber bundle.
The adhesives SYLGARD® 184 (hardness: Shore A50) produced by Dow Corning and ECCOBOND® UV 9501 (hardness: Shore D43) produced by Emerson & Cuming have proven particularly suitable for protecting the transition region 14 . Neither of these adhesives transmits excessively high stresses to the sensitive optical fibers 21 during mechanical load either through their thermal expansion or through an excessively high strength. Also, they are both equally 30 able to withstand climatic tests. SYLGARD® is based on silicone and ECCOBOND® is based on acrylate.
ECCOBOND® UV 9501 can be cured using LW light within 3 to 8 seconds and is therefore distinguished by particularly simple processing. SYLGARD® 184 is thermally curable, e.g. by heating to 100° C. for one hour, and is therefore more complex to handle.
Comparative bending tests under the same conditions as those described above, applied to fiber bundles with the transition regions protected in this way, showed that there were no longer any broken fibers.
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A leached fiber bundle with the light outlet points positioned as accurately as possible is provided, in which the end faces are not completely fused together, but rather are only fused together at their contact surfaces. The interstices formed are permanently filled with adhesives with the aid of a pressure reduction. To protect the optical fibers from mechanical load, adhesives are introduced into the transition region between the fixed end region and a flexible region. This allows the leached fiber bundles to be produced more economically and also improves their service life.
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BACKGROUND OF THE INVENTION
For years people have been attempting to develop a convenient screening assay to determine whether a patient has Primary Open Angle Glaucoma (POAG) or is at risk for developing POAG. The currently used diagnosis is based on an evaluation of a patient's visual field and many risk factors such as intraocular pressure, family history of Glaucoma, race, age, and the appearance of the optic disk. All of these factors are considered in reaching the diagnosis of POAG. However, the testing is not simple, requires a highly skilled person for proper evaluation, and is extremely time-consuming and expensive and is unreliable.
Because of the above-referenced current method of diagnosis of POAG or risk for developing POAG, there is a continuing need and has been a continuing search for a clear marker, or test system, that can be used in mass testing of the public to determine POAG risk. In earlier work of these co-inventors reported in U.S. Pat. No. 4,863,912, and a divisional application which matured into U.S. Pat. No. 4,997,826, these present co-inventors developed a therapy for Tetrahydrocortisol use in Glaucoma treatment.
Tetrahydrocortisol is a normal cortisol metabolite found in urine and serum of normal humans but not in Trabecular Meshwork (TM) cells isolated from POAG eyes. Cortisol is metabolized only slowly by normal TM cells. However, in TM cells from primary open angle glaucoma (POAG) patients, the rate limiting enzyme delta-4-reductase is aberrantly hyperexpressed, and activity of the 3-oxidoreductase (also called 3-hydroxysteroid dehydrogenase) is reduced. This enzyme imbalance leads to the accumulation of 5-alpha and 5-beta-dihydrocortisol in POAG TM cells. It was in these patients that it was postulated that 5-beta-dihydrocortisol is toxic to TM cells and compromises TM function. Since the trabecular meshwork is the major site for aqueous humor outflow, compromised TM function leads to an increase in intraocular pressure. It is believed that tetrahydrocortisol may antagonize the action of 5-beta-dihydrocortisol, in a yet to be defined manner, and that it also may function as an inhibitor of A-ring reductase activity.
In earlier work of these co-inventors reported in 1983 in Investigative Ophthalmology & Vis Science (24:1413, 1983) and 1985 in Investigative Ophthalmology and Vis Science (26:890, 1985), it was reported that 5-beta-dihydrocortisol is metabolized in the TM cells by an enzyme 3-alpha-hydroxysteroid dehydrogenase (3-alpha-HSD) to 3-alpha, 5-Beta-Tetrahydrocortisol. This is a normal metabolic pathway. In the earlier work as reported, the inventors identified two enzyme defects in cultured trabecular meshwork from patients with Primary Open Angle Glaucoma. As compared to control cells, the POAG derived cells had an increase in cortisol delta 4-reductase and a decrease in 3-alpha-hydroxysteroid dehydrogenase. This finding, however, had little diagnostic value since it required culturing cells from either autopsy eyes or from surgical specimens. Put another way, an assay on cells from the TM is simply not practical as something that can be used on the population at large to determine POAG risk. Therefore, in 1983 in an effort to find a further diagnostic assay, an enzyme which was observed to have a dramatic increase in patients suffering from trabecular meshwork cells, namely cortisol delta-4 reductase, was tested in peripheral lymphocytes from blood samples of patients known to be suffering from Glaucoma as compared to patients known not to be suffering from Glaucoma. The levels of cortisol delta-4 reductase were found to be the same in POAG and non-POAG derived specimens. Therefore, it was then concluded that there was no correlation between levels of this enzyme in the TM and the levels in cells in the blood specimens, and the search for a correlating enzyme as a diagnostic marker stopped.
It can be seen that there is a real and continuing need for a simple, general population test that can be used on the public at large by laboratory workers to determine patient risk of Primary Open Angle Glaucoma.
Thus it is a primary objective of the present invention to provide a mass screening assay which can be used as a marker test for POAG and those patients at risk of developing POAG, which are collectively referred to herein as "at risk" patients.
Another objective of the present invention is to provide such an assay which is simple, straightforward and which can be properly interpreted by people of lower skill levels than those required to make the overall composite evaluations presently used in the medical field that involve such subjective data as evaluation of visual field, family history, race, age and appearance of the optic disk.
Another objective of the present invention is to develop a simple blood assay test which correlates predictably and easily and quickly with Primary Open Angle Glaucoma risk determination.
Yet another objective of the present invention is to develop a simple testing kit which can be used in determining Primary Open Angle Glaucoma risk.
The method and means of accomplishing these objectives as well as others will become apparent from the detailed description of the invention which will follow hereinafter.
SUMMARY OF THE INVENTION
An assay for determining patients at risk of Primary Open Angle Glaucoma is provided. The assay involves obtaining a patient blood sample and testing cells in the blood sample for 3-alpha-hydroxysteroid dehydrogenase enzyme activity to determine if it is significantly decreased from the normal level of patients not suffering from POAG. From the developed data the patient is categorized as either an at risk patient for POAG, a patient that has POAG, or a patient that has no present risk of POAG.
DETAILED DESCRIPTION OF THE INVENTION
As reported in our earlier work of 1983 and 1985, there were two enzyme defects in cultured trabecular meshwork cells observed in patients with Primary Open Angle Glaucoma. However, since the increased levels of the enzyme Cortisol delta 4 reductase found in TM cells did not correlate with blood cells, it was presumed that the second enzyme phenomena observed in TM cells, namely a decrease in 3-alpha-hydroxysteroid dehydrogenase (3-alpha-HSD) would also not correlate. Surprisingly, however, it has now been found that the decrease in 3-alpha-hydroxysteroid dehydrogenase (3-alpha-HSD) found in TM cells does correlate with a corresponding decrease in 3-alpha-HSD in peripheral lymphocyte cells. This unpredicted and previously unobserved phenomena provides the basis for the current assay.
It is not known why patients suffering from Primary Open Angle Glaucoma or at high risk in developing the same have a decreased activity of 3-alpha-HSD in the trabecular meshwork. Nor is it known why this observed phenomena of enzyme decrease for 3-alpha-HSD correlates with peripheral lymphocyte assays when the earlier observed phenomena of increase of delta-4 reductase does not correlate. However, this unpredicted phenomena does provide the basis for a uniform assay which can be performed quickly and easily on peripheral blood samples of the public at large. Moreover, because differences in level, i.e., decrease in 3-alpha-HSD in patients at risk of Primary Open Angle Glaucoma and those not suffering from POAG is marked (in many instances the normal patients have a twofold or threefold higher level of 3-alpha-HSD in comparison with POAG patients), the test results are extremely easy to interpret.
It should be mentioned that this diagnostic indicator only functions effectively for Primary Open Angle Glaucoma. Patients suffering from Secondary Glaucomas, e.g., Glaucoma caused by physical damage to the eye such as scar tissue, etc., that does not involve a defective functioning of the TM cells and cannot be predicted by this assay. Nevertheless, the assay is extremely useful because most Glaucoma sufferers in fact suffer from Primary Open Angle Glaucoma, as opposed to Secondary Glaucomas.
In accordance with the process of the present invention, lymphocytes are simply isolated from venous blood, and labeled 5-beta-dihydrocortisol (3H-5-beta-DHF) is added. If 3-alpha-HSD is present, it will metabolize the labeled 5-beta-DHF in accordance with the following equation: ##STR1## Thus, if lots of 3-alpha-5-beta-tetrahydrocortisol is produced, that is an indicator of high levels of 3-alpha-HSD since it is needed for the reaction to proceed. Correspondingly, if little of the 5-beta-DHF is converted to 3-alpha-5-tetrahydrocortisol, that is evidence of decreased levels 3-alpha-HSD. In other words, the amount of produced tetrahydrocortisol directly corresponds to the level of 3-alpha-HSD. Higher levels of tetrahydrocortisol mean higher levels of 3-alpha-HSD, and correspondingly, lower levels of tetrahydrocortisol mean lower levels of 3-alpha-HSD.
The amount of tetrahydrocortisol produced is quantified and expressed in units of specific activity measurement. Generally speaking, on average the units of activity of 3-alpha-HSD in normal patients are found to be 27.5×10 -14 moles of 3-alpha-5-beta-tetrahydrocortisol formed per hour at 37° C. per 1 million cells as compared to 13.7×10 -14 moles of 3-alpha-5-beta-tetrahydrocortisol formed per hour at 37° C. per 1 million cells in POAG patients. The difference between the two groups was found to be highly significant. As can be seen, a marked difference exists that can easily be observed.
The following examples are offered to illustrate but not limit the process of the present invention.
EXAMPLES
Sixteen (16) patients known to be suffering from Primary Open Angle Glaucoma and sixteen (16) non-POAG patients were selected as controls.
Isolation of peripheral blood lymphocytes:
Blood samples are collected using the anti coagulant EDTA and used within 4 hrs of collection. Two volumes of RPMI medium (Gibco BRL) are added to 1 volume of blood, it is layered on Ficol (Pharmacia) and centrifuged for 20 mins. at 2000 rpm. The lymphocyte layer is removed with a Pasteur pipette and washed three times with the RPMI medium and finally resuspended in the same medium (1-2 million cells per ml). An equal amount of trypan blue is mixed with an aliquot for counting with a hemocytometer.
3α-HSD Assay:
0.05 μCi of 3 H-5-beta-dihydrocortisol (5-beta-DHF) is added to borosilicate tubes and evaporated to dryness. The labeled 5-beta-DHF is prepared by incubating labeled cortisol with a suitable biological material such as bacteria or mammalian liver or adrenal extract which metabolizes the cortisol to 5-beta-DHF and other products. The 5-beta-DHF formed is isolated and purified by standard methods using High Performance Liquid Chromatography. 0.5 ml of lymphocyte suspension is added to the 5-beta-DHF test tube and incubated at 37° C. for 1 hr. Control tubes are incubated with the medium and substrate. After incubation all of the steroids are extracted with 5 ml of ethylacetate and evaporated to dryness. The labeled steroids are separated on Thin Layer Chromatography and quantitated. The activity is expressed in moles of 3-alpha-5-beta-tetrahydrocortisol (3-alpha-5-beta-THF) formed per hour at 37 ° C. per 1×10 6 cells.
In the following table, the activities are expressed as 10 -14 moles of 3-alpha-5-beta-THF formed per hour at 37 ° C. per 1 million cells. These are the same units as expressed earlier.
TABLE______________________________________PATIENTS NORMAL CONTROL (POAG PATIENTS)______________________________________1 32.0 14.02 33.0 8.03 40.0 14.04 43.0 11.05 31.0 6.06 20.0 14.07 24.0 25.08 27.0 14.09 29.0 15.010 22.0 11.011 22.0 18.512 21.0 9.013 40.0 13.514 23.0 26.615 17.0 7.516 16.7 12.6MEAN: 27.5 13.7SD: 8.3 5.7SE: 2.1 1.4______________________________________ P<0.0001
The reduction of 3-alpha-HSD activity for the patients was similar to earlier work previously reported for trabecular meshwork of POAG patients. The reduced levels of 3-alpha-HSD activity in the POAG patients suggests its role in the etiology of POAG, i.e., a deficiency in 3-alpha-HSD activity results in the formation of decreased amounts of the hypotensive metabolic 3-alpha-5-beta-tetrahydrocortisol. Thus it can be seen that this simple blood test can be used to identify patients at risk for Primary Open Angle Glaucoma. As can be seen from the data and earlier description as well, those patients that are at risk of POAG or that in fact have it, generally have 3-alpha-HSD levels of from 25% or more and generally 50% or more lower than the levels of normal patients. Using the units herein expressed, the range is generally from 0 to 24 for at risk patients and preferably or most frequently from 3 to 17 for patients classified as at risk.
It should be mentioned that in addition to enzyme activity measurements in peripheral blood lymphocytes, a similar diagnosis could be predicated upon other cells or an antibody or nucleic acid based assay in lymphocytes or other cells as well. These changes are contemplated as within the spirit and scope of the invention.
The test solutions and instructions therefor can be conveniently provided in a simple assay test kit. It can therefore be seen that the invention accomplishes all of its stated objectives.
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An assay for determining patients either having Primary Open Angle Glaucoma or at risk of developing Primary Open Angle Glaucoma. The assay involves testing cells, preferably lymphocyte cells, for 3α-HSD activity and determining from the level of assayed activity whether the patient is either suffering from Primary Open Angle Glaucoma or at risk therefor.
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BACKGROUND
This invention relates to valve assemblies. It has particular application to valves which are used typically in relatively inaccessible locations, e.g. valves of the type which are used in subsea pipelines.
The components of valves, e.g. gate valves which are used in subsea locations are subject to wear, corrosion, and erosion and hence periodically need replacement. It has been proposed to mount the flow control components of such valves, typically the gates and seats, in an insert which can be removably mounted in a receiver receptacle. The receptacle can be coupled to the flow line which the valve controls. This enables the insert to be removed either by a diver or a remotely operated vehicle for the replacement of the valve components. In such arrangements it is necessary to provide a metal seal between the insert and the receiver. In a known arrangement the receiver is provided with tapering faces against which the surface of the insert can seal. The receiver of this arrangement is very complex to produce, the most common method being by casting. However, even when cast the machining is still very complex and it is an expensive process.
The K. B. Bredtschneider et al. U.S. Pat. No. 3,179,121 discloses a ball valve construction with a ball and seats manually removable as a unit. The seats seal against the valve body with elastomeric seal means on a tapered surface.
The M. R. Jones U.S. Pat. No. 3,589,674 discloses another ball valve structure with a second pressure balancing stem in which the the ball, seats and balance stems are manually removable as a unit.
The J. A. Burkhardt et al. U.S. Pat. No. 3,799,191 discloses a gate valve structure with a removable body containing the gate, seats, stem and stem operating means. The removable body is secured to the valve body by a lock ring.
The R. L. Ripert U.S. Pat. No. 4,387,735 discloses a valve structure removable from a pipeline wherein the valve is received within a support structure attached to the pipeline. The support structure has seal rings mounted therein which a worm gear mechanism activates into engagement with the removable valve structure to form a fluid tight conduit.
The R. L. Ripert U.S. Pat. No. 4,431,022 discloses a removable valve structure received within a support structure similar to that of the '735 patent. The valve structure has all components mounted therein, including a sealing means on each end of the valve which is biased outwardly to engage parallel plates on the support structure. A pressure responsive means for moving the seal rings inwardly during installation and removal is also disclosed.
The J. E. Lawson U.S. Pat. No. 4,874,008 discloses a valve mounting structure whereby hydraulic studs are used to secure a valve body between mounting members which are part of a block manifold used in oil and gas production.
SUMMARY
According to the present invention there is provided a valve arrangement comprising a body portion removably receivable in a receptacle portion, the body portion including valve elements for controlling fluid flow through a flowpath in the body portion, and the receptacle portion including flowpaths which, when the body portion is received in the receptacle portion, communicate with the flowpath in the body portion, annular sealing members disposed in the opening of each receptacle flowpath, each sealing member being movable axially in its opening, and means coupled to said sealing member, and engagable by said body portion when it is inserted into said receptacle portion to urge said sealing members into sealing engagement with the surface of the body portion.
The means engageable by the body portion may comprise a lever assembly coupled to each sealing member. Each lever assembly may have a bifurcated portion which is coupled to its sealing member at diametrically opposite positions. Each lever may exhibit a degree of resilience whereby it acts like a spring to maintain sealing contact between the body portion and the sealing members. The body portion may carry sealing means for sealing against said sealing members. The sealing means may comprise annular metal-to-metal seals each of which are located in an annular groove formed in the body portion.
The body portion may carry a locking ring adapted to engage a thread on the wall of the receptacle bore which receives the body portion, said locking ring being engagable by an appropriate tool which is operable to rotate the locking ring to cause the body portion to move axially relative to the receptacle.
Each lever may be shaped to define an elbow or heel which abuts the receptacle body and forms a pivot point about which the lever can pivot when a lower part of the body portion comes into contact with the lever. The forward part of the body portion may be tapered to define a ramp which engage each lever assembly.
An object of the present invention is to provide a valve arrangement of the insert type which can be produced by a less complex manufacturing method.
Another object is to provide an insert type valve which can be easily installed and removed from its mounting receptacle.
A further object is to provide an insert type valve which is particularly adaptable to use in relatively inaccessible locations such as subsea oil and gas wells.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention are set forth below and further made clear by reference to the drawings wherein:
FIG. 1 is an elevation view, partly in section, of a valve assembly in accordance with the present invention, the valve being shown in a position prior to its final assembly position.
FIG. 2 is a view similar to that of FIG. 1 showing the components in their assembled position.
FIG. 3 is an enlarged sectional view on the line 3--3 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, a valve assembly comprises a receptacle 10 which can receive a valve insert assembly 11. The receptacle 10 comprises a metallic block formed with a first through bore 12 into which the insert 11 is designed to locate. The bore 12 has a first bore portion 14, a second bore portion 15 which is formed with internal threads 16, a third through bore portion 17 and a slotted portion 18. A second bore 20 extends through the receptacle 10 perpendicular to the first bore 12. The second bore 20 opens into the fourth portion 18 of the first bore 12. The oppositely facing portions of the second bore 20 which open into the bore 12 have stepped wall portions 22. The second bore 20 constitutes a flow path for fluid such as oil flowing in a subsea flow line. Typically the receptacle 10 will be connected to such a flow line.
Each stepped portion 22 of the bore 20 defines a pocket which receives a tubular sealing member or subs 23, 24. The outer wall of each sealing sub 23, 24 is stepped in a manner corresponding to that of the wall pocket 22. The thinner wall part 25 of each sealing sub carries a sealing arrangement shown generally at 28. This comprises a metal seal ring 29 for providing a metal-to-metal seal between each sealing sub 23, 24 and its pocket wall, together with a secondary elastomeric seal shown at 30. Each sealing sub 23, 24 is mounted so that it can move axially within its respective pocket 22.
Each sealing sub 23, 24 is coupled to a thrust lever 32, 33 which depends from its associates sealing sub. Each thrust lever has a bifurcated upper portion 35 (see FIG. 3) having a semicircular wall 36 which fits closely at both sides with clearance around the circumferential part of the respective sealing sub 23, 24. The opposite limbs constituting the bifurcated portions are hinged to each sealing sub by pins 38. Each lever has a heel portion 39 disposed against the wall of the bore portion 18 and an inwardly slanting lower portion 40. Each lever is formed from a material which has a certain degree of inherent resilience.
The insert assembly 11 has a body portion 50 which is generally cylindrical and has an upper flanged part 51 which is arranged to locate in the bore portion 14, an intermediate part 52 which is arranged to locate in the bore portion 17 and a lower portion 53. The lower portion 53 has axially extending, diametrically opposite slots 49 which receive the projecting end portions of the sealing subs 23, 24. The lower portion 53 has a diametrically extending through bore 54 which provides a flow path for fluid. In the completed valve assembly this bore portion is designed to be in alignment with the bore 20 of the receptacle. An axially extending closed bore 55 extends into the body portion 50 and accommodates the components of a gate valve shown generally at 56. These components are generally conventional components of a gate valve and will not be described in detail since their construction and operation will be apparent to the man skilled in the art. The upper part 51 of the housing 50 is connected to an actuating assembly 58 for the gate valve assembly 56. A locking ring 59 is mounted around the lower part of the actuating arrangement 58 and the upper body part 51. The upper circumferential part of the locking ring 59 is castellated and the lower outer periphery of the locking ring has threads which can engage the threads 16 on the bore portion 15. The lowermost part of the housing 50 is formed with a tapering wall 62.
The wall of the housing 50 around opposite ends of its through bore 54 is formed with annular grooves 63. Each annular groove 63 accommodates a pressure energized metal-to-metal annular seal 64. A further annular groove 65 extends concentrically around the annular groove 63 and accommodates a secondary elastomer O-ring seal 68.
In use in order to locate the insert 11 in the receptacle 10 the insert is lowered so that is moves into the bore 12 of the receptacle. The tapering portion 62 on the lower end of the insert acts as a lead-in chamfer for this movement. The insert 11 is orientated angularly relative to the receptacle by means of a pin (shown by dotted line 69) which projects radially inwardly from the wall of the bore 12 and engages an axially extending slot formed in the housing 50 of the insert. As shown in FIG. 1 the diametrically opposed slots 49 formed on the lower housing portion 53 allow the insert 11 to pass between the two sealing subs 23 and 24. The pin 69 and groove arrangement just referred to also assist in preventing the nose 62 of the insert from coming into contact and damaging the sealing subs.
The insert is lowered until the locking ring 59 comes into contact with the threads 16 formed on the bore portion 15. This position is illustrated in FIG. 1 of the drawings. It will be noted that at this stage there is clearance between the axially inner end faces of the sealing subs 23, 24 and the outer peripheral wall of the housing 50 and also between the lower portion 62 of the housing 50 and the levers 32 and 33. In order to move the insert further into the receptacle the locking ring 59 is rotated relative to the receptacle. The castellation on the locking ring enable it to be engaged by an appropriate remotely operated tool. Slots can be provided in the top face of the receptacle body to provide reaction points for such a tool. Initially the locking ring 59 is rotated approximately two revolutions in a clockwise sense to advance the insert to a point at which contact is established between the lower outer part 62 of the housing 50 and the levers 32, 33. Continued rotation of the locking ring advances the insert assembly 11 axially into the bore 12 and the ramp provided by the tapered portion 62 urges the levers about their heels 39, hence causing the sealing subs 23, 24 to move axially in their pockets 22 towards the wall of the body portion 50. When the insert has been advanced to its fully inserted position shown in FIG. 2 the sealing subs 23 and 24 have been urged by the interaction of the housing 50 with the levers 32 into close engagement with the wall around the bore 54 through the housing 50. This junction is sealed by the metal-to-metal seals 64 carried by the housing portion 50.
The thrust levers 32, 33 are hinged to the sealing subs 23, 24 in such a way as to provide an appropriate mechanical advantage. It will be seen that the sealing subs 23 and 24 are sealed in their pockets by the sealing assemblies 28, primarily the metal-to-metal seal 29. The secondary seal 30 is a back up seal which serves to protect the metal sealing surface from being exposed to sea water. A sleeve arrangement can be provided on each sealing sub to protect the area between it and the body from any build up of sediment or debris which might otherwise prevent removal of the insert when that is required. When the components are in their operative positions and the valve is open pressure acting behind the sealing subs 23, 24 operates to maintain them in contact with the body 50 hence preventing seal fretting and ingress of debris. Also when the valve is close the pressure acts on the upstream sealing sub.
Each thrust lever 32, 33 is designed to provide a minimum thrust load and to accommodate a tolerance variation of relative components of the order of 0.020 inches within deflection of the lever arm so as to ensure face-to-face make up at the interface of the seal 64. It should be noted that the seals 28 on the sealing subs 23, 24 will be a larger size than the seal 64 to thereby provide a pressure bias which maintains face-to-face contact under all conditions and prevents seal fretting due to cyclic loading.
The resilience of the levers 32, 33 ensures that they act like springs to maintain the sealing contact between the sealing subs 23, 24 and the seals 64 carried by the insert body 50.
It will be appreciated that removal of the insert assembly 11 is substantially the reverse of the installation procedure described above. Initially an over torque is applied to the locking ring 59 by applying a counter clockwise rotation to the ring and once this is overcome the necessary torque reduces significantly since the springback of each metal seal 64 is typically 0.002 inches. As rotation continues (after approximately six revolutions of the locking ring) shoulders machined on the insert body coincide with similar shoulders machined on the thrust levers causing the sealing subs to retract back into their respective pockets ready for reinstallation. The insert can then be retrieved for replacement of those valve components which need renewing.
The present arrangement has the advantage that it is more simple and more economic to produce than the known prior art devices. The sealing subs 23, 24 are urged permanently into contact with the body 50 of the insert and a metal-to-metal seal is provided between those two members. The sealing subs 23 and 24 are mounted in their respective pockets 22 such that they can be retrieved as well. The annular seals 68 around the seals 64 enable a test facility to be provided to test the insert body connection. The arrangement can be accurately machined to provide full bore alignment between the receptacle and the insert and the arrangement of levers gives the mechanical advantage which results in a reduced operating torque.
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A valve assembly has a body portion (11) which can be removably receivable in a receptacle (10). The body carries the valve element such as a gate which controls fluid through a flowpath in the body. The openings of a flowpath in the receptacle accommodate annular sealing members (23, 24) which are movable axially in the opening. Means such as a lever arrangement (32, 33) are coupled to each sealing members and are contactable by the body (11) on its insertion in the receptacle such that the sealing members are moved axially toward the body to seal around the flowpath openings of the body.
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RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 754,830, filed Dec. 27, 1976, now U.S. Pat. No. 4,133,442.
BACKGROUND OF THE INVENTION
The invention relates to pressure vessels and their manufacture, and in particular relates to a split tank closure assembly.
DESCRIPTION OF THE PRIOR ART
Bag-molded, fiberglass-reinforced tanks are disclosed, for example, in U.S. Pat. No. Re. 25,241 to Randolph and No. 3,138,507 to Wiltshire. Split tank assemblies of the general class to which the present invention is directed are shown in U.S. Pat. Nos. 2,709,924 to Russell et al and 3,388,823 to Fleming et al, for instance. Split tanks of the type herein disclosed provide full access to the interior of the tank for placement and removal of rigid filter elements therein and various other purposes. In the known prior art, there is an absence of applications of bag-molded fiber-reinforced tanks, with their attendant manufacturing economies and other advantages, in the field of split tank assemblies.
SUMMARY OF THE INVENTION
The invention is directed to a split tank assembly and the method of its manufacture, wherein a generally conventional bag-molded, fiber-reinforced tank is transversely sectioned and fitted on each section with supplemental circumferential flanges adjacent the plane of separation.
In a first embodiment, a pair of mating tank sections are each provided with external flange receiving grooves adjacent their open faces and with flanges that include portions mechanically interlocked on the grooves. The plane of separation between the open tank faces is sealed by an O-ring disposed on the exterior of the tank sections between the opposed flanges. The flanges are advantageously formed of sheet metal stock, and include conical skirt portions flaring forwardly and outwardly from interlocked groove-engaging portions. In assembly, the conical skirt portions are clasped by complementarily shaped sides of an encircling split band. Circumferential tightening of the band causes its sides to wedge the flanges axially together, resulting in axial compression of the O-ring. This axial compression forces the O-ring to constrict radially and effectively seal against the sidewall surfaces of the tank sections.
The invention includes a method of severing an integrally molded tank into a pair of mating sections simultaneously with the formation of the flange-receiving grooves and O-ring seating surfaces. The method comprehends the use of a specially formed cutting tool in a single operation which minimizes dimensional variation of the relative positions of the flange grooves and sealing surfaces. The resulting dimensional uniformity advantageously avoids the necessity of remating only the original sections of a common tank so that tank sections may be randomly stored and assembled. In addition, a method of pressure testing the structural integrity of the severed tank sections and the quality of the sealing surfaces is disclosed.
In another embodiment of the invention, mating tank sections are fabricated by severing integrally molded units, as above disclosed, while, by contrast, they are provided with fiber-reinforced plastic flanges bonded on their exterior surfaces. As before, an O-ring is disposed at the mating faces of the tank sections externally of the tank wall sections between opposed flanges. The disclosed flange structure is arranged to permit the O-ring to effect a seal on the flange surfaces to avoid the necessity of machining or other surface preparation on the main bodies of the tank sections. The flange structure, in addition, affords high seal reliability by allowing the contact sealing force of the O-ring to be increased by pressure contained in the tank. The fiber-reinforced plastic flanges are circumferentially continuous rings having a tank section receiving bore. The bore is slightly tapered to direct and control movement of a bonding agent therein when the flange is slipped over a tank section which has been locally precoated with the bonding agent. The resulting bonded joint, moreover, has improved strength by virtue of a wedge-locking action between the tapered bore and hardened bonding medium. An additional advantage of this embodiment is its all plastic construction, which eliminates corrosion problems resulting from attack by materials carried in the tank or in the surrounding environment.
In a still further embodiment of the invention, a pair of mating tank sections are provided with external flange receiving grooves adjacent their open faces. An additional groove is provided in each tank section between the open face of the section and the flange receiving groove and each additional groove is provided with an O-ring. A unitary flange encircles the sections to clamp the O-rings in place and to axially restrain the link sections since the flange has hooked end portions which are received in the flange receiving grooves.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a split tank assembly constructed in accordance with the principles of the invention;
FIG. 2 is a fragmentary, cross sectional view of a tank wall area at a plane of separation of a pair of mating tank sections on a somewhat enlarged scale;
FIG. 3 is a plan view of a split band subassembly used in the tank assembly of FIG. 1;
FIG. 4 is a fragmentary, perspective view of one side of the split band subassembly of FIG. 3, showing its constructional details;
FIG. 5 is a fragmentary, perspective view of a portion of the band subassembly of FIG. 3, showing details of a flexible hinge strip;
FIG. 6 is an enlarged, cross sectional view, similar to FIG. 2, illustrating constructional details of a second embodiment of the tank assembly;
FIG. 7 is a cross sectional view of a portion of a tank assembly constructed in accordance with another embodiment of the invention, wherein the tank sections are internally isolated by a flexible wall;
FIG. 8 is a somewhat schematic, axial end view of apparatus for machining the tanks of FIGS. 1, 2, and 7;
FIG. 9 is a side elevational view of the apparatus of FIG. 8;
FIG. 10 is an enlarged, cross sectional view of a portion of the apparatus and tank illustrated in FIG. 9;
FIG. 11 is a plan view of a test ring assembly for testing tanks to be used in the assembly of FIGS. 1, 2, and 7;
FIG. 12 is a fragmentary, cross sectional view of the test ring of FIG. 11 taken along the line 12--12;
FIG. 13 is a perspective view of a portion of the test ring of FIG. 11, showing details of a latch interlock feature thereof; and
FIG. 14 is an enlarged cross sectional view similar to FIGS. 2 and 6, illustrating constructional details of a further embodiment of the tank assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring particularly to FIGS. 1 and 2, there is illustrated a split tank assembly 10 constructed in accordance with the principles of the invention. The assembly 10 includes a pair of mating tank sections 11 and 12 formed by transversely splitting an elongated tank having generally cylindrical sidewalls and domed end walls. Preferably, the tank is originally an integral bag-molded, glass-reinforced, closed tank such as that shown in the aforementioned U.S. Pat. No. Re. 25,241, the disclosure of which is incorporated herein by reference. The tank assembly 10 also includes a pair of circumferential flanges 13 and 14, a closure band 15, and an O-ring seal or gasket 16.
As indicated in FIG. 1, the tank is severed at a transverse plane, preferably though not necessarily, near one or the other of its ends so that the tank sections 11 and 12 are of unequal lengths. The plane of separation defines opposed radial open faces 19 and 20 of the upper and lower tank sections 11 and 12, respectively. In this instance, the longer section 12 may be considered, for example, as a receptacle for a filter medium for fluids passing through the tank and the shorter section 11 as a closure member for the receptacle. One or both sections 11 and 12 may be provided with a port for introduction and discharge of fluid into the interior of the assembly. In FIG. 1, a port 23 is provided at the top center of the upper section 11.
Exterior surfaces 26 and 27 of the tank section sidewalls are generally cylindrical and of equal diameter. Substantially identical circumferential grooves 28 are cut, in a manner to be described, on these exterior surfaces 26 and 27. The grooves 28 on each section 11 and 12 preferably are of the same spacing from their associated end faces 19 and 20. The sidewalls of the upper and lower tank sections 11 and 12 are somewhat thickened along an axial zone extending from their respective end faces 19 and 20 beyond the grooves 28 to ensure that adequate strength resides in these sections subsequent to the cutting of the grooves. When the tank sections are formed by bag-molding, this additional wall thickness may be provided by disposing additional reinforcing fibers in this zone prior to introduction of the bag. The wall area remaining radially inside the grooves after the latter are cut must retain sufficient strength against axial forces developed by pressure within the tank tending to separate these sections, while the spacing of the grooves 28 from their respective end faces 19 and 20 must be sufficient to provide adequate area to avoid failure through shear under this axial pressure force. The grooves 28 are rectangular in cross section so as to provide abutment surfaces 29 lying in planes parallel to and facing rearwardly from the respective end faces 19 and 20. The outer surfaces of the tank sections 11 and 12 are beveled at 31 adjacent the end faces 19, 20 to provide sealing seats for the O-ring 16.
The circumferential flanges 13 and 14 are preferably identical, and are unitary elements having a single radial split (not shown) to permit elastic expansion over the cylindrical walls 26 and 27 and contraction into their respective grooves 28. Each flange includes a conical skirt portion 36 and an integral cylindrical portion 37. The cylindrical portion 37 includes a reverse fold 38 at its distal edge to form a shoulder 39 to axially retain its associated tank section by engagement with the groove abutment surface 29. Ideally, the flanges 13 and 14 are formed from sheet stock of a suitable grade of stainless steel for corrosion resistance, and are rolled into their illustrated cross sectional shape and circumferential configuration. The free inside diameter of the cylindrical flange portion 37 is substantially equal to or slightly less than the diameter of the cylindrical outer tank surfaces 26 and 27. After being expanded over a tank section, a flange 13 or 14 is provisionally self-retained on the associated tank section when the reverse fold of the cylindrical portion 37 is released into a groove 28. The flange skirt portions 36 are spaced rearwardly from the associated tank end faces 19 and 20 so that they cooperate to define therebetween with the outer surface of the tank sections an annular space in which the O-ring 16 is retained.
Referring to FIGS. 3 through 5, the closure band 15 comprises a pair of semicircular segments 41 and 42 joined at one end by a flexible strip hinge 43 suitably welded or otherwise fixed to the adjacent ends of the segments. At their opposite ends, the segments 41 and 42 are connected by a threaded bolt 44. The bolt is assembled through U-shaped elements 45 welded on ends of the segments 41 and 42. Preferably, the band subassembly 15 is formed of corrosion-resistant stainless steel.
As shown most clearly in FIG. 2, the band segments 41, 42 have a generally trapezoidal cross section including an outer wall portion 46 and canted or conical wall portions 47. Short cylindrical flanges or ribs 48 extend axially from the canted wall portions 47 of the segments 41 and 42. The included angle of the canted wall portions 47, for example about 40 degrees, is complementary to the angle formed by the flange skirts 36. The band subassembly 15 is positioned around the tank sections 11 and 12 and associated flanges 13 and 14 by separating the segments 41 and 42 through elastic flexure of the strip 43. The bolt 44 may then be installed and tightened.
The O-ring 16 is formed of relatively soft elastomeric material, for example, approximately 40 durometer, and preferably has a circular cross section. The O-ring is dimensioned such that its inside diameter in its free state is approximately equal to the mean diameter of the beveled surfaces 31 or, in other words, slightly less than the diameter of the outer cylindrical tank surfaces 26 and 27. The various elements of the tank assembly 10 are illustrated approximately to scale. As shown, by way of comparison, the O-ring is relatively large in cross sectional diameter in comparison to the nominal thickness of the tank wall section.
The clamp assembly 15 is tightened to produce a wedge action on the flange skirt portions 36 to draw the flanges 13 and 14, and therefore the tank sections 11 and 12, axially together. The O-ring is axially compressed between the flange skirts 36. This compression causes the O-ring to be distorted into tight sealing engagement with the beveled edges 31 of the tank sections 11 and 12.
FIGS. 8 through 10 illustrate a preferred manner of making the tank sections 11 and 12 of FIGS. 1 and 2. An integral tank 49 is positioned in a work station indicated generally at 50. The work station 50 includes a set of support rollers 51 and 52, rotatably mounted on supports 53. At least one set of rollers 51 is rotatably driven by a gear reducing motor 55 so that, through friction, the rollers cause the tank to rotate about its longitudinal axis. An upper set of rollers 54 spring-biased vertically downwardly maintains the tank 49 in positive engagement with the support rollers 51 and 52.
With particular reference to FIG. 10, the tank 49 is axially located in the work station 50 by a rotary coupling, indicated generally at 57. The rotary coupling 57 includes a threaded extension 58 tightened into the threaded tank port 23 until an adjacent shoulder 59, provided with wrenching flats, tightly abuts the apex, designated 61, of the tank such that there is no axial free movement between the tank and the coupling 57. A cylindrical portion 62 of the coupling extends through a clearance hole 63 in a fixed plate 64. Thrust washers 66 and 67 are assembled on the cylindrical portion 62 and a threaded stud 68 on opposite sides of the plate 64. The washer 67 is retained against the cylindrical portion by a nut 69 tightened on the threaded stud 68. The length of the cylindrical portion 62 of the coupling assembly is dimensioned such that minimal clearance is provided for the plate 64 between the washers 66 and 67 so that substantially no axial relative movement between the coupling assembly 57 and the stationary plate 64 is possible. The tank 49 is thereby restrained against axial movement while it is permitted to rotate about its longitudinal axis. The diametral clearance of the cylindrical portion 62 of the coupling assembly 57 in the hole 63 accommodates any tolerance associated with the diameter and concentricity of the sidewalls of the tank 49.
A rotary cutter 71 is pivotally mounted on an arm 72 for movement relative to the tank 49 in a plane corresponding to the desired transverse plane of separation of the tank into the sections 11 and 12 of FIGS. 1 and 2. A motor 73, also mounted on the arm 72, drives the rotary cutter or tool 71. The spring-loaded upper rollers 54 are supported on the cutter arm 72. As viewed in FIG. 8, the rollers 54 and rotary cutter 71 are in a retracted position, permitting loading of the tank 49 in the work station for connection with the rotary couplings 57.
The tank is caused to rotate about its longitudinal axis through rotation of the drive rollers 51 upon energization of the gear reducing motor 55. The arm 72 is lowered to bring the spring-loaded idler rollers 54 into contact with the tank 49 to hold the tank in positive engagement with the drive rollers 51 and additional idler rollers 52. The rotary cutter is caused to operate at a high rate of rotation by its associated motor 73 when brought into contact with the tank 49. As shown in FIG. 9, the cutter, which may be a unitary body or a stack of appropriately configured cutters, is provided with axially spaced cutting surfaces 77 through 79, which correspond exactly in profile to the shape of the desired grooves 28 and bevel 31. The central surface area 79 of the cutter 71 includes a cut-off portion 80 projecting sufficiently far from the remaining portions of the cutter 71 to completely sever through the wall of the tank 49. The disclosed use of a single cutter 71, with all of its elements 77-80 fixed relative to one another, permits the grooves 28 and beveled surfaces 31 to be formed with close dimensional tolerances with respect to one another. Thus, independent of the dimensional variations in the construction of the tank 49 itself, it will be appreciated that the spacing of the grooves 28, their associated beveled surfaces 31, and the plane of separation therebetween will be uniform from one tank to the next so that the upper section 11 of one tank and the lower section 12 of another tank may be readily mated without dimensional problems.
FIGS. 11 through 13 illustrate apparatus 83 for testing the integrity of the tank sections 11 and 12 as produced by the rotary cutter 71. The apparatus 83 includes a pair of semicircular segments 84 and 85 which are adapted to fit over the circumference of the tank sections 11 and 12. The segments 84 and 85 are joined at one end by a hinge 86. At the opposite end, the segments 84 and 85 are locked together by a latching block 87. The block 87, which is rotatably supported with a manually operated rod 88, is formed with a pair of integral extensions 89. In the position illustrated in FIGS. 11 and 13, the extensions 89 enbrace projecting areas of the segments 84 and 85 to prevent separation of the segments at the radial plane of separation designated 93.
Pinned to the operating rod 88 is a safety latch 96. In the illustrated position of FIGS. 11 and 13, the latch 96 is in registration with a locking pin 97 supported for movement in a direction generally parallel to the axis of rotation of the rod 88 by a housing 98 welded or otherwise fixed to the adjacent ring segment 84. The pin 97 is biased to its illustrated position by a compression spring 99 and is adapted to be driven rightwardly, as viewed in the figures, when a chamber 102 is pressurized to exert a force on a diaphragm 103 to which the pin 97 is secured. At a rightward position (not shown) the pin 97 enters a notch 104 on the safety latch 96, thereby preventing movement of the latching block 87 by operation of the rod 88.
As indicated in FIG. 12, the cross section of the semicircular segments 84 and 85 is adapted to complement the exterior configuration of the tank indicated in phantom. The segments 84 and 85 each include a pair of inwardly extending, circumferential ribs 106 adapted to be received in the circumferential grooves 28 of the tank sections 11 and 12. The flanges or ribs 106 are axially spaced such that by engagement with the abutment surfaces 29 of the grooves 28, they maintain the tank sections at a relative axial spacing 107 substantially equal to that existing in the assembly illustrated in FIG. 2. Each of the segments 84 and 85 includes a circumferentially extending inner recess or groove 111. A circumferentially continuous elastomeric tube 112 is disposed within the recess 111. A fitting 113 extends radially from segment 84 to provide fluid communication to the interior of the tube 112.
Fluid pressurization of the tube 112 through the fitting 113 causes it to expand into tight engagement with the beveled tank surfaces 31, thereby substituting for the function of the O-ring 16. With the plane of separation between the tanks 11 and 12 thereby sealed by the tube 112, the tank sections 11 and 12 may be tested against leakage or other structural faults by immersing the tank under a liquid while it is internally pressurized by introducing pressurized fluid, such as air, through its port 23. In this manner, any leakage paths which might result from manufacturing defects in the tank or from machining operations of the rotary cutter 71 informing the grooves 28 and bevels 31 are revealed by evidence of bubbles rising from the tank sections 11 and 12 through the liquid in which it is immersed. Possible defects which may be discovered are delamination of fibers in the area of the grooves 28 and bevel surfaces 31 or imperfect bevel surfaces 31 which would prevent adequate seating of the tube 112, and therefore the O-ring 16. Where desired, the bevel surfaces 31 may be sealed by a suitable nonporous coating, such as an air-drying acrylic coating, to avoid leakage through these surfaces as a result of the slight porosity characteristic of machined fiber-reinforced plastic surfaces.
The fitting 113 is pressurized with air or any other suitable fluid through a supply line 116. A T-fitting 117 to which the supply line 116 and tube fitting 113 are connected assures that the diaphragm chamber 102 will be pressurized whenever the tube 112 is pressurized. The aforementioned displacement of the pin 97 into interlocking relationship with the slot 104 associated with the latching block 87 protects against inadvertent operation of the control rod 88 while the tube 112 is pressurized, thereby avoiding uncontrolled opening of the segments 84 and 85 upon rotation of the block extensions 89 out of engagement of the segment projections 91 and 92 and overexpansion of the tube 112.
FIG. 7 illustrates a modification of the tank assembly of FIGS. 1 and 2, wherein the interior zones of the tank sections designated 11' and 12' are isolated by a flexible wall 121. In this embodiment, the flexible wall 121 is provided in the form of a rolling diaphragm, itself generally known to those skilled in the art. The diaphragm 121 has the form of a cup and, according to conventional practice, may be fabricated of fiber-reinforced, elastomeric material in order to maintain its shape. An open circumferential edge 126 of the diaphragm 121 is vulcanized or otherwise joined in fluidtight relation to a peripheral seal member 127 of circular cross section and analogous to the O-ring 16 of FIG. 2.
The plane of separation between the tank sections 11' and 12' may be more near the longitudinal center of the tank than that of FIG. 1, or at the center, to allow the diaphragm to move longitudinally through a stroke as long as possible. An intermediate position of the dipharagm 121 is illustrated in phantom in FIG. 7 where the sides of the diaphragm have been caused to roll upon themselves. The circumferential flanges 13 and 14 and closure band 15 have been designated by the same numerals as those of FIGS. 1 and 2, since these components may be substantially the same as the previously described embodiment. Preferably, the circumferential seal member 127 effects a seal on beveled sufaces 31 in the same manner as the O-ring 16, while the various elements are so proportioned that the end faces 19 and 20 have a spacing somewhat greater than the thickness of the diaphragm edge 126 to ensure adequate compression of the seal member by relative axial closing movement of the flanges 13 and 14.
The assembly of FIG. 7 is particularly suited for use where two fluids are to be kept isolated from one another within the tank. A typical application of this structure is an accumulator for domestic water storage systems, where air is maintained at a pressure on one side of the diaphragm 121 while water is disposed on the opposite side. Ordinarily, in such use both tank sections 11' and 12' are provided with individual ports.
In FIG. 6, there is shown another embodiment of the invention. As in the previous embodiments, cylindrical tank sections 131 and 132 are fabricated by transversely severing an integral bag-molded, fiber-reinforced tank such as that described in the aforementioned patents. In this embodiment, however, a pair of substantially identical flanges 133 are bonded to the exterior surfaces of the tank sections 131 and 132. The sidewalls of the tank sections 131 and 132 illustrated in FIG. 6 correspond to those illustrated in the embodiment of FIG. 2, but need not be reinforced by additional wall thickness since the bonding assembly of the flanges 133 avoids the necessity of grooving the side-walls. The tank sections 131,132 may be formed by cutting through a tank with a conventional cut-off tool or other appropriate means.
The flanges 133 preferably are molded as circumferentially continuous rings of fiber-reinforced, plastic material, which may be the same as or similar to the material of the tank sections 131 and 132. The flanges 133 include integral, cylindrical portions 135 and radial skirt portions 136. As seen, a leading surface 137 of the skirt portion 136 is generally conical and analogous to the forward surface of the skirt portion 36 of the metal flanges of FIGS. 1 and 2. The bore, designated 138, of the flanges 133 is slightly tapered outwardly in a forward direction so that its major diameter is immediately adjacent the conical lead surface 137. The minor diameter of each flange 133 is approximately equal to the nominal outside diameter of the tank sections to enable it to be readily assembled over a tank section.
Each flange 133 preferably is bonded or locked to its associated tank sections 131 or 132 by a suitable epoxy or other adhesive. This is ideally accomplished by applying a reactive epoxy mix in a circumferentially continuous band about the exterior of the tank sections in an axial width approximately equal to two-thirds of the length of a flange 133, but spaced slightly away from the end faces designated 141 and 142 of the tank sections 131 and 132 to assure that the outer surfaces of the tank sections 131 and 132 immediately adjacent these end faces do not become coated with bonding material upon installation of the flanges 133. After application of the epoxy bonding agent, a flange 133 is slipped over its associated tank section from the rearward end of the tank forwardly over the epoxy and finally adjacent the end face of the tank. The tapered bore 148 of the flange 133 tends to scoop up any thickness of excess bonding material resulting from an uneven application and ensures that a sufficient amount of the bonding material is distributed circumferentially about the tank section. Upon hardening, the bonding medium, designated 146, cooperates with the tapered bore in the manner of a taper lock to mechanically interlock a flange 133 to its associated tank section 131 or 132, thereby enhancing the adhesive strength of the bonding medium.
An O-ring 151 is disposed between the conical surfaces 137 of the opposed flanges 133. Like the O-ring 16 of the embodiment of FIG. 2, the O-ring 151 is circumferentially continuous about the exterior of the tank sections 131 and 132 and is relatively soft, e.g., 40 durometer. The inside diameter of the O-ring 151 is approximately equal to the outside diameter of the tank sections 131 and 132, desirably with a slight interference in order that the ring be frictionally retained on one of the tank sections 132 when the other section 131 and its flange are removed. As seen in FIG. 6, the lower flange 133 is displaced somewhat further from the end face 142 of its associated tank section 132 in comparison to the spacing of the flange associated with the upper tank section 131 and its associated end face 141. This arrangement permits the O-ring 151 to be provisionally retained on the outer surface of the lower tank section 132 when the upper tank section 131 is removed so that manual assembly of the tank sections in the field is facilitated by reducing the number of elements which must be simultaneously manipulated.
A closure band 153 is constructed in substantially the same manner as the band 15 illustrated in FIGS. 3 through 5, but is somewhat wider in axial length to accommodate the axial thickness of the flange skirt portions 136. As with the formerly described band 15, the band 153 is circumferentially split to permit it to be expanded over the flanges 133 and thereafter pulled tight by a draw bolt, such as the bolt 44 illustrated in FIG. 3, to cause the flanges 133 to be drawn axially together by wedging action of canted sides 156 operating on rearward faces 157 of the flange skirts 136. This drawing together of the flanges 133 causes a direct axial compression of the O-ring 151 to produce tight sealing engagement between the O-ring and forward conical surfaces 137 of the flanges 133, thereby sealing off the interior of the tank sections 131 and 132 from the exterior environment of the tank.
It is not necessary for the O-ring 151 to contact the wall sufaces of the tank sections 131 or 132 to effectively seal the interior of the tank, since the bonding agent 146 effectively eliminates any axial leakage paths between the flanges 133 and outer surfaces of the tank sections. It will also be understood that owing to the geometry of the conical flange surfaces 137, in service the actual contact force between these surfaces and the O-ring 151 will be generally increased in proportion to the pressure within the tank sections 131 and 132, since such pressure acts directly on the O-ring to expand it against these surfaces.
In FIG. 14, there is shown a still further embodiment of the invention. As in the previous embodiments, cylindrical tank sections 231 and 232 are fabricated by transversely severing an integral bag-molded, fiber-reinforced tank such as that described in the aforementioned patents. In this embodiment, however, there is provided a flanged closure band 233 having inwardly facing reverse folds 234 and 235 which are retained in a first pair of circumferential grooves 236 and 237. The grooves are preferably formed during the aforementioned cut-off operation.
The closure band 233 is constructed in substantially the same manner as the band 15 illustrated in FIGS. 3 through 5. The band 233 is circumferentially split to permit it to be expanded and then contracted by a draw bolt to meet the reverse folds 234 and 235 into the grooves 236 and 237.
A pair of O-rings 238 and 239 are respectively received in a second pair of circumferential grooves 240 and 241 to seal the assembly. To aid in forming such a seal, a continuous circumferential band 242 is received within a recess 243 formed in the sections 231 and 232.
To assemble the sections 231 and 232, the O-ring 239 is installed in its groove 241 and the band 242 is then applied to the recess 243 in the section 232 to cover the O-ring. The O-ring 238 is installed in its groove 240 and the top section 231 is then inserted within the projecting portion of the band. The band compresses the O-rings about 20 percent to ensure a tight joint. The closure band is then applied and tightened.
Although for purposes of illustration in the various embodiments herein disclosed, an elongated tank having generally cylindrical sidewalls has been disclosed, it will be understood that certain aspects of the invention may be put to advantage with other tank configurations, such as spherical or nearly spherical assemblies, and that various modifications and rearrangements of parts may be resorted to without departing from the scope of the invention.
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A tank closure assembly adapted to releasably couple tank sections formed by transversely splitting an integral bag-molded fiber-reinforced tank. According to one aspect of the invention, the assembly includes external circumferential flanges secured to the tank sections adjacent their severed faces and in opposed relation to each other. An O-ring seal, disposed externally of the tank sections and between the flanges, is compressed into sealing engagement with surrounding surfaces, by tightening of a circumferential band encircling the flanges, to seal the tank sections at their plane of separation. According to another aspect of the invention, the assembly includes a unitary clamping band having hooked ends which engage grooves adjacent the severed faces of the tank sections and the clamping band retains a pair of O-rings which seal the tank at their plane of separation. A method of machining a tank to simultaneously form the split sections and suitable flanges receiving grooves thereon is disclosed, as well as a method of pressure-testing the machined tank sections prior to assembly of the flanges and O-ring seal.
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CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY
The present application claims the benefit under 35 U.S.C. §119(a) to a Korean patent application filed in the Korean Intellectual Property Office on Mar. 3, 2010 and assigned Serial No. 10-2010-0019074, the entire disclosure of which is hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a sound outputting apparatus in a mobile terminal and a method thereof, and more particularly, to an apparatus for outputting a sound with Hearing Aids Compatibility (HAC) in a mobile terminal, and a method thereof.
BACKGROUND OF THE INVENTION
In recent years, with the rapidly increasing supply of mobile terminals, it has become a modern person's necessity. Since the mobile terminal can provide not only a unique voice call service, but also all types of data transmission service, and various additional services, it may serve as a multimedia communication device. Recently, a mobile terminal with HAC for hearing handicapped persons has been developed.
The mobile terminal with HAC is managed according to an HAC standard. The HAC standard includes items such as intensity, Signal to Noise Ratio (SNR), and Frequency Response. When the mobile terminal satisfies given conditions requiring the foregoing items, the performance thereof can be recognized as a mobile terminal for HAC. In an embodiment, SNR among them is classified into a T-Category grade of T1 to T4 according to sound signal intensity and noise degree. When the mobile terminal has a grade T3 or T4, a performance thereof can be recognized as a mobile terminal for HAC.
To improve SNR, the related art increases a gain of a receiver dedicated amplifier in a modem chip of the mobile terminal. In general, because the receiver dedicated amplifier in the modem chip has a relatively small output, when a gain is extremely increased, signal intensity is increased but the quality of sound is distorted. When the quality of sound is distorted, a hearing handicapped person wearing a hearing aid cannot adequately hear a sound.
SUMMARY OF THE INVENTION
To address the above-discussed deficiencies of the prior art, it is a primary object to provide an apparatus for outputting a sound in a mobile terminal for HAC stably amplifying and outputting a sound without distortion of the sound quality, and a method thereof.
In accordance with an aspect of the present invention, a sound output apparatus includes a modem chip including a first amplifier configured to amplify and transfer an electric signal to a switch. The sound output apparatus also includes the switch configured to selectively connect an output line of the first amplifier to a receiver or a second amplifier. The sound output apparatus also includes the second amplifier connected with the receiver and the switch, and configured to amplify and transfer an electric signal received from the first amplifier to the receiver when the switch connects the output line of the first amplifier to the second amplifier. The sound output apparatus further includes the receiver connected with the switch and the second amplifier, and configured to convert and output an electric signal received from the first amplifier or the second amplifier into a sound.
In accordance with another aspect of the present invention, a sound output method of a sound output apparatus including a switch electrically connecting an output line of a first amplifier to a second amplifier or a receiver is provided. The method includes checking whether a Hearing Aids Compatibility (HAC) mode is set to ‘ON’ or ‘OFF’. The method also includes controlling the switch to connect the output line of the first amplifier to the second amplifier when the HAC mode is set to ‘ON’. The method further includes controlling the first amplifier to amplify and transfer an electric signal to the second amplifier when a sound output command is input. The method further includes controlling the second amplifier to amplify and transfer the electric signal to a receiver. The method also includes controlling the receiver to convert and output the electric signal into a sound.
The present invention may stably transfer a sound to hearing handicapped persons with HAC without distortion of the sound quality. In addition, when determining a T-Category grade of a mobile terminal for HAC, it can acquire a higher grade.
Before undertaking the DETAILED DESCRIPTION OF THE INVENTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, such a device may be implemented in hardware, firmware or software, or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
FIG. 1 illustrates a configuration of a mobile terminal with a sound output apparatus according to an embodiment of the present invention;
FIG. 2 illustrates an audio processing unit and a control unit that are structural elements of a sound output apparatus according to an embodiment of the present invention;
FIG. 3 illustrates a sound output method according to an embodiment of the present invention;
FIG. 4 illustrates a transfer procedure of a sound signal when an HAC mode is set to ‘ON’ in the sound output apparatus according to an embodiment of the present invention; and
FIG. 5 illustrates a transfer procedure of a sound signal when an HAC mode is set to ‘OFF’ in the sound output apparatus according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 through 5 , discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged mobile terminal. Detailed descriptions of well-known functions and structures incorporated herein may be omitted to avoid obscuring the subject matter of the present invention.
The present invention describes a mobile terminal by way of example. However, the present invention is not limited thereto. That is, the present invention may be applicable to all devices outputting a sound. Further, a mobile terminal according to an embodiment of the present invention is a terminal capable of outputting a sound. The mobile terminal may preferably be a mobile communication terminal, a Portable Multimedia Player (PMP), a Personal Digital Assistant (DA), Smart Phone, or MP3 player.
When the mobile terminal is a mobile communication terminal, it may be an International Mobile Telecommunication 2000 (IMT-2000) terminal, Wideband Code Division Multiple Access (WCDMA) terminal, Global System For Mobile Communication/General Packet Radio Service (GSM/GPRS) terminal, or Universal Mobile Telecommunication Service (UMTS) terminal.
As used herein, the term “sound” means an audible sound that a person can hear. The sound is created by vibration of a vibration plate and output by a receiver or a speaker. As used herein, the term “sound signal” means an electric signal converted from the “sound”. The receiver or the speaker receives a sound signal, and converts and outputs the received sound signal into a sound.
FIG. 1 is a block diagram illustrating a configuration of a mobile terminal 100 with a sound output apparatus according to an embodiment of the present invention.
The mobile terminal 100 includes a radio frequency (RF) communication unit 110 , an audio processing unit 120 , a storage unit 130 , an input unit 140 , a display unit 150 , and a control unit 160 .
The RF communication unit performs transmitting and receiving functions of corresponding data for RF communication of the mobile terminal. The RF communication unit 110 may include an RF transmitter (not shown) up-converting a frequency of a transmitted signal and amplifying the signal, and an RF receiver (not shown) low-noise-amplifying a received signal and down-converting the signal. Moreover, the RF communication unit 110 may receive data through an RF channel and output it to the control unit 160 . The RF communication unit 110 may transmit data provided from the control unit 160 through the RF channel.
The audio processing unit 120 may include a CODEC. The CODEC can be configured by a data CODEC processing packet data and an audio CODEC processing an audio signal such as a sound. The audio processing unit 120 converts a digital audio signal into an analog audio signal through the audio CODEC, and outputs the converted analog audio signal through a receiver or a speaker. The audio processing unit converts an analog audio signal provided from a microphone (MIC) into a digital audio signal through the audio CODEC. The audio processing unit 120 constitutes a sound output apparatus of the present invention. Structural elements of the audio processing unit 120 will be explained in detail with reference to FIG. 2 .
The storage unit 130 stores programs and data necessary for an operation of the mobile terminal 100 , and can be divided into a program area and a data area. The storage unit 130 can be configured by a volatile storage medium, a nonvolatile storage medium, or a combination thereof. The volatile storage medium includes a semiconductor memory such as RAM, DRAM, or SRAM. The nonvolatile storage medium may include a hard disk.
The input unit 140 receives user key operation signals for controlling the mobile terminal 100 and transfers them to the control unit 160 .
The input unit 140 can be configured by either a key pad such as 3*4 keyboard or Qwerty keyboard including numeral keys, character keys, and arrow keys or a touch panel. The mobile terminal 100 may include a button key, a jog key, and a wheel key besides the key pad or the touch panel. The input unit 140 generates and transfers input signals executing functions (call function, moving image function, music play function, image display function, or camera photographing function) to the control unit 160 . In the present invention, when a user selects an HAC mode as ‘ON’ or ‘OFF’ using the input unit 140 , the input unit 140 generates and transfers an input signal corresponding to a user selection to the control unit 160 .
The display unit 150 can be configured as Liquid Crystal Display (LCD), Organic Light Emitting Diodes (OLED), or Active Matrix Organic Light Emitting Diodes (AMOLED). The display unit 150 visibly provides menus, input data, function setting information, and various other information of the mobile terminal 100 to a user. The display unit 150 outputs a booting screen, an idle screen, a menu screen, a call screen, and other application screens of the mobile terminal 100 . The display unit 150 according to an embodiment of the present invention may display a menu screen selecting an HAC mode as ‘ON’ or ‘OFF’. The user may view the menu screen using the input unit 140 and set the HAC mode to ‘ON’ or ‘OFF’.
The control unit 160 controls an overall operation of the mobile terminal 100 and signal flow between internal blocks of the mobile terminal 100 . The control unit 160 according to an embodiment of the present invention controls the audio processing unit 120 to output a sound. The control unit 160 includes structural elements configuring the sound output apparatus of the present invention. The structural elements of the control unit 160 will be explained in detail with reference to FIG. 2 .
FIG. 2 is a block diagram illustrating an audio processing unit 120 and a control unit 160 that are structural elements of a sound output apparatus according to an embodiment of the present invention.
The audio processing unit 120 according to an embodiment of the present invention includes a receiver 121 , a switch 122 , and a second amplifier 123 . The control unit 160 includes a modem chip 161 . The modem chip 161 includes a first amplifier 162 . FIG. 2 shows that a receiver 121 , a switch 122 , and a second amplifier 123 are included in a block differing from that of the modem chip 161 . However, the present invention is not limited thereto. The receiver 121 , the switch 122 , the second amplifier 123 , and the modem chip 161 can be configured as one block in the sound output apparatus.
The receiver 121 is a device converting a sound signal that is an electric signal into a sound. When an electric signal with various frequencies is applied to a voice coil included in the receiver 121 , it generates mechanical energy according to electrical intensity and frequency, and generates vibration at a vibration plate attached to the voice coil to generate sound pressure recognized by human's ears. The receiver 121 may be a HAC special receiver with a ‘T-COIL’ or a general receiver. The ‘T-COIL’ is a coil included in the voice coil that amplifies the sound pressure generated by the voice coil. The ‘T-COIL’ according to an embodiment may enclose a wound periphery of a voice coil in a disc shape.
Moreover, the receiver according to an embodiment of the present invention may be a speaker combined receiver. The speaker combined receiver can selectively act as a receiver or a speaker. Further, the receiver 121 may include a headset such as a wired headset or a Bluetooth headset. In this embodiment, the receiver is provided at an area contacting with the human's ear in a headset. When the receiver 121 is configured to be included in the Bluetooth headset, the portable terminal 100 further includes a Bluetooth communication module (not shown). The control unit 160 controls the Bluetooth communication module to transmit a sound signal to the Bluetooth headset. A receiver 121 included in the Bluetooth headset converts a sound signal into a sound, and outputs the sound.
The switch 122 selectively connects a sound signal received from the modem chip 161 to a receiver 121 or a second amplifier 123 . The switch 122 operates under the control of the control unit 160 . When an HAC mode is set to ‘ON’, the switch 122 connects a fourth sound signal line 14 to a first signal line 11 to connect the first amplifier 162 to the second amplifier 123 . When the HAC mode is set to ‘OFF’, the switch 122 connects a second sound signal line 12 to the first signal line 11 to connect the first amplifier 162 to the receiver 121 . An ‘HAC mode’ of the present invention is a mode that outputs a sound suitable for a hearing aid user. A sound in a HAC mode of an ‘ON’ state is amplified and output larger in comparison with that in a HAC mode of an ‘OFF’ state. The user sets the HAC mode to ‘ON’ using a hearing aid, and sets the HAC mode to ‘OFF’ in a general call.
The second amplifier 123 amplifies a sound signal received from the first amplifier 162 . The second amplifier 123 according to an embodiment of the present invention can be configured by an audio amplifier such as a speakerphone amplifier, which may be analog amplifier or a digital amplifier. In one embodiment, the second amplifier 123 is an amplifier that exhibits higher efficiency and lower noise than a first amplifier 162 being a private use of a receiver.
The control unit 160 can be configured in a single chip form constructed by a modem chip 161 . The control unit 160 may be also configured in a multi-chip form constructed by an application processor chip to control the modem chip 161 and an application. The modem chip 161 according to an embodiment of the present invention includes a first amplifier 162 . The first amplifier 162 according to the present invention is a receiver dedicated amplifier. In one embodiment, the first amplifier 162 exhibits smaller intensity than that of a maximum output of the second amplifier 123 .
Referring to FIG. 2 , the receiver 121 connects with the switch 122 through the second sound signal line 12 . The receiver 121 connects with the second amplifier 123 through the third sound signal line 13 . The receiver 121 receives a sound signal from the switch 122 or the second amplifier 123 , and converts and outputs the received sound signal into a sound.
The switch 122 connects with the first amplifier 162 through the first sound signal line 11 . The switch 122 connects with the receiver 121 through the second sound signal line 12 . The switch 122 connects with the second amplifier 123 through the fourth sound signal line 14 . Further, the switch 122 connects with the modem chip 161 through a switch control signal line 15 . The switch 122 receives a control signal from the modem chip 161 through the switch control signal line 15 . The switch 122 selectively connects the first sound signal line 11 to the second sound signal line 12 or the fourth sound signal line 14 according to the received control signal. When the switch 122 connects the first sound signal line 11 to the second sound signal line 12 , the first amplifier 162 connects with the receiver 121 and transfers an amplified sound signal by the first amplifier 162 to the receiver 121 . When the switch 122 connects the first sound signal line 11 with the fourth sound signal line 14 , the first amplifier 162 connects with the second amplifier 123 , and controls the second amplifier 123 to again amplify the sound signal amplified by the first amplifier 162 , and transfers the amplified sound signal to the receiver 121 .
The second amplifier 123 connects with the receiver 121 through the third sound signal line 13 , and connects with the switch 122 through the fourth sound signal line 14 . Further, the second amplifier 123 connects with the modem chip 161 through a second amplifier control signal line 16 . The second amplifier 123 operates under the control of the modem chip 161 . When the switch 122 connects the first sound signal line 11 with the fourth sound signal line 14 , the second amplifier 123 connects with the first amplifier 162 . When the second amplifier 123 receives a sound signal from the switch 122 , it amplifies the sound signal and transfers the amplified sound signal to the receiver 121 through the third sound signal line 13 .
The first amplifier 162 connects with the switch 122 through the first sound signal line 11 , and operates under the control of the modem chip 161 . The first amplifier 162 amplifies a sound signal under the control of the modem chip 161 and transfers the amplified sound signal to the switch 122 .
The modem chip 161 connects with the switch 122 through a switch control signal line 15 , and controls the switch 122 to connect a first sound signal line 11 to one of the second sound signal line 12 or the fourth sound signal line 14 . Moreover, the modem chip 161 connects with the second amplifier 123 through the second amplifier control signal line 16 , and controls the second amplifier 123 to amplify a sound signal and to transfer the amplified sound signal to the receiver 121 . In this situation, the modem chip 161 controls the second amplifier 123 to amplify the sound signal such that a sound of suitable intensity is transferred to a hearing aid.
The receiver 121 , the switch 122 , the second amplifier 123 , the modem chip 161 , the first amplifier 121 , the first to fourth sound signal lines 11 , 12 , 13 , 14 , the switch control signal line 15 , and the second amplifier control signal line 16 may be structural elements configuring a sound output apparatus of the present invention.
Furthermore, the mobile terminal 100 may include a configuration in which a switch 122 and the second amplifier 123 are included in the control unit 160 .
The foregoing embodiment has described a configuration of a sound output apparatus of a mobile terminal 100 according to an embodiment of the present invention. Hereinafter, a sound output method according to an embodiment of the present invention will be explained.
FIG. 3 is a flowchart illustrating a sound output method according to an embodiment of the present invention.
In FIG. 3 , it is assumed that the control unit 160 is configured by a modem chip 161 . It is assumed that a menu setting an HAC mode to ‘ON’ or ‘OFF’ is included in the mobile terminal 100 . The HAC mode can be previously set to ‘ON’ or ‘OFF’. When the HAC mode is set to ‘ON’, the switch 122 maintains a connected state between the first sound signal line 11 and the second sound signal line 12 . When the HAC mode is set to ‘OFF’, the switch 122 maintains a connected state between the first sound signal line 11 and the fourth sound signal line 14 .
The modem chip 161 controls an input unit 141 to check whether an HAC mode is selected as ‘ON’ or ‘OFF’ by a user (block 301 ). In detail, the modem chip 161 may control a display unit 150 to display an HAC mode setting menu screen. The HAC mode setting menu screen may include an input window setting an HAC mode to ‘ON’ or ‘OFF’. A user may identify the HAC mode setting menu screen displayed on a display unit 150 and set an HAC mode to ‘ON’ or ‘OFF’ using the input unit 140 .
When the user selects an HAC mode as ‘ON’, the modem chip 161 controls the switch 122 to connect the first sound signal line 11 to a second amplifier 123 (block 302 ). In detail, the modem chip 161 transfers a control signal including a command connecting the fourth sound signal line 14 to the first sound signal line 11 through the switch control signal line 15 . The switch 122 receives a control signal from the modem chip 161 . When the first sound signal line 11 and the second sound signal line 12 are connected to each other, the switch 122 blocks the connection between the first sound signal line 11 and the sound signal line 12 , and connects the first sound signal line 11 to the fourth sound signal line 14 . If the first sound signal line 11 is connected to the fourth sound signal line 14 , the modem chip 161 maintains a connected state of the switch 122 .
The modem chip 161 controls the input unit 140 or the RF communication unit 110 to check whether a sound output command is input (block 303 ). In an embodiment of the present invention, when the modem chip 161 receives an RF signal including another call user's sound through the RF communication unit 110 , it may determine that the sound output command is input.
The modem chip 161 amplifies a sound signal by the first amplifier 162 and transfers the amplified sound signal to the second amplifier 123 through the first sound signal line 11 and the fourth sound signal line 14 (block 304 ). The modem chip 161 controls the second amplifier 123 to amplify a received sound signal (block 305 ). The modem chip 161 transfers a control signal to the second amplifier 123 through the second amplifier control signal line 16 . When the second amplifier 123 receives the control signal, it amplifies a sound signal according to the received control signal. The modem chip 161 controls the second amplifier 123 to transfer the amplified sound signal to the receiver 121 (block 306 ). Next, the modem chip 161 controls the receiver 121 to convert and output the sound signal into a sound (block 307 ).
FIG. 4 is a block diagram illustrating a transfer procedure of a sound signal when a HAC mode is set to ‘ON’ in the sound output apparatus according to an embodiment of the present invention.
In FIG. 4 , the modem chip 161 transfers a switch control signal to the switch 122 through the switch control signal line 150 , thereby controlling the switch 122 to connect the first sound signal line 11 to the fourth sound signal line 14 . The first amplifier 162 transfers a sound signal to the switch 122 through a first sound signal line 11 , and the switch 122 transfers a sound signal to the second amplifier 123 through the fourth sound signal line 14 . The modem chip 161 transfers a second amplifier control signal to the second amplifier 123 through a second amplifier control signal line 16 . The second amplifier 123 amplifies a sound signal according to a control signal, and transfers the amplified sound signal to the receiver 121 through a third sound signal line 13 .
When the HAC mode is set to ‘ON’, the sound signal is amplified once again by a second amplifier 123 exhibiting high efficiency and low noise. Accordingly, a hearing aid user can hear a stable sound with non-distorted sound equality.
When a user selects the HAC mode as ‘OFF’ in block 301 , the modem chip 161 controls a switch 122 to connect a receiver 121 to the first sound signal line 11 (block 308 ). In detail, the modem chip 161 transfers a control signal including a command connecting the first sound signal line 11 to the second sound signal line 12 to the switch 122 . When the first sound signal line 11 is previously connected to the second signal line 12 , the modem chip 161 maintains a connection state of the switch 122 . If the first sound signal line 11 is connected to the fourth sound signal line 14 , the modem chip 161 controls the switch 122 to connect the first sound signal line 11 to the second sound signal line 12 .
When the modem chip 161 determines that the sound output command is input in block 309 , it controls the first amplifier 162 to amplify the sound signal and transfer the amplified sound signal to the receiver 121 through the first sound signal line 11 and the second sound signal line 12 (block 310 ). The sound signal transferred to the receiver 121 is a sound signal amplified by the first amplifier 162 . Subsequently, the modem chip 161 controls the receiver 121 to convert and output the sound signal into a sound (block 311 ).
FIG. 5 is a block diagram illustrating a transfer procedure of a sound signal when a HAC mode is set to ‘OFF’ in the sound output apparatus according to an embodiment of the present invention.
Referring to FIG. 5 , the modem chip 161 transfers a switch control signal to the switch 122 through the switch control signal line 150 to control the switch 122 to connect the first sound signal line 11 to the second sound signal line 12 . Further, the first amplifier 162 transfers a sound signal to the switch through the first sound signal line 11 , and the switch 122 transfers the sound signal to the receiver 121 through the second sound signal line 12 .
A general user sets an HAC mode to ‘OFF’ using the mobile terminal 100 . In this situation, an SNR is not required to conform to an HAC standard, and it is sufficient that the sound signal is amplified by the first amplifier 162 . A general user as well as a hearing aid user can use the mobile terminal 100 by setting the HAC mode to ‘OFF’.
Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims.
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An apparatus and method for outputting a sound with Hearing Aids Compatibility (HAC) in a mobile terminal. The sound output apparatus includes a modem chip including a first amplifier amplifying and transferring an electric signal to a switch, a switch that selectively connects an output line of the first amplifier to a receiver or a second amplifier, a second amplifier connected with the receiver and the switch and that amplifies and transfers an electric signal received from the first amplifier to the receiver when the switch connects the output line of the first amplifier to the second amplifier, and a receiver connected with the switch and the second amplifier and that converts and outputs an electric signal received from the first amplifier or the second amplifier into a sound. This allows for the stable transfer of a sound to hearing handicapped persons with HAC without distortion of the sound quality.
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BACKGROUND OF THE INVENTION
This invention relates to improvements in the suspension system for a vehicle, and is specifically related to controlling the disposition of the vehicle body relative to the vehicle wheels when the vehicle is subject to load distribution changes.
In recent times there has been a trend towards resilient sprung suspension systems incorporating variable damping and spring rates in an attempt to improve vehicle stability and reduce generally vertical movement of the vehicle body relative to the surface being traversed. Some more advanced suspension systems, commonly referred to as "active" and "semi-active" suspensions, incorporate a number of electronic sensors which monitor information, such as vertical wheel travel and body roll, as well as speed, acceleration, steering and braking commands. This and other data is processed by a computer which instructs hydraulic or pneumatic actuators to override the normal function of resilient springs in order to interpret, compensate and adjust the suspensions performance to suit speed, terrain and other factors in order to maintain a level ride and controlled distribution of weight to all wheels. These suspension systems require an external intelligent back-up system, and call for a substantial input of external energy, drawn from the vehicle engine, to operate actuators that affect the adjustment to the suspension system.
A range of constructions of "active" and "semi-active" suspensions for vehicles have been proposed including systems operating on the basis of compression and/or displacement of fluids, such systems currently in use incorporate a pump to maintain the working fluid at the required pressure and to effect high speed fluid distribution, and sophisticated control systems to regulate the operation of the suspension system in accordance with sensed road and/or vehicle operating conditions. These known systems incorporating pumps and electronic control systems, that are both required to operate substantially continuous while the vehicle is in operation, and are comparatively expensive to construct and maintain, and require substantial energy input in operation. As a result, these systems have limited acceptability in the vehicle industry.
There is disclosed in International Patent Application No. WO93/01948 a vehicle having a load support body, and a pair of front ground engaging wheels and a pair of rear ground engaging wheels connected to the body to support same, and wherein each wheel is displaceable relative to the body in a generally vertical direction. Interconnected between each wheel and the body is a fluid ram including upper and lower fluid filled chambers that vary in volume in response to vertical movement between the respective wheels and the body. In that suspension system a front wheel ram and the diagonally opposite rear wheel ram have the upper chamber of the front ram interconnected with the lower chamber of the rear ram and the lower chamber of the front ram interconnected to the upper chamber of the rear ram. Similarly the respective chambers of the other front ram and rear ram are likewise interconnected. There is thus provided two individual fluid circuits, each comprising a front ram and a diagonally opposite rear ram. Each of the conduits interconnecting the respective upper and lower chambers has a conventional pressure accumulator in communication therewith. The two circuits are interconnected to a pressure balance device arranged to maintain equip-pressure in the two circuits as is described in detail in the previously referred to International Patent Application No. WO93/01948.
As most vehicles are non-symmetrically loaded for a large portion of the operating time thereof such that loads carried are located so the rear wheels carry more weight than the front wheels, or the load is closer to one side of the vehicle than the other, thus causing the vehicle body to tilt toward the heavier side or end.
SUMMARY OF THE INVENTION
It is the object of this invention to provide a vehicle suspension system which determines changes in the vehicular height and inclination and adjusts the fluid in appropriate circuits to establish the optimum relative heights, while also providing the optimum load distribution to the wheels.
With this object in view, there is provided a vehicle suspension system comprising a vehicle body, a plurality of wheels arranged in lateral and longitudinal spaced relation to support the vehicle body, individual fluid ram means operably connected between each wheel and the vehicle body to provide support for the body, each fluid ram means comprising a double acting ram having an upper and lower hydraulic chamber, conduit means individually communicating the upper chamber of the respective rams with the lower chamber of the respective diagonally opposite ram to comprise a fluid circuit, a fluid reservoir to receive fluid from the fluid circuit, a fluid pump to deliver fluid to the fluid circuit as required, control means operable to provide communication of each fluid circuit selectively with the pump or reservoir for respective supply of fluid to or reception of fluid from the connected fluid circuit to control the fluid volume in the fluid circuits, and actuator means operable in response to the disposition of a respective wheel relative to the vehicle body to effect actuation of the control means to connect the fluid circuit of that wheel to the pump or reservoir as required so that in operation the collective positional relation of all the wheels defines the height and attitude of the vehicle.
Conveniently, the actuator means (and the control means) is interconnected between the wheel and the body to respond to the relative vertical disposition therebetween to open or close said body attitude control means. A further control valve is also provided said attitude control means associated with the individual wheels to exercise overall control of the fluid flow from the pump and to the reservoir respectively. The further control valve is responsive to imbalance within set limits in the pressure in the respectve circuits interconnecting the two pairs of diagonally opposite wheels. Thus, fluid is only permitted to flow from the pump and/or to the reservoir when the imbalance between the respective circuits is within the set limit. This construction enables the control means to level the vehicle in response to load changes provided the articulation of the wheels is within set limits.
The invention will be more readily understood from the following description of one practical arrangement of the suspension system as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of the suspension system with the vehicle on level ground with the vehicle body also level,
FIG. 2 is similar to FIG. 1 but the front rams are fully extended and the rear fully retracted.
FIG. 3 shows the rams in the reverse disposition to that shown in FIG. 2.
FIG. 4 shows in more detail the control mechanisms as shown in FIGS. 1 to 3.
DETAILED DESCRIPTION
The drawing showing the suspension in different working dispositions have the same reference numerals for the same components in each drawing.
The chassis or body 13 of the vehicle has connected thereto. Linkages which can be in the form of known components commonly referred to as leading arms, trailing arms, radius rods, wishbones, or struts, which locate the wheels relative to the vehicular chassis 13 and are identified as 9, 10, 11 and 12. Strut 9 locates wheel unit 5 with reference to chassis 13, strut 10 locates wheel unit 6 to the chassis 13, strut 11, interconnects, wheel unit 7 to the chassis 13, while strut 12 interconnects wheel unit 8 and chassis 13. The struts are normally mounted at each end by way of rubber bushings or socket and ball couplings which provide flexible omnidirectional couplings.
Each of the hydraulic rams, 1, 2, 3 and 4 is of the double acting variable length construction and having variable volume upper and lower chambers. The upper chambers are all `a` while the lower chambers are marked `b` so that 1a for example refers to the upper chamber of the front left ram 2.
Each ram is hydraulically connected to the diagonally opposite ram by way of two connecting conduits or pipes so that the upper chamber 1a of the front left wheel ram 1 is directly in communication with the back right lower chamber 3b, while lower chamber 1b is connected to upper chamber 3a. Similarly the chambers of the front right ram chambers 2a and 2b are connected to rear left ram chambers 4b and 4a respectively. The interconnecting conduits are numbered 14 between 1a-3b, 15 between 1b and 3a, while the diagonally opposite pair of pipes are numbered 16 and 17 which interconnect 2a-4b, and 2b-4a respectively.
These conduits are normally constructed of reinforced rubber or steel and usually measure between 1/4" to 1" in bore to provide relatively unrestricted communication between the ram chambers and accumulators and between diagonally opposite rams. The sizing of these tubes is important and should be selected in conjunction with optional restrictor valves set into the conduits to fine tune the level of communication between diagonally opposite rams so that maximum communication occurs between the rams and their nearest associated accumulator for dynamic high velocity low amplitude input absorption while also providing sufficient restriction/friction in the conduits to ensure the high frequency inputs are not primarily transferred to the accumulators associated with the hydraulic circuits of other wheels. The portion of the connecting conduits between the rams and their nearest accumulators should therefore be of a larger bore than the conduits between the accumulators of one wheel and the accumulators of the other diagonally opposite wheel (and the branch lines to the load distribution unit referred to hereinafter). These need only to be large enough to permit fluid flow of slower and larger wheel travel movements associated with axle articulation and cornering forces.
With reference to FIG. 1, four accumulators or gas springs 19, 20, 21, 22 are normally provided and are in direct communication with the rams 1, 2, 3 and 4 respectively or via the nearest portions of the communicating conduits 14, 15, 16 and 17 respectively. Additional optionally and usually smaller accumulators numbered 23, 24, 25 and 26 are also similarly associated with rams 1, 2, 3 and 4 in the same respective sequence.
A hydraulic tank or reservoir 27 is connected via conduit 28, to hydraulic pump 29 to provide fluid to the pump. This may be an electrically driven pump or a pump driven by a vehicle engine such as by the fan belt either by itself or in parallel with the vehicle's power steering pump. Conduit 30 interconnects the pump 29 to a spool valve 31 and at a convenient location between the pump 29 and the spool valve 31, an accumulator 32 is normally located to provide a pressurised storage of fluid to be used on demand. The spool valve 31 also communicates the conduit 43 from the reservoir 27 to the conduit 42.
The spool valve 31 connects with two conduits 33 and 42 as shown and provides a switching means to vary and close off the flow through the two conduits 33 and 42. Conduit 33 is a continuation of conduit 30 and therefore conducts the fluid once it has passed through valve 31 when it is in the open position. Conduit 33 subdivides into four smaller tributaries 33a, 33b, 33c, 33d which conduct pressurised fluid to four additional spool valves numbered 34, 35, 36, 37 which are associated one with each wheel struts 9, 10, 11 and 12 respectively.
Spool valve 34, is featured by way of example in FIG. 4, and will be described in more detail in context therewith. Single conduits 38, 39, 40 and 41 interconnects each of the spool valves 34, 35, 36, 37 respectively with main conduit 14, 16, 15, 17 also respectively.
It should be noted that all conduits may be joined to any appropriate part of the associated fluid circuits and are only drawn in the actual positions shown in the figures for convenience and clarity. Moreover, hydraulic manifolds may be centrally located so that these functionally interconnect the various parts of the circuits without there being a requirement to route the conduits substantially all around the vehicle. Fluid supply and return conduits such as conduits 30, 33 and 42 are normally made of small bore steel pipe similar to that used in vehicle brake systems.
Fluid which is to be returned to the central tank 27 form the main circuits 14, 15, 16, 17 is conducted to spool valves 34, 35, 36, 37 via common conduits 38, 39, 40, 41 and from said spool valves through return conduits 42a, 42b, 42c, 42d respectively which may conveniently be joined to form one simple pipe 42 as shown. Conduit 42 is interrupted by spool valve 31 and when this is in the open position fluid may be returned via the tube 43 leading back to the reservoir 27.
The central load distribution unit 18 is mounted to the vehicles body or chassis in any convenient manner as is the spool valve 31 and also as is the termination of mechanical linkage 49 between these two components as will be seen in greater detail in FIG. 4.
The load equalisation unit 18 has four internal chambers of variable volume marked 18a, 18b, 18c, 18d and are hydraulically connected with respective main conduits so that chamber 18a is in communication with the main conduit 14 by way of branch line 14a, while chamber 18b communicates with main conduit 17 via branch line 17b, and chamber 18c communicates with main conduit 15 via branch line 17b, and chamber 18c communicates with main conduit 15 via conduit 15c, and chamber 18d communicates with conduit 16 via branch line 16d. The function and operation of the load distribution unit 18 is described in further detail hereinafter and in International Patent Application No. WO93/01948 previously referred to herein.
The branch line 14a to 16d may generally be of similar bore size to the main hydraulic conduits to which they connect. In practice the branch lines may often be omitted in entirely as the main conduits can be arranged so as to run directly past the load equalisation unit so that a single hydraulic fitting can be used to functionally joins each of the main tubes to each of the respective equalisation chambers.
Located at any point in the vehicle there may be provided, additionally and optionally, an extra spring component (of any known construction) which is acted upon by two (or more) independent circuits to soften the ride of those two circuits with reference to those specific circuits only. Accordingly, in the drawings a unit 44 is shown interconnected between conduits 17 and 15 near rams 4 and 3 respectively to provide supplementary resilience towards the rear of the vehicle specifically in the pitch and squat longitudinal axis of the vehicle. Similar units to 44 may alternatively or additionally be interposed between conduits 14 and 16 to provide extra compliance of the front of the vehicle in the same axis of required or such units may be combined in series to function collectively to stiffen roll response.
Components 47a, 47b, 47c and 47d represent valves or restrictors which can variably restrict and/or stop the flow of fluid along the associated conduits. These valves may comprise of spool or poppet valves with electrical solenoid actuation which respond to commands from one or more sensors such as an accelerometer and throttle movement or position sensor, or the valves may be actuated via a hydraulic pressure actuator which responds to relative varying pressure gradients or mechanical means which respond to simple inertial resistance of weight in one or more planes.
FUNCTIONAL SEQUENCE OF EVENTS
It is assumed that the functions of the chassis 13, the radius rods 9, 10, 11, 12 and the interconnecting bushes are as has previously been discussed. Similarly the components such as the hydraulic rams 1, 2, 3, 4, the conduits 14, 15, 16 and 17, the pump 29, and the tank 43, and all other items described in the Patent Applications previously referred to do not require further description with regard to their functions in the contexts shown.
FIG. 1 therefore illustrates a vehicle which is stationary and on a flat plane surface. It was described in the previous Patent Applications that the vehicles fitted with the type of hydraulic suspension shown were optionally able to be levelled, tilted, raised and lowered. In FIG. 1 therefore, the hydraulic rams are shown in their mid stoke position indicating the vehicle is set up at its normal driving height and the vehicle is on a flat or plane surface. When the rams are in the mid stroke position there is as much potential wheel travel in the upwards direction as there is in the downward direction therefore axle articulation is maximised.
FIG. 2, illustrates a vehicle in which the front rams 1 and 2 are fully extended so that the front of the vehicle is said to be at maximum height while the rear of the vehicle is set at the minimum height because the rams 3 and 4 are fully contracted. It can also be assumed from this diagram that the vehicle is on a flat plane for the same reasons as sighted above.
FIG. 3, shows a vehicle in which the front left and rear right rams 1 and 3 are fully retracted while the front right and rear left rams 2 and 4 are fully extended. It can be deduced from this FIG. 3 therefore that the vehicle is not on a flat plane surface and that the front left wheel 1 and the rear right wheel 3 are raised relative to the diagonally opposite wheels 2 and 4 due to undulations in the terrain surface as opposed to a voluntary tilting as in FIG. 2. The situation shown in FIG. 3 is commonly referred to as axle articulation.
FIG. 4 is an enlarged detail drawing of portion of the suspension levelling and control apparatus as shown in the previous drawings. The conduit 30 shown in this drawing refers to the same conduit shown in FIGS. 1, 2 and 3 being the connecting pipe taking fluid from the pump 29 (and accumulator 32) to the spool valve 31.
Similarly conduit 43 corresponds with the same conduit in the other drawings and this conducts fluid back from the spool valve 31 to the tank 27. The spool valve 31 is normally conveniently mounted on the vehicle body at 48a and 48b, as is the load distribution unit 18 at 48c.
Within the spool valve 31 there are two channels 31a and 31b (or grooves, holes or passages) which permit fluid to flow from the conduits from 30, 43 through the spool valve 31 into the corresponding conduits 33, 42. The spool valve 31 can also vary fluid flowthrough and can close off both channels 31a and 31b simultaneously. At one end of the spool valve there is optionally a spring 31c that assists in return of the spool valve to the central stroke position. This spring is not necessary if the spool valve is mechanically connected to the rod 50.
The mechanism which causes the spool valve to move is the load distribution unit 18. In this particular embodiment the load distribution unit 18 is connected to the spool valve 31 by way of two jointed arms 49a, 49d which reduce the degree of movement transferred to the spool valve 31 which therefore can be manufactured in a conveniently smaller size. It is equally feasible to mount the spool valve 31 directly onto the end of the rod 50 of the load distribution unit 18. In FIG. 4, the rod 50 of the load distribution unit and the spool valve 31 are both represented in their central positions and it should be understood that they move correspondingly.
In the aforementioned prior Patent Application the function of the load distribution unit 18 was described in some detail and will not be described again to the same degree of detail here except to say that when the vehicle happens to be on an uneven surface, (as described above with reference to FIG. 3, when the rams 1 and 3 become foreshortened) the introduced volume of the rods into the cylinders, causes a corresponding amount of fluid to be displaced into the chambers 18a and 18c of the load distribution unit 18 thereby causing the pistons 50a and 50b which are joined to rod 50 to be displaced downward as seen in FIG. 4 in the load distribution unit. This in turn causes the spool valve mechanism 31 to be similarly moved down thereby effectively closing both the channels 31a and 31b in the conduits between the pump and tank and each of the valves 34, 35, 36, 37.
Spool valves 34, 35, 36, 37 shown in FIGS. 1, 2, 3 are respectively conveniently positioned between each wheel units and the chassis so that as the wheels travel up and down with reference to the chassis the wheel location the valves 34, 35, 36 and 37 are caused to be extended and contracted accordingly. In FIG. 4 only one such spool valve 34 is represented. It is to be understood that the other wheel locating valves associated with the other wheels are in communication with conduit branch lines 33b, 33c, 33d on the delivery circuit 33, and by conduits 42b, 42c, 42d to the return circuits 42 each connected to the spool valve 31.
The housing of the valve 34 is connected at the end 51a to the vehicle chassis 13 and at the other end 51b to the suspension strut 9 by suitable pivot connections.
The spool valves, 34, are similar to the spool valve 31 in construction although in this instance there is normally only one elongated groove or hole or passage 34a in the spool valve piston 34b.
When a load is removed from the vehicle this typically allows the gas in the gas springs or accumulators 19, 20 21, 23 into the rams 1, 2, 3 4 causes the rams to extend so that the vehicle chassis raises. If the vehicle happens to be on flat ground when the weight is uniformly removed the relative pressures of the four circuits 14, 15, 16, 17 will remain constant relative to each other and the pistons 50a and 50b in the load distribution unit 18 will not be moved. Furthermore if the weight is removed or added equidistantly between any pair of wheels, asymmetrically with respect to one of the major axes, then the rod 50, part of the load distribution unit 18, will remain stationary. If a weight is applied or removed asymmetrically with respect to both major axes the rod 50 will be caused to move to effect a redistribution of weight onto all wheels. This functioning is more fully described in the previously referred to prior patent application and hereinafter.
As represented in FIG. 4, the vehicle is in a too high position as indicated by extended condition of the ram 1 and the wheel location valve 34 which has become extended. The extension of the spool valve 34 therefore draws the valves piston 34b down which opens the channel 34a to permit fluid to be expelled from the wheel ram 1. It should be noted that the weight of the vehicle is on the two chambers of the wheel cylinder-rams and if the wheel valve 34 is opened and the central spool valve 31 also happens to be open (because no axle articulation is taking place) then the fluid under pressure will be forced through both these valves in sequence and then into the unpressurised storage tank 27, and the vehicle will thus be lowered. If the rod 50 of the load distribution unit 18 is not centrally located (because an axle articulation is taking place) then the spool valve 31 will be in the closed position and this will prevent the passage of fluid from the wheel cylinder I to the tank 27 in spite of the wheel location valve 34 being open. This prevents the unnecessary draining of the fluid out of the wheel ram 1, which would otherwise result when axle articulation occurs such as when the front and diagonally opposite rear wheels are both in holes for example.
If axle articulation occurred in a vehicle where the central spool valve 31 was not provided there would be no provision for distinguishing between the wheel being located in the correct position through axle articulation occurring or incorrectly positioned resulting from weight being removed from the vehicle.
The combination of the two valves in sequence therefore defines:
a. when it is appropriate to allow the flow of fluid from the wheel ram, to the tank 27 or
b. when it is appropriate to permit fluid to flow from the pump to the wheel ram or
c. when it is appropriate to prevent the flow of fluid in any direction.
These concepts may further be explained as follows:
If for example the ram 1 is too contracted, this may be the result of a load having been applied onto the vehicle or that there is a temporary axle articulation occurring. In the case of axle articulation occurring it would be inappropriate to deliver extra fluid from the pump to the common circuits of associated rams 1, 3 which are perceived to be too short, as the vehicle would then become gradually raised up with respect to diagonally opposite wheels 1, 3 at the expense of lifting the other pair of diagonally opposed wheel 2, 4 off the ground. It should be remembered that during the axle articulation motion taking place fluid is temporarily delivered into two chambers of the load distribution unit 18 and removed from the other pair of chambers, and when the wheels return to the flat ground position the fluid is immediately returned to the rams.
If on the other hand the rams are "perceived" by the valves 34, 35, 36, 37 to be too contracted and this has actually occurred because a load has been symmetrically applied onto the chassis then the spool valves 34, 35, 36, 37 and the spool valve 31 would all be in the `open` position thereby permitting fluid to be introduced from the pump into the appropriate circuits without the fluid simultaneously escaping back to the tank.
The construction of the spool valves 34, 35, 36, 37 are such they permit a long stroke action of the spool valve so that most of the time the valve is open either between the wheel cylinder and the tank as seen in FIG. 4 or open between the wheel cylinder and the pump. An optional central neutral overlap zone is normally provided which effectively closes off both conduits when the wheel ram is just at the correct extension position, in which event no fluid introduction or extraction is required.
It should be noted that while the levelling system being disclosed describes a slow acting system commonly referred to as a passive system the same principles can be applied to fast acting systems known as "active suspension systems" which effect wheel position moves and height adjustments with major fluid motions to and from central accumulators, and a high output, engine driven hydraulic pump in response to many electronic sensors interpreting the road surface and other conditions at high speed.
When the system disclosed herein is applied to fast acting systems, such as the active systems, the central load distribution unit may be reduced in size as it is not required to act as a storage receptacle of fluid during wheel articulation motions as the fluid is primarily pumped directly to and from the tank and is not transferred to other locations within the same circuit. When the present system is used as an active suspension systems the load distribution unit 18 need only be large enough in size to sense the relative pressures of the two pairs of diagonally opposite wheel valves and to cause the movement in the spool valve 31 which in combination with the location of the wheel valves 34 to 37 permit the intelligent introduction or removal from the appropriate circuits of fluid, even at high speed.
In conventional active suspension systems weight distribution adjustments are not normally made as a result of axle articulation motions and relative motions of diagonally opposite wheels, but are rather calculated individually on the basis of the position of each individual wheel with reference to the position of the chassis and road. The advantage of using the present system in a more active suspension context is that it is sometimes advantageous to not permit an interaction of wheels as in the slow passive system.
In the previous proposal it has been assumed that the pump is switched on when corrections to the height or and voluntary tilt/trim attitude changes need to be made. This therefore requires that the vehicle is given a wide spectrum of what has to be considered an acceptable height and trim inclination for most of the time. The prior disclosed height adjustment system therefore initiates gross changes which occur periodically and which are sometimes noticeable or disturbing to the occupants of the vehicle. The slow acting height control system now disclosed on the other hand normally operates continuously and makes the assumption that the vehicle is rarely at the correct height and inclination and therefore the control system continually makes very minor and very slow adjustments which are too slow to have any real direct effect on individual fast wheel travel motions but collectively influence the average height and trim of the vehicle if the vehicles height or attitude changes from the chosen position.
Accordingly, in FIG. 4, the central load distribution unit 18 may be optionally varied in construction from the previously disclosed prior art in that the piston rod assembly 50 is maintained in a central position on average by allowing some slow leakage between chambers if the unit 50 becomes decentralised through leakages or malfunctions else where in the system. A typical recentralisation mechanism is shown in FIG. 4, will now be described.
The cylindrical tube of the load distribution unit 18 is provided with a fixed central wall numbered 52a dividing the cylinder into two fixed size chambers. Coaxially located within the cylinder and protruding through both end walls 52b, 52c and the central dividing wall 52a of the cylinder is a rod 50 bearing two pistons 50a, 50b permanently fixed to the rod 50 so that one piston is attached to the common rod within each main chamber, thereby subdividing the two main chambers into four smaller chambers comprising of two pairs of reciprocal volume chambers as shown at 18a, 18b, 18c, 18d.
Within any two chambers which are reciprocal in functional direction there are located two springs numbered 56a, 56b which urge the piston rod assembly to take up a mean central position so that each of the four chambers contains a similar volume of fluid if/when fluid is leaked from one chamber to the other. One such way of providing some leakage between chambers at the appropriate times is shown in the diagram in which the pistons 50a, 50b are provided with one or more small apertures which remain open at all times except for when the pistons are substantially located in the central position.
In FIG. 4, the pistons 50a, 50b are provided with two apertures or cylindrical holes through the pistons and all the holes may be numbered 53. Loosely fitting within each of the holes 53 there is slidably and optionally located a pin 55 with flange or head section 55a under which there is an `0` ring which seals fluid into the chambers when the undersurface of the pin head is tightly located against the surface of the associated piston. The pins protrude through the piston and on the opposite side of the piston to the flanged head, the pins are provided with a further flange 55b which holds a spring 55c in compression between the flange 55b and the piston surface, as drawn. This spring serves to hold the piston heads `0` ring tightly in place against the pistons surface to prevent leakage around the pin and through the oversized hole into the other chamber on the other side of the piston. The pins 55 are elongated so as to make contact with the cylinder end walls when the piston is pushed to the end wall the pin makes contact with the chambers fixed end wall. This permits sufficient slow seepage to enable the main springs 54 to relocate the piston and rod assembly 50 over a period of time so that temporary oscillations do not otherwise effect the performance and overall position of the load distribution unit. This centralisation of the rod assembly may equally well be performed with the alternative introduction of external conduits between chambers which can be arranged to allow leakage between the chambers as a consequence of any convenient triggering mechanism, such as the relative movement of the piston rod assembly and its housing.
In FIGS. 1, 2 and 3 there is shown an optional spring unit 44 which essentially may consist of a cylinder enclosing two free pistons having limited movement and being located between positioning stops and having a spring mechanism, such as an hydropneumatic accumulator, located therebetween. Thus, for example when the spring unit 44 is interconnected between two circuits such as 15, and 17 for example this provides specific extra spring resilience between these circuits without influencing any other circuits. In this way the spring rate for the pitch axis may be extended or softened so as to provide extra comfort for passengers towards the rear of the vehicle without adversely influencing the roll resistance of the other circuits.
Also in FIGS. 1 to 3 there are restrictors 47a, 47b, 47c and 47d as previously indicated. These restrictors are optionally provided to restrict the fluid flow between chambers in response to various situations such as rapid acceleration and/or deceleration. Some vehicles are supplied with wheel supporting arms and rods with a specific type of geometry which is designed to minimise pitch and squat under high acceleration forces and since the presently proposed suspension system also provides resistance to pitch and squat movements it is sometimes beneficial to provide valves in some or all the main conduits to effectively stop the hydraulic system working in specific instances such as under hard acceleration or braking to prevent over compensation. If this is not done, some vehicles may be found to have an inbuilt predisposition towards raising up at one or both ends under acceleration or braking or both. These unwanted effects can also minimise by the careful sizing of the wheel rams, ram bores and rods with reference to the amount of gas supplied in the gas spring and in conjunction with the restrictors in the circuits.
It has been previously mentioned that the spool valve 34 in FIG. 4 comprises of the grooved piston portion with a cylindrical tube, however, the purpose and construction of the lower portion 60 has not been discussed in detail. It will be seen that the joining cleat 51b that attaches the valve to the radius rod(s) is in fact made up of a hollow tube portion 61 into which the threaded shaft 62 can be inserted. On top of this is a bulbous component 63 which represents a servo attached to the tube portion 61. This may typically comprise of a small electrical motor driving a threaded sleeve in a bearing so that the threaded sleeve is meshed with the threaded shaft 62. When the threaded sleeve which is part of the servo rotates the threaded shaft is thereby caused to be drawn down into the hollow tube 61 or to be pushed up out of same according to the sense of rotation and pitch direction of thread. A servo is fitted as above described to each of the wheel location valves.
The mechanism 60 therefore provides an adjustment means to reposition the piston portion of the spool valve 34 with reference to the ports accommodating tubes 38, 33a and 42a. For example, when the threaded rod 62 is wound out of the tube 61 by the servo 63, the spool valves piston is thrust upwards so that a new higher position is established in the cylinder at which point the spool valve switches fluid from being returned from the main circuit to the tank 27 to receiving fluid from the pump to the main circuit. This then causes the associated circuit and ram to perceive that the ram is too contracted (the vehicle is too low) and this will then cause the vehicle to be raised until the new height is established at which point the valve switches over. The servo may comprise of a small electrical motor such as that found in electrical window winders or electrical car window winders and some such motors can be accurately calibrated to turn a precise number of revolutions to cause the vehicle to be raised or lowered evenly when all the servo motors are operated simultaneously. The electrical control and switching mechanism may either be initiated automatically or controlled manually by the vehicle operator according to specific requirements. All four servos may therefore be electrically linked and incorporate a reference datum point to ensure that all four valves, and therefore wheels, adopt the correct relative position to each other and the chassis.
Additionally, it can be arranged that the vehicles operator or another agent (such as a mercury switch) may cause two of the spool valves eg 34, 37 to adjust their switching positions to raise the left side while the other sides valves (eg 35, 36) are caused to lower the right side of the vehicle to enable the vehicle to adopt a roll position for ease of loading for example.
Alternatively the two valves 34, 35 associated with the two front wheels may, for example be adjusted upwards to cause the main circuits 14, 16 to be open to the pump to raise the front of the vehicle while the rear two valves 36, 37 may be instructed to either maintain their level or dump fluid to the tank whereby the rear of the vehicle will subside while the front is raised up.
The adjustment means as described by 60 would normally be connected to a switching mechanism conveniently located near the driver. The switch itself may be the same or similar to known switches that are commonly used for the four way controls of remote mirror positions which are adjustable from within the occupants compartment.
Alternatively the electrical control switches (not illustrated) and the servo mechanism 61 described above may be omitted if only one position of vehicle height is ever required. Alternatively again, the adjustable length component 60, to 63 may be made up of a cable mechanism similar to known clutch or brake cable mechanisms which are able to contract or lengthen the adjustable portions' length thereby effectively establishing new heights or trim levels at the operators behest. The four (or optionally eight) cables may conveniently terminate within the drivers compartment and all four may be operated collective by for example running all four cables over a small adjustable position pulley wheel attached to a control lever and additionally the four cables may each divide into two to become paired with the cables originating from the orthogonally disposed wheels so that as a lever arm tightens two cables (for example those associated with the front wheels) the two rear wheel cables are permitted to relax (and be drawn back to pretensioning springs within the unit equivalent to 60), so that the rear of the vehicle becomes lowered as fluid from the rear rams and circuits is returned to the tank.
It should be noted that reverse engineering techniques can be applied to make alternative mechanisms similar to those described herewith and such devices may achieve similar end results, but these are considered dependent upon and pursuant to the principles embodied in the mechanisms described above, and as such, behest the alternative parallel embodiments are considered to be encompassed within the scope of this patent application.
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A vehicle suspension system comprising a vehicle body supported upon a plurality of wheels arranged in lateral and longitudinal spaced relation. Individual double acting fluid rams connected between each wheel and the vehicle body to provide the support for the body, each ram having an upper and lower hydraulic chamber. Conduits individually communicating the upper chamber of the respective rams with the lower chamber of the respective diagonally opposite ram and fluid reservoir, and fluid pump arranged to draw fluid from the reservoir. Body attitude control means operable to connect each conduit individually to the pump or reservoir to respectively supply fluid to or receive fluid from the connected conduit. Individual actuators operable in response to the disposition of a respective wheel relative to the vehicle body to effect selective actuation of the control means to connect the circuit of that wheel to the pump or reservoir to maintain a preselected attitude of the vehicle body.
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BACKGROUND
[0001] 1. Technical Field
[0002] The disclosure generally relates to gas turbine engines.
[0003] 2. Description of the Related Art
[0004] A gas turbine engine typically maintains pressure differentials between various components during operation. These pressure differentials are commonly maintained by various configurations of seals. In this regard, labyrinth seals oftentimes are used in gas turbine engines. As is known, labyrinth seals tend to deteriorate over time. By way of example, a labyrinth seal can deteriorate due to rub interactions from thermal and mechanical growths, assembly tolerances, engine loads and maneuver deflections. Unfortunately, such deterioration can cause increased flow consumption resulting in increased parasitic losses and thermodynamic cycle loss.
SUMMARY
[0005] Gas turbine engine systems involving hydrostatic face seals with anti-fouling provisioning are provided. In this regard, an exemplary embodiment of a hydrostatic seal for a gas turbine engine comprises: a face seal having a seal face; a seal runner; and means for reducing a potential for debris to foul the hydrostatic seal formed by the seal face and the seal runner.
[0006] An exemplary embodiment of a turbine assembly for a gas turbine engine comprises: a turbine having a hydrostatic seal; the hydrostatic seal having a seal face, a seal runner, a carrier, and a biasing member; the seal face and the seal runner defining a high-pressure side and a lower-pressure side of the seal; the carrier being operative to position the seal face relative to the seal runner; and the biasing member being located on the lower-pressure side of the seal and being operative to bias the carrier such that interaction of the biasing member and gas pressure across the seal causes the carrier to position the seal face relative to the seal runner.
[0007] An exemplary embodiment of a gas turbine engine comprises: a compressor; a shaft interconnected with the compressor; and a turbine operative to drive the shaft, the turbine having a hydrostatic seal; the hydrostatic seal having a seal face, a seal runner and a biasing member; the seal face and the seal runner defining a high-pressure side and a lower-pressure side of the seal; the biasing member being located on the lower-pressure side of the seal and being operative to bias positioning of the seal face relative to the seal runner.
[0008] Other systems, methods, features and/or advantages of this disclosure will be or may become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features and/or advantages be included within this description and be within the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0010] FIG. 1 is a schematic diagram depicting an exemplary embodiment of a hydrostatic face seal with anti-fouling provisioning.
[0011] FIG. 2 is a schematic diagram depicting an exemplary embodiment of a gas turbine engine.
[0012] FIG. 3 is a schematic diagram depicting a portion of the low-pressure turbine of FIG. 2 , showing detail of the embodiment of the hydrostatic face seal with anti-fouling provisioning of FIG. 1 installed therein.
DETAILED DESCRIPTION
[0013] Gas turbine engine systems involving hydrostatic face seals with anti-fouling provisioning are provided, several exemplary embodiments of which will be described in detail. In this regard, hydrostatic face seals can be used at various locations of a gas turbine engine, such as in association with a low-pressure turbine. Notably, a hydrostatic seal is a seal that uses balanced opening and closing forces to maintain a desired separation between a seal face and a corresponding seal runner. Use of a hydrostatic face seal requires maintaining a metered airflow through orifices of the seal in order to produce desired seal characteristics. Such a metered airflow can be altered (e.g., interrupted) by the introduction of debris, which may be present in the gas turbine engine for a variety of reasons.
[0014] In order to reduce the possibility of a seal being fouled by debris, some embodiments incorporate the use of one or more anti-fouling provisions. By way of example, such provisions can include locating one or more potential debris-producing components of the seal to the lower-pressure side of the seal. Additionally or alternatively, an air bearing supply channel of the seal that limits the potential for debris to become stuck in the channel can be used. For instance, in some embodiments, the channel does not incorporate bends. Additionally or alternatively, an air bearing supply channel can be shielded to prevent debris from entering the channel.
[0015] An exemplary embodiment of a hydrostatic face seal with anti-fouling provisioning is depicted schematically in FIG. 1 . As shown in FIG. 1 , hydrostatic face seal 10 is provided by a stationary stator assembly 12 and a rotating rotor assembly 14 . The stator assembly includes an arm 16 that extends from a mounting bracket 18 , which facilitates attachment, removal and/or position adjustment of the stator assembly in the engine. Notably, other embodiments may not incorporate such a mounting bracket.
[0016] Stator assembly 12 also incorporates a carrier 20 that carries a face seal 22 . Face seal 22 is annular in shape and includes a seal face 24 , which is one of the seal-forming surfaces of the hydrostatic seal. A vent 25 also is provided through face seal 22 .
[0017] Carrier 20 is axially translatable so that seal face 24 can move, with the carrier, away from or toward (e.g., into contact with) a seal runner 26 (which is the other of the seal-forming components of the hydrostatic seal) of rotor assembly 14 . In this embodiment, an anti-rotation lock 28 is provided to prevent circumferential movement and assist in aligning the seal carrier to facilitate axial translation of the carrier.
[0018] A biasing member 30 , which is provided as a spring in this embodiment, biases the seal face against the seal runner until overcome by gas pressure. Multiple springs may be disposed about the circumference of the seal. In this regard, the biasing force of the biasing member can be selected to maintain a desired pressure differential between a high-pressure cavity (P HIGH ) and a lower-pressure cavity (P LOW ) of the seal. Notably, a piston ring 32 is captured between opposing surfaces 34 , 36 of the stator assembly and carrier, respectively, to control gas leakage between the arm of the stator assembly and the carrier.
[0019] With respect to the rotor assembly, rotor assembly 18 supports the seal runner 26 , which is annular in shape. Specifically, the rotor assembly includes an arm 40 that extends from a mounting bracket 42 , which facilitates attachment, removal and/or position adjustment of the rotor assembly. Notably, other embodiments may not incorporate such a mounting bracket.
[0020] With respect to anti-fouling provisions, the embodiment of FIG. 1 incorporates several such means. For instance, seal 10 locates the biasing member 30 in the lower-pressure cavity side (P LOW ) of the seal. Notably, the biasing member has the potential to produces debris. By locating the biasing member on the lower-pressure cavity side of the seal, any debris produced by the biasing member will have a tendency to move away from the seal face and seal runner and, therefore, should not foul the seal. This is in contrast to a seal that locates the biasing member on the high-pressure side. In such an embodiment, debris from the biasing member can be drawn (due to the pressure differential and corresponding gas flow across the seal) between the seal face and seal runner, thus fouling the seal.
[0021] As another example, seal 10 incorporates an air bearing supply channel 46 that limits the potential for debris to become stuck in the channel. Specifically, air bearing supply channel 46 is formed through face seal 22 from a side 48 (which includes seal face 24 ) to an opposing side 50 (which is attached to carrier 20 ). Notably, carrier 20 includes an orifice 52 that is aligned with the air bearing supply channel. So configured, air can be provided from the high-pressure side of the seal, through orifice 52 , then through air bearing supply channel 46 to seal location 54 , which is located between side 48 and seal runner 26 .
[0022] In order to reduce the potential for debris to become stuck in the air bearing supply channel, channel 46 of the embodiment of FIG. 1 does not incorporate bends. That is, the channel is a substantially straight through-hole. While a constant diameter straight through-hole is less susceptible to debris accumulation when compared with internal passages that have sharp bends, it is preferable to tailor the diameter along the tube towards a desired pressure distribution. Thus, in the embodiment of FIG. 1 , channel 46 includes a cylindrical portion 45 that is interconnected with a cylindrical portion 47 (of smaller diameter) via a conical portion 49 such that the channel exhibits a non-uniform diameter along its length. It should be noted that the cylindrical portion 47 could be connected to orifice 52 without incorporation of a cylindrical portion 45 . In this case, the non-uniform diameter of the channel inside face seal 22 consists of a lead-in conical portion 49 and the cylindrical section 47 . Connecting cylindrical portions 45 and 47 with a conical portion 49 accelerates the flow and reduces residence times of any debris particles. Therefore, the potential for debris accumulation is reduced.
[0023] Alternatives to straight through-hole configurations that may reduce a tendency for debris to get stuck in the internal face seal channels could involve internal cavities that serve reservoirs. These could be formed by relatively large diameter holes drilled radially inward and deeper than that needed to feed an axial air bearing supply hole, which is typically similar to cylindrical portion 47 .
[0024] Seal 10 also incorporates a shield for reducing the potential of debris to enter the air bearing supply channel. Specifically, a shield 60 is provided that extends outwardly from carrier 20 in a vicinity of orifice 52 . The shield forms a physical barrier that discourages debris travelling on a radially inward trajectory from entering the orifice. Additionally, for debris to enter orifice 52 of the embodiment of FIG. 1 , the debris is required to pass through a narrow opening 62 defined by the shield and a surface 64 of the carrier. Notably, since the orifice is located radially outboard of surface 64 , the tortuous path formed by the shield and the orifice location may prevent debris from entering the air bearing supply channel.
[0025] FIG. 2 is a schematic diagram depicting an exemplary embodiment of a gas turbine engine, in which an embodiment of a hydrostatic face seal with anti-fouling provisioning can be used. As shown in FIG. 2 , engine 100 is configured as a turbofan that incorporates a fan 102 , a compressor section 104 , a combustion section 106 and a turbine section 108 . Although the embodiment of FIG. 2 is configured as a turbofan, there is no intention to limit the concepts described herein to use with turbofans, as various other configurations of gas turbine engines can be used.
[0026] Engine 100 is a dual spool engine that includes a high-pressure turbine 110 interconnected with a high-pressure compressor 112 via a shaft 114 , and a low-pressure turbine 120 interconnected with a low-pressure compressor 122 via a shaft 124 . It should also be noted that although various embodiments are described as incorporating hydrostatic face seals with anti-fouling provisioning in low-pressure turbines, such seals are not limited to use with low-pressure turbines.
[0027] As shown in FIG. 3 , low-pressure turbine 120 defines a primary gas flow path 130 along which multiple rotating blades (e.g., blade 132 ) and stationary vanes (e.g., vane 134 ) are located. In this embodiment, the blades are mounted to turbine disks, the respective webs and bores of which extend into a high-pressure cavity 140 . For instance, disk 142 includes a web 144 and a bore 146 , each of which extends into cavity 140 .
[0028] A relatively lower-pressure cavity 148 is oriented between high-pressure cavity 140 and turbine hub 150 , with a seal 10 (described in detail before with respect to FIG. 1 ) being provided to maintain a pressure differential between the high-pressure cavity and the lower-pressure cavity. Recall that seal assembly 10 incorporates a stator assembly 12 and a rotor assembly 14 . Notably, the stator assembly is mounted to a non-rotating structure of the turbine, whereas the rotor assembly is mounted to a rotating structure. In the implementation of FIG. 3 , the rotor assembly is mounted to turbine hub 150 .
[0029] It should be noted that seal 10 is provided as a removable assembly, the location of which can be adjusted. As such, thrust balance trimming of engine 100 can be at least partially accommodated by altering the position of the seal assembly.
[0030] In operation, the seal face intermittently contacts the seal runner. By way of example, contact between the seal face and the seal runner can occur during sub-idle conditions and/or during transient conditions. That is, contact between the seal face and the seal runner is maintained until gas pressure in the high-pressure cavity is adequate to overcome the biasing force, thereby separating the seal face from the seal runner. During normal operating conditions, however, the seal face and the seal runner should not contact each other.
[0031] Since the embodiments described herein are configured as lift-off seals (i.e., at least intermittent contact is expected), materials forming the surfaces that will contact each other are selected, at least in part, for their durability. In this regard, a material comprising carbon can be used as a seal face material. It should be noted, however, that carbon can fracture or otherwise be damaged due to unwanted contact (e.g., excessively forceful contact) between the seal face and the seal runner as may be caused by pressure fluctuations and/or vibrations, for example. It should also be noted that carbon may be susceptible to deterioration at higher temperatures. Therefore, carbon should be used in locations where predicted temperatures are not excessive. By way of example, use of such a material may not be appropriate, in some embodiments, in a high-pressure turbine.
[0032] It should be emphasized that the above-described embodiments are merely possible examples of implementations set forth for a clear understanding of the principles of this disclosure. Many variations and modifications may be made to the above-described embodiments without departing substantially from the spirit and principles of the disclosure. By way of example, although the embodiments described herein are configured as lift-off seals, other types of seals can be used. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the accompanying claims.
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Gas turbine engine systems involving hydrostatic face seals with anti-fouling provisioning are provided. In this regard, a representative turbine assembly for a gas turbine engine comprises: a turbine having a hydrostatic seal; the hydrostatic seal having a seal face, a seal runner, a carrier, and a biasing member; the seal face and the seal runner defining a high-pressure side and a lower-pressure side of the seal; the carrier being operative to position the seal face relative to the seal runner; and the biasing member being located on the lower-pressure side of the seal and being operative to bias the carrier such that interaction of the biasing member and gas pressure across the seal causes the carrier to position the seal face relative to the seal runner.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is concerned with flow valves operated by flow transfer means which regulate small flows of control, operating by pressure differentials.
2. Description of the Related Art
A great variety of flow valves is known which are commanded by pressure differences.
U.S. Pat. No. 2,980,385 of E. J. Hunter et al. discloses a valve which has a substantially hemispherical yieldable membrane, which walls shall be relatively thick, so that this membrane does not become locked at the flow outlets when pressures are very high in its concave portion. The excess thickness of the walls, on the contrary, prevents that the valve reacts before small pressure differentials, the valve being thus able to be permanently closed or being able to release a very small stream of flow, without releasing the required flow when a small opening of the valve is commanded.
U.S. Pat. No. 3,493,008 of P. J. Scaglione discloses a valve with an active element of valve made up of a disc cup and a metallic hermetically sealed, flexible type bellow. The walls of the metallic, flexible bellow are subject to the pressure differences on both sides of their faces, being able to become deformed if the internal pressure is higher than the external one, this forcing the design of a bellow with more resistant walls when operating at high pressures, thus a low sensitivity valve being obtained before small variations of pressure. On the other hand, the disc cup is basically rigid and its seal looses effectiveness with the valve seat when the flow of the line carries impurities. In addition, due to the structure of the valve, a substantial loss of load is produced.
The state of the art valves which act by pressure differentials are complex as regards their structure with a great loss of load and they have little versatility with respect to the flow pressures in the line, that is to say, these valves must be designed in such a way to control the flows which are in a rather close range of pressures and loose their efficiency before great changes of pressure in the line.
SUMMARY OF THE INVENTION
The invention, on the contrary, offers a valve of the differential type which is sensitive to small changes of pressure and resistant to great working pressures. The valves of the invention, on the other hand, result from a very simple design and with little components, thus making the manufacture of small size valves possible.
The valves of the invention basically consist in a rigid valve body with an opening for flow inlet and one flow outlet, which are oriented in a substantially cross way each other. At the lower end of the flow inlet there is a valve seat, and between the inlet and outlet of flow, the body of the valve has a constant-section main cavity, cylindrical preferably, which is coaxially oriented to the flow inlet, this main cavity having a ring-shaped broadening in the zone communicating with the flow outlet over the valve seat. On the other hand, the main cavity of the valve body is communicated in its farthest zone of the flow inlet with an inlet of control flow. Additionally, the flow outlet is communicated with one or more outlets of the control flow. These inlets and outlets of the control flow are associated with control flow transfer means, which regulate small flows of control, these transfer means of the control flow being those which are commanded (manually or automatically, directly or remotely) to open, close or define a predetermined opening condition of the valve.
The most outstanding features of the invention are obtained thanks to an elastomeric body located inside the main cavity of the valve body, which is at least made up of two coaxial zones: one first sealing zone and a second zone of radial seal, being able to have an intermediate zone or a thin wall zone.
The sealing zone is located at the lower base of the elastomeric body and is formed by a relatively thick mass body with a slightly lower section than the section of the main cavity and with a slightly greater height than the ring-shaped broadening height of the main cavity, so that this sealing zone does not significantly collapse in the axial direction before the working pressures. The base of the sealing zone has a central hole allowing the transfer of flow from the inlet of the flow to the main cavity and vice versa. The lower surface of the sealing zone has a slightly greater section than the section of the valve seat and the upper surface of said zone has a section which is equal to or greater than its lower surface.
The radial seal zone of the elastomeric body is located on the opposite end to that of the sealing zone and acts on the side walls of the main cavity. This radial seal zone is made up of relatively thick portions of wall which external surface is of a geometry which is similar to that of the surface of the main cavity in that sector and its section is tight to the section of said main cavity.
The valve of the invention may have whether an intermediate zone or a thin wall zone defining a mantle between the sealing zone and the radial seal zone; or else it may have a compressing spring located in the main cavity of the valve body, which exercises an axial force on the sealing zone which tends to keep it in contact with the valve seat. The valves of the invention may also jointly show the wall zone of the elastomeric body and the compressing ring.
The elastomeric body of the valves of the invention has been designed as a mono-block and its geometry is variable depending on the function performed by each section of it (sealing zone, radial seal zone, and, eventually, the wall zone). In this way, and unlike the valves of the state of the art, the modification of a dimensional parameter in the active element of the valve in order to meet a certain requirement of the flow line, does not affect other operating parameters. For example, if you are working with high pressures, the valve may be designed with a stronger sealing zone, but a thin wall zone may be kept which is not affected by the excess pressures, because, as discussed below, this zone of thin wall becomes protected by the walls of the main cavity of the valve body. In this example, the valve obtained behaves well under high pressures without loosing sensitivity before a decrease of pressure in the line.
BRIEF DESCRIPTION OF DRAWINGS
Below, a detailed description of the invention is disclosed based on the drawings, where:
FIG. 1 shows a sectional elevational view of a first modality of the valve of the invention, in which it is closed.
FIG. 2 is the same view as FIG. 1, but showing the valve opened.
FIG. 3 shows a sectional elevational view of a second modality of the valve of the invention, in which it is closed.
FIG. 4 is the same view as FIG. 3, but showing the valve opened.
FIG. 5 shows a sectional elevational view of a third modality of the valve of the invention, in which it is closed.
FIG. 6 is the same view as FIG. 5, but showing the valve opened.
FIG. 7 shows a sectional elevational view of a fourth modality of the valve of the invention, in which it is closed.
FIG. 8 is the same view as FIG. 7, but showing the valve opened.
FIG. 9 shows a sectional elevational view of a fifth modality of the valve of the invention, in which it is closed.
FIG. 10 is the same view as FIG. 9, but showing the valve opened.
FIG. 11 shows a sectional elevational view of a sixth modality of the valve of the invention, in which it is closed.
FIG. 12 is the same view as FIG. 11, but showing the valve opened.
FIG. 13 shows a sectional elevational view of a seventh modality of the valve of the invention, in which it is closed.
FIG. 14 is the same view as FIG. 13, but showing the valve opened.
FIG. 15 shows a sectional elevational view of an eighth modality of the valve of the invention, in which it is closed.
FIG. 16 is the same view as FIG. 15, but showing the valve opened.
DETAILED DESCRIPTION OF INVENTION
FIGS. 1 and 2 show a first modality of the invention in closed and opened position, respectively. Valve 1.1 is made up of a valve body 2.1 having an opening for the flow inlet 4.1 and a flow outlet 6.1 oriented in a substantially cross way to said flow inlet 4.1.
The valve body 2.1 has a valve seat 8.1 inside said flow inlet 4.1. Between the flow inlet 4.1 and the flow outlet 6.1, the valve body 2.1 has a main cavity 10.1 of constant section, cylindrical preferably, which is coaxially oriented to the flow inlet 4.1. This main cavity 10.1 has a ring-shaped broadening 12.1 in the zone which communicates with the flow outlet 6.1 over valve seat 8.1. On the other hand, the main cavity 10.1 is communicated in its farthest zone to the flow outlet 4.1 with an inlet of the control flow 14.1.
Additionally, the flow outlet 6.1 is communicated with one or more outlets of the control flow 16.1.
The valve of this first modality has the flow transfer means which regulate small flows of control. These flow transfer means consist in a secondary or control valve 18.1 installed between the inlet of the control flow 14.1 and the outlet of the control flow 16.1. The secondary or control valve 18.1 may be any valve of the state of the art allowing a preset regulation of the flow between a minimum closed position and a preset maximum position (open).
In addition, the valve 1.1 includes an elastomeric body 20.1 with a constant cross section, cylindrical preferably, which is hollow and open in its upper base, the same being located inside the main cavity 10.1, so that it is lightly compressed in the axial direction in order to exert a force on the valve seat 8.1. This elastomeric body 20.1 is made up of three coaxial zones: a first sealing zone 22.1, a second zone of wall 24.1 and a third zone of radial zone 26.1.
The sealing zone 22.1 is located at the lower base of the elastomeric body 20.1 and is formed by a relatively thick mass body with a slightly lower section than the section of the main cavity 10.1 and with a slightly greater height than the ring-shaped broadening height 12.1 of said main cavity 10.1, so that this sealing zone 22.1 does not significantly collapse in the axial direction before the working pressures. The base of the sealing zone 22.1 has a central hole 28.1 allowing the transfer of flow from the inlet of the flow 4.1 to the main cavity 10.1 and vice versa. The lower surface of the sealing zone 22.1 has a slightly greater section than the section of the valve seat 8.1 and the upper surface of said zone has a section which is equal to or greater than its lower surface.
The wall zone 24.1 is located in the intermediate section of the mantle of the elastomeric body 20.1 and is made up of a portion of wall which is relatively thin and its section is inferior to the section of the main cavity 10.1, this portion of the wall being liable to become buckled and transmit axial stresses before the pressures exercised inside said main cavity 10.1.
The zone of radial seal 26.1 acts on the side walls of the main cavity 10.1 and is forming the section of the open upper base of the elastomeric body 20.1. This zone of radial seal 26.1 is formed by portions of wall of a greater thickness than that of the zone of wall 24.1, which external surface has a similar geometry to that of the surface of the main cavity 10.1 in that sector, and its section is tight to the section of said main cavity 10.1.
Although in this modality, the end of the zone of radial seal 26.1 of the elastomeric body 20.1 is free to displace in the axial direction of said main cavity, also a variant of the valve may be considered in which said end of the zone of radial seal 26.1 is anchored to the wall of the main cavity 10.1 of the valve body 2.1, by means of a ring-shaped projection, for example, in the external wall of said zone of radial seal 26.1 which is held back in a corresponding ring-shaped recess of said main cavity 10.1.
FIG. 1 shows valve 1.1 in a closed condition. In this condition, when housing the elastomeric body 20.1, the main cavity 10.1 is covered by the wall zone 24.1 of it, forming a chamber 11.1 and a sealing is formed in the valve seat 8.1 through the sealing zone 22.1 of said elastomeric body 20.1, initially due to the axial compression exercised by the walls of the mantle of it (wall zone 24.1), because of its dimensional excess in the axial direction with respect to the height of the main cavity 10.1.
When valve 1.1 is closed and the flow floods the inlet opening of the flow 4.1, the latter enters through the central hole 28.1 of the elastomeric body 20.1, the latter also flooding the chamber 11.1, and because the section of said chamber 11.1 is greater than the section of the valve seat 8.1, the pressure of the flow exerts a resulting force which compresses the sealing zone 22.1 of the elastomeric body 20.1 against the valve seat 8.1, the sealing of the valve being thus increased. The flow also floods the inlet of the control flow 14.1 which tops out in the secondary or control valve 18.1, which, in this condition, is closed.
When the secondary or control valve 18.1 is opened, the flow which is held back by pressure in chamber 11.1 is discharged through the inlet of the control flow 14.1 going through said control valve 18.1 in order to be released through the outlet of the control flow 16.1 to the outlet opening of flow 6.1 due to the differences of pressure existing between chamber 11.1 and the outlet opening of flow 6.1. During this process of flow discharge from chamber 11.1, the pressure in said chamber is lower than the pressure in the inlet opening of flow 4.1, so that the flow found in said inlet 4.1 moves through the central hole 28.1 of the elastomeric body 20.1 to enter chamber 11.1, but this entry of flow does not get to increase the pressure in said chamber, since the control valve 18.1 is opened releasing the flow, and in this first moment the thin walls of the elastomeric body 20.1 tend to recover their initial height. However, the greater pressure of the flow in the external face of the sealing zone 22.1 of the elastomeric body 20.1--which is exerted from the flow inlet opening 4.1--produces a resulting axial force which displaces the sealing zone 22.1, moving it away from the valve seat 8.1, the wall zone 24.1 being collapsed, which is left exercising a greater restoring force in axial direction, which tends to overcome the force exerted by the flow pressure entering from the opening of the flow inlet 4.1. In this situation, with the elastomeric body 20.1 partially collapsed and far from the valve seat 8.1, the flow is able now to freely move from the inlet opening of flow 4.1 to the outlet opening of the flow 6.1 as depicted in FIG. 2.
In FIG. 2 valve 1.1 of the first modality of the invention is shown in open condition. In this condition, the chamber 11.1 has decreased its volume due to the collapsing of the wall zone 24.1. Depending on the flow which is transferred by the control valve 18.1, the pressure in the chamber 11.1 may change, and with this, the separation between the sealing zone 22.1 and the valve seat 8.1 may also vary, thus varying the opening and closing degree of the valve 1.1. This allows to command the opening, closing and adjustment of the valve with greater accuracy and lesser energy.
When the control valve 18.1 is totally or partially closed, a greater quantity of flow begins to enter from the flow inlet opening 4.1 through the central hole 28.1 to the chamber 11.1, this increasing its volume of flow and lowering the sealing zone 22.1 moving the same closer to the valve seat 8.1, thus reducing the section of free passage of flow from the inlet opening of flow 4.1 to the outlet opening of flow 6.1 until closing, if the control valve 18.1 is commanded to close.
FIGS. 3 and 4 depict a second modality of the invention in closed and open position, respectively. This modality is a variant of the first modality depicted in FIGS. 1 and 2, but a compressing spring 30.1 has been included inside the chamber 11.1, initially being lightly compressed between the upper surface of the sealing zone 22.1 and the upper surface of the main cavity 10.1 of the valve body 2.1. This compressing spring 30.1 allows the use of the valve in flow networks of greater pressure. The description of the elements and their operation is quite similar to that already explained with respect to the first modality of the invention.
The third modality of the valve of the invention is depicted in FIGS. 5 and 6 in closed and open positions, respectively. This modality, unlike the other modalities, is provided with a fixed axial stem--as described below--which serves as guide to the displacement of the elastomeric body and, mainly, produces a self-cleaning effect on the central hole of the sealing zone, thus avoiding the blocking of this hole with impurities that may be carried by the flow of the network.
This third modality consists in a valve 1.2 which is made up of a valve body 2.2 having an inlet opening for the flow 4.2 and a flow outlet 6.2 which is oriented in a substantially cross way to said flow inlet 4.2.
The valve body 2.2 has a valve seat 8.2 inside said flow inlet 4.2. Between the flow inlet 4.2 and the flow outlet 6.2, the valve body 2.2 has a main cavity 10.2 of constant section, cylindrical preferably, which is coaxially oriented to the flow inlet 4.2. This main cavity 10.2 has a ring-shaped broadening 12.2 in the zone which communicates with the flow outlet 6.2 over valve 8.2. On the other hand, the main cavity 10.2 is communicated in its farthest zone to the flow outlet 4.2 with an inlet of the control flow 14.2. Additionally, the flow outlet 6.2 is communicated with one or more outlets of the control flow 16.2.
The valve of this third modality has flow transfer means which regulate small flows of control. These flow transfer means consist in a secondary or control valve 18.2 installed between the inlet of the control flow 14.2 and the outlet of the control flow 16.2. The secondary or control valve 18.2 may be any valve of the state of the art allowing a preset regulation of the flow between a minimum closed position and a preset maximum position (open).
In addition, the valve 1.2 includes an elastomeric body 20.2 with a constant cross section, cylindrical preferably, which is hollow and open in its upper base, the same being located inside the main cavity 10.2, so that it is lightly compressed in the axial direction in order to exert a force on the valve seat 8.2. This elastomeric body 20.2 is made up of three coaxial zones: a first sealing zone 22.2, a second zone of wall 24.2 and a third zone of radial zone 26.2.
The sealing zone 22.2 is located at the lower base of the elastomeric body 20.2 and is formed by a relatively thick mass body with a slightly lower section than the section of the main cavity 10.2 and with a slightly greater height than the ring-shaped broadening height 12.2 of said main cavity 10.2, so that this sealing zone 22.2 does not significantly collapse in the axial direction before the working pressures. The base of the sealing zone 22.2 has a central hole 28.2 allowing the transfer of flow from the inlet of the flow 4.2 to the main cavity 10.2 and vice versa. The lower surface of the sealing zone 22.2 has a slightly greater section than the section of the valve seat 8.2 and the upper surface of said zone has a section which is equal to or greater than its lower surface.
The wall zone 24.2 is located in the intermediate section of the mantle of the elastomeric body 20.2 and is made up of a portion of wall which is relatively thin and its section is inferior to the section of the main cavity 10.2, this portion of the wall being liable to become buckled and transmit axial stresses before the pressures exercised inside said main cavity 10.2.
The zone of radial seal 26.2 acts on the side walls of the main cavity 10.2 and is forming the section of the open upper base of the elastomeric body 20.2. This zone of radial seal 26.2 is formed by portions of wall of a greater thickness than that of the zone of wall 24.2, which external surface has a similar geometry to that of the surface of the main cavity 10.2 in that sector, and its section is tight to the section of said main cavity 10.2.
In this third modality of the invention, the valve body 2.2 has an axial stem 32.2, which is interlocked or anchored to said valve body 2.2. This axial stem 32.2 has a longitudinal groove 34.2 involving at least a section slightly greater than the thickness of the sealing zone 22.2, the axial stem 32.2 tightly going through the central hole 28.2 of the lower base of the elastomeric body 20.2.
Although in this modality, the end of the zone of radial seal 26.2 of the elastomeric body 20.2 is free to displace in the axial direction of said main cavity, also a variant of the valve may be considered in which said end of the zone of radial seal 26.2 is anchored to the wall of the main cavity 10.2 of the valve body 2.2, by means of a ring-shaped projection, for example, in the external wall of said zone of radial seal 26.2 which is held back in a corresponding ring-shaped recess of said main cavity 10.2.
FIG. 5 depicts valve 1.2 in a closed condition and with flow in its inlet line. In an initial and prior condition, when valve 1.2 is installed in the network and the latter has no load of flow, and when housing the elastomeric body 20.2, the main cavity 10.2 is covered by the wall zone 24.2 of it, forming a chamber 11.2 and a sealing is formed in the valve seat 8.2 through the sealing zone 22.2 of said elastomeric body 20.2, initially due to the axial compression exercised by the walls of the mantle of it (wall zone 24.2), because of its dimensional excess in the axial direction with respect to the height of the main cavity 10.2.
When valve 1.2 is closed and the flow floods the inlet opening of the flow 4.2, the latter enters through the central hole 28.2 of the elastomeric body 20.2 and of the longitudinal groove 34.2 of the axial stem 32.2, also flooding the chamber 11.2, and because the section of said chamber 11.2 is greater than the section of the valve seat 8.2, the pressure of the flow exerts a resulting force which compresses the sealing zone 22.2 of the elastomeric body 20.2 against the valve seat 8.2, the sealing of the valve being thus increased. The flow also floods the inlet of the control flow 14.2 which tops out in the secondary or control valve 18.2, which, in this condition, is closed.
If the zone of radial seal 26.2 has an internal trunk-conical, ring-shaped wall as depicted in FIGS. 5 and 6, then the pressure inside the chamber 11.2 shall exert a resulting force on this internal ring-shaped wall which shall displace the zone of radial sealing 26.2 downwards, thus compressing the wall zone 24.2.
When the secondary or control valve 18.2 is opened, the flow which is held back by pressure in chamber 11.2 is discharged through the inlet of the control flow 14.2 going through said control valve 18.2 in order to be released through the outlet of the control flow 16.2 to the outlet opening of flow 6.2 due to the existing differences of pressure between chamber 11.2 and the outlet opening of flow 6.2. During this process of flow discharge from chamber 11.2, the pressure in said chamber is lower than the pressure in the inlet opening of flow 4.2, so that the flow found in said inlet 4.2 moves through the central hole 28.2 of the elastomeric body 20.2, and through the longitudinal groove 34.2 of the axial stem 32.2, to enter chamber 11.2, but this entry of flow does not get to increase the pressure in said chamber, since the control valve 18.2 is opened releasing the flow, and in this first moment the thin walls of the elastomeric body 20.2 tend to recover their initial height. However, the greater pressure of the flow in the external face of the sealing zone 22.2 of the elastomeric body 20.2--which is exerted from the flow inlet opening 4.2--produces a resulting axial force which displaces the sealing zone 22.2, moving it away from the valve seat 8.2, the elastomeric body 20.2 being displaced upwards, the latter maintaining its wall zone 24.2 collapsed, exercising a greater restoring force in axial direction, which tends to overcome the force exerted by the flow pressure entering from the opening of the flow inlet 4.2. In this situation, with the elastomeric body 20.2 partially collapsed and far from the valve seat 8.2, the flow is able now to freely move from the inlet opening of flow 4.2 (through the longitudinal groove 34.2) to the outlet opening of the flow 6.2 as depicted in FIG. 6.
In FIG. 6 valve 1.2 of the modality of the invention is depicted in open condition. In this condition, the chamber 11.2 has decreased its volume due to the displacement of the elastomeric body 20.2 (which keeps its wall zone 24.2 collapsed). Depending on the flow which is transferred by the control valve 18.2, the pressure in the chamber 11.2 may change, and with this, the separation between the sealing zone 22.2 and the valve seat 8.2 may also vary, thus varying the opening and closing degree of the valve 1.2. This allows to command the opening, closing and adjustment of the valve with greater accuracy and lesser energy.
When the control valve 18.2 is totally or partially closed, a greater quantity of flow begins to enter from the flow inlet opening 4.2 through the central hole 28.2 and the longitudinal groove 34.2 to the chamber 11.2, this increasing its volume of flow and lowering the sealing zone 22.2 moving the same closer to the valve seat 8.2, thus reducing the section of free passage of flow from the inlet opening of flow 4.2 to the outlet opening of flow 6.2 until closing, if the control valve 18.2 is commanded to close.
FIGS. 7 and 8 depict a fourth modality of the invention in closed and open position, respectively. This modality is a variant of the third modality depicted in FIGS. 5 and 6, but a compressing spring 30.2 has been included inside the chamber 11.2, initially being lightly compressed between the upper surface of the sealing zone 22.2 and the upper surface of the main cavity 10.2 of the valve body 2.2. This compressing spring 30.2 allows the use of the valve in flow networks of greater pressure. The description of the elements and their operation is quite similar to that already explained with respect to the third modality of the invention.
The fifth modality of the valve of the invention is depicted in FIGS. 9 and 10 in closed and open positions, respectively. This modality, unlike the other modalities, is provided with a mobile axial stem, provided with a longitudinal groove of constant or variable cross section, which, in combination with a secondary cavity in the valve body, acts as transfer means for the control flow, as described below.
This fifth modality consists in a valve 1.3 which is made up of a valve body 2.3 having an inlet opening for the flow 4.3 and a flow outlet 6.3 which is oriented in a substantially cross way to said flow inlet 4.3.
The valve body 2.3 has a valve seat 8.3 inside said flow inlet 4.3. Between the flow inlet 4.3 and the flow outlet 6.3, the valve body 2.3 has a main cavity 10.3 of constant section, cylindrical preferably, which is coaxially oriented to the flow inlet 4.3. This main cavity 10.3 has a ring-shaped broadening 12.3 in the zone which communicates with the flow outlet 6.3 over valve seat 8.3. On the other hand, the main cavity 10.3 is communicated in its farthest zone to the flow outlet 4.3 with an inlet of the control flow 14.3. Additionally, the flow outlet 6.3 is communicated with one or more outlets of the control flow 16.3.
The valve 1.3 includes an elastomeric body 20.3 with a constant cross section, cylindrical preferably, which is hollow and open in its upper base, the same being located inside the main cavity 10.3, so that it is lightly compressed in the axial direction in order to exert a force on the valve seat 8.3. This elastomeric body 20.3 is made up of three coaxial zones: a first sealing zone 22.3, a second zone of wall 24.3 and a third zone of radial zone 26.3.
The sealing zone 22.3 is located at the lower bottom of the elastomeric body 20.3 and is formed by a relatively thick mass body with a slightly lower section than the section of the main cavity 10.3 and with a slightly greater height than the ring-shaped broadening height 12.3 of said main cavity 10.3, so that this sealing zone 22.3 does not significantly collapse in the axial direction before the working pressures. The base of the sealing zone 22.3 has a central hole 28.3 allowing the transfer of flow from the inlet of the flow 4.3 to the main cavity 10.3 and vice versa. The lower surface of the sealing zone 22.3 has a slightly greater section than the section of the valve seat 8.3 and the upper surface of said zone has a section which is equal to or greater than its lower surface.
The wall zone 24.3 is located in the intermediate section of the mantle of the elastomeric body 20.3 and is made up of a portion of wall which is relatively thin and its section is inferior to the section of the main cavity 10.3, this portion of the wall being liable to become buckled and transmit axial stresses before the pressures exercised inside said main cavity 10.3.
The zone of radial seal 26.3 acts on the side walls of the main cavity 10.3 and is forming the section of the open upper base of the elastomeric body 20.3. This zone of radial seal 26.3 is formed by portions of wall of a greater thickness than that of the zone of wall 24.3, which external surface has a similar geometry to that of the surface of the main cavity 10.3 in that sector, and its section is tight to the section of said main cavity 10.3.
Although in this modality, the end of the zone of radial seal 26.3 of the elastomeric body 20.3 is free to displace in the axial direction of said main cavity, also a variant of the valve may be considered in which said end of the zone of radial seal 26.3 is anchored to the wall of the main cavity 10.3 of the valve body 2.3, by means of a ring-shaped projection, for example, in the external wall of said zone of radial seal 26.3 which is held back in a corresponding ring-shaped recess of said main cavity 10.3.
In this fifth modality of the invention, the valve body 2.3 has an axial stem 32.3 having an anchorage end 40.3 and a driving end 42.3. The anchorage end 40.3 of the axial stem 32.3 is interlocked or anchored to the sealing zone 22.3 of the elastomeric body 20.3. The driving end 42.3 of the axial stem 32.3 goes through the valve body 2.3 by an axial hole 44.3 of the same. Said axial hole 44.3 undergoes a broadening in its recess, thus defining a secondary cavity 38.3 in the valve body 2.3, from which point the outlet or outlets of the control flow 16.3 start. The secondary cavity 38.3 is provided with lower sealing means 46.3 and upper sealing means 48.3 which are tight to the axial stem 32.3.
In addition, the axial stem 32.3 has a longitudinal groove 34.3 extending from the beginning of the anchorage end 40.3 to such a length that, when the elastomeric body 20.3 is compressed against the valve seat 8.3, said groove tops out in a position which is immediately prior to the lower sealing means 46.3 of the secondary cavity 38.3, thus the terminal portion of the driving end 42.3 of the axial stem 32.3 being free of longitudinal groove 34.3. The lower and upper sealing means do not exert any sealing effect on the surface of the longitudinal groove 34.3, which shall only seal the rest of the mantle of the axial stem 32.3 (surface without groove) in the section which is affected by said sealing means. The inlet of control flow 14.3 is facing the longitudinal projection of the longitudinal groove 34.3 of the axial stem 32.3.
The valve has flow transfer means which regulate small control flows. These flow transfer means are made up of the secondary cavity 38.3 itself, the lower seal means 46.3 and the upper ones 48.3, and of the limit portion of the axial stem 32.3, where the longitudinal groove is interrupted 34.3.
FIG. 9 depicts valve 1.3 in a closed condition by the initial application of an external axial force on the driving end 42.3 of the axial stem 32.3 and with flow in its inlet line. In this situation, the anchorage end 40.3 of the axial stem 32.3 compresses the sealing zone 22.3 of the elastomeric body 20.3 against the valve seat 8.3 at the same time as the upper terminal end of the longitudinal groove 34.3 is in a position which is not locked by the lower sealing means 46.3 of the secondary cavity 38.3, so that these sealing means exert their effectively sealing action on the flat walls of the axial stem 32.3.
In an initial and prior condition, when valve 1.3 is installed in the network and the latter has no load of flow, and when housing the elastomeric body 20.3, the main cavity 10.3 is covered by the wall zone 24.3 of it, forming a chamber 11.3 due to the dimensional excess of the elastomeric body 20.3, in the axial direction (excess with respect to the height of the main cavity 10.3).
When valve 1.3 is closed and the flow floods the inlet opening of the flow 4.3, the latter enters through the central hole 28.3 of the elastomeric body 20.3 and of the longitudinal groove 34.3 of the axial stem 32.3, also flooding the chamber 11.3, and because the section of said chamber 11.3 is greater than the section of the valve seat 8.3, the pressure of the flow exerts a resulting force which compresses the sealing zone 22.3 of the elastomeric body 20.3 against the valve seat 8.3, the sealing of the valve being thus increased. The flow also floods the inlet of the control flow 14.3, but the lower sealing means 46.3 prevents the entering of flow to the inside of the secondary cavity 38.3, since the single possible passage of flow is through the longitudinal groove 34.3 of the axial stem 32.3, which, in this condition, is out of the action of the sealing means. Under this condition of closed valve with flow load inside, the valve shall remain closed, although the action of the external force may end on the axial stem 32.3.
If the zone of radial seal 26.3 has an internal trunk-conical, ring-shaped wall as depicted in FIGS. 9 and 10, then the pressure inside the chamber 11.3 shall exert a resulting force on this internal ring-shaped wall which shall displace the zone of radial sealing 26.3 downwards, thus compressing the wall zone 24.3.
When the valve is opened by applying an axial force applied in the driving end 42.3 of the axial stem 32.3, the longitudinal groove can be approached beyond the lower sealing means 46.3, and moves away from the sealing zone 22.3 of the valve seat 8.3. In this condition and due to the differences of pressure existing between chamber 11.3 and the outlet opening of flow 6.3, the flow which is held back by pressure in chamber 11.3 is discharged through the inlet of control flow 14.3 by the longitudinal groove 34.3 in that zone--since the sealing means do not act in the groove--going to the secondary cavity 38.3, and from this the flow is released through the outlet of the control flow 16.3 to the outlet opening of flow 6.3.
Once the opening of the valve 1.3 is started, the external force may be stopped in the driving end 42.3, and it shall continue opened. Indeed, during this process of flow discharge from chamber 11.3, the pressure in said chamber is lower than the pressure in the inlet opening of flow 4.3, so that the flow found in said inlet 4.3 moves through the central hole 28.3 of the elastomeric body 20.3, and through the longitudinal groove 34.3 of the axial stem 32.3 to enter chamber 11.3, but this entry of flow does not get to increase the pressure in said chamber, since the flow continues being released by the secondary cavity 38.3 to the outlet of the control flow 16.3. However, the greater pressure of the flow in the external face of the sealing zone 22.3 of the elastomeric body 20.3--which is exerted from the flow inlet opening 4.3--produces a resulting axial force which displaces the sealing zone 22.3, moving it away from the valve seat 8.3, the elastomeric body 20.3 being displaced upwards, the latter maintaining its wall zone 24.3 collapsed, exercising a greater restoring force in axial direction, which tends to overcome the force exerted by the flow pressure entering from the opening of the flow inlet 4.3. In this situation, with the elastomeric body 20.3 partially collapsed and far from the valve seat 8.3, the flow is able now to freely move from the inlet opening of flow 4.3 (through the longitudinal groove 34.3) to the outlet opening of the flow 6.3 as depicted in FIG. 10.
In FIG. 10 valve 1.3 of the fifth modality of the invention is depicted in open condition. In this condition, the chamber 11.3 has decreased its volume due to the displacement of the elastomeric body 20.3 (which keeps its wall zone 24.3 collapsed). Depending on the flow actually being transferred through the port which defines the longitudinal groove 34.3 in the lower sealing means 46.3 the pressure in the chamber 11.3 may vary, and with this, the separation between the sealing zone 22.3 and the valve seat 8.3 may also vary, thus varying the opening and closing degree of the valve 1.3. This allows to command the opening, closing and adjustment of the valve with greater accuracy and lesser energy.
When the control valve 1.3 is totally or partially closed by applying an axial force which approaches the elastomeric body 20.3 to the valve seat 8.3 and which tends to close the port which defines the longitudinal groove 34.3 in the lower sealing means 46.3, a greater quantity of flow begins to enter from the flow inlet opening 4.3 through the central hole 28.3 and the longitudinal groove 34.3 to the chamber 11.3, this increasing its volume of flow and lowering the sealing zone 22.3 moving the same closer to the valve seat 8.3, thus reducing the section of free passage of flow from the inlet opening of flow 4.3 to the outlet opening of flow 6.3 until closing, if the driving end 42.3 is commanded to close.
FIGS. 11 and 12 depict a sixth modality of the invention in closed and open position, respectively. This modality, unlike the two previous ones, has an elastomeric body 20.4 made up of only two coaxial zones: one sealing zone 22.4 and a second zone of radial sealing 26.4, and also includes a compressing spring 30.4 inside the chamber 11.4, initially being lightly compressed between the upper surface of the sealing zone 22.4 and the upper surface of the main cavity 10.4 of the valve body 2.4.
The valve 1.4 which is made up of a valve body 2.4 having an inlet opening for the flow 4.4 and a flow outlet 6.4 which is oriented in a substantially cross way to said flow inlet 4.4.
The valve body 2.4 has a valve seat 8.4 inside said flow inlet 4.4. Between the flow inlet 4.4 and the flow outlet 6.4, the valve body 2.4 has a main cavity 10.4 of constant section, cylindrical preferably, which is coaxially oriented to the flow inlet 4.4. This main cavity 10.4 has a ring-shaped broadening 12.4 in the zone which communicates with the flow outlet 6.4 over valve seat 8.4. On the other hand, the main cavity 10.4 is communicated in its farthest zone to the flow outlet 4.4 with an inlet of the control flow 14.4. Additionally, the flow outlet 6.4 is communicated with one or more outlets of the control flow 16.4.
The valve of this sixth modality has flow transfer means which regulate small flows of control, which consist in a secondary or control valve 18.4 installed between the inlet of the control flow 14.4 and the outlet of the control flow 16.4. The secondary or control valve 18.4 may be any valve of the state of the art allowing a preset regulation of the flow between a minimum closed position and a preset maximum position (open).
In addition, the valve 1.4 includes an elastomeric body 20.4 with a constant cross section, cylindrical preferably, which is hollow and open in its upper base, the same being located inside the main cavity 10.4. This elastomeric body 20.4 is made up of two coaxial zones: a first sealing zone 22.4 and a second zone of radial zone 26.4.
The sealing zone 22.4 is located at the lower bottom of the elastomeric body 20.4 and is formed by a relatively thick mass body with a slightly lower section than the section of the main cavity 10.4 and with a slightly greater height than the ring-shaped broadening height 12.4 of said main cavity 10.4, so that this sealing zone 22.4 does not significantly collapse in the axial direction before the working pressures. The base of the sealing zone 22.4 has a central hole 28.4 allowing the transfer of flow from the inlet of the flow 4.4 to the main cavity 10.4 and vice versa. The lower surface of the sealing zone 22.4 has a slightly greater section than the section of the valve seat 8.4 and the upper surface of said zone has a section which is equal to or greater than its lower surface.
The zone of radial seal 26.4 acts on the side walls of the main cavity 10.4 and is forming the section of the open upper base of the elastomeric body 20.4. This zone of radial seal 26.4 is formed by portions of thick walls which do not significantly collapse in axial direction before working pressures, and its external surface has a similar geometry to that of the surface of the main cavity 10.4 in that sector, its section being tight to the section of the main cavity 10.4. The open end of the elastomeric body 20.4 is free to displace in the axial direction of the main cavity 10.4.
As already mentioned, the valve 1.4 has a compressing ring 30.4 located inside the elastomeric body 20.4 with one of the ends of the spring 30.4 in contact with the internal sealing zone 22.4 and with the other end of the spring in contact with the main cavity 10.4 of the valve body 2.4.
FIG. 11 depicts the valve 1.4 in closed condition. In this situation, the compressing ring 30.4 exerts a force downwards, thus compressing the sealing zone 22.4 against the valve seat 8.4 so that the whole elastomeric body 20.4 is displaced to the lower position of said main cavity 10.4 defining a chamber 11.4. Initially, when the line is without load, the single action of the spring 30.4 determines the closing of the valve.
When valve 1.4 is closed and the flow floods the inlet opening of the flow 4.4, the latter enters through the central hole 28.4 of the elastomeric body 20.4, also flooding the chamber 11.4, and because the section of said chamber 11.4 is greater than the section of the valve seat 8.4, the pressure of the flow exerts a resulting force which compresses the sealing zone 22.4 of the elastomeric body 20.4 against the valve seat 8.4, the sealing of the valve being thus increased. The flow also floods the inlet of the control flow 14.4, which tops out in the secondary or control valve 18.4, which, in this condition, is closed.
When the secondary or control valve 18.4 is opened, the flow which is held back by pressure in chamber 11.4 is discharged entering through the inlet of the control flow 14.4 going through said control valve 18.4 in order to be released through the outlet of the control flow 16.4 to the outlet opening of flow 6.4 due to the differences of pressure existing between chamber 11.4 and the outlet opening of flow 6.4. During this process of flow discharge from chamber 11.4, the pressure in said chamber is lower than the pressure in the inlet opening of flow 4.4, so that the flow found in said inlet 4.4 moves through the central hole 28.4 of the elastomeric body 20.4 to enter chamber 11.4, but this entry of flow does not get to increase the pressure in said chamber, since the control valve 18.4 is opened releasing the flow, and in this first moment the action of the spring 30.4 still keeps valve 1.4 in closed condition. However, the greater pressure of the flow in the external face of the sealing zone 22.4 of the elastomeric body 20.4 --which is exerted from the flow inlet opening 4.4--produces a resulting axial force which overcomes the action of the spring 30.4 and displaces the sealing zone 22.4, moving it away from the valve seat 8.4, compressing said spring 30.4, which is left exerting a greater restoring force in axial direction, which tends to overcome the force exerted by the flow pressure entering from the opening of the flow inlet 4.4. In this situation, with the elastomeric body 20.4 far from the valve seat 8.4, the flow is able now to freely move from the inlet opening of flow 4.4 to the outlet opening of the flow 6.4 as depicted in FIG. 12.
In FIG. 12 valve 1.4 of the sixth modality of the invention is depicted in open condition. In this condition, the chamber 11.4 has decreased its volume due to the displacement of the elastomeric body 20.4 and the spring 30.4 has been compressed. Depending on the flow which is transferred by the control valve 18.4, the pressure in the chamber 11.4 may change, and with this, the separation between the sealing zone 22.4 and the valve seat 8.4 may also vary, thus varying the opening and closing degree of the valve 1.4. This allows to command the opening, closing and adjustment of the valve with greater accuracy and lesser energy.
When the control valve 18.4 is totally or partially closed, a greater quantity of flow begins to enter from the flow inlet opening 4.4 through the central hole 28.4 to the chamber 11.4, this increasing its volume of flow and lowering the sealing zone 22.4 moving the same closer to the valve seat 8.4, thus reducing the section of free passage of flow from the inlet opening of flow 4.4 to the outlet opening of flow 6.4 until closing, if the control valve 18.4 is commanded to close.
FIGS. 13 and 14 depict a seventh modality of the invention in closed and open position, respectively. This modality is similar to the fourth modality as described in FIGS. 7 and 8, but the elastomeric body 20.5 is free to move in its two ends and is made up of only two coaxial zones: one first sealing zone 22.5 and a second zone of radial sealing 26.5, the compressing spring 30.4 being initially lightly compressed between the upper surface of the sealing zone 22.5 and the upper surface of the main cavity 10.5 of the valve body 2.5.
FIGS. 15 and 16 depict an eighth modality of the invention in closed and open position, respectively. This modality is similar to the fifth modality as described in FIGS. 9 and 10, but the elastomeric body 20.6 is made up of only two coaxial zones: one first sealing zone 22.6 and a second zone of radial sealing 26.6, the compressing spring 30.6 being initially lightly compressed between the upper surface of the sealing zone 22.6 and the upper surface of the main cavity 10.6 of the valve body 2.6.
The invention has been described based on eight preferred modalities, in which different combinations of some of its components have been considered. In all modalities there is still an elastomeric body made up of at least two axial zones: one sealing zone in an end, and one zone of radial sealing in the other end, a zone of thin wall being able to exist which is intermediate to the other ones.
In case that the elastomeric body is made up of only two zones (a sealing one and a radial sealing), the spring shall be always present in order to contribute the necessary restoring forces to produce the sealing of the valve, when the pressure in the chamber is reduced. The spring also allows to reduce the negative effect of the water hammer produced in the line, thus reducing the flow leaks which, on the contrary, would be produced due to the sudden increase of the pressure which acts on the external surfaces of the elastomeric body subject to the flow entering.
When the zone of thin wall exists in the elastomeric body, there may be a compressing spring or not in the valve chamber, exerting a force which tends to compress the sealing zone against the valve seat. In this same case in which the elastomeric body is made up of three axial zones, this elastomeric body may be fixed to the valve body in its zone of radial sealing or free in its two ends.
In the cases in which the elastomeric body has it zone of radial sealing free, the internal surface of the zone of radial sealing may be cylindrical or prismatic, trunk-conical (or trunk-pyramid) or inverted trunk-conical (or inverted trunk-pyramid), depending on the fact that a pressure inside the chamber shall exert a resulting force which does not affect the displacement of the zone of radial sealing, or else that the resulting force displaces the zone of radial sealing upwards, or else that the resulting force displaces the zone of radial sealing downwards, respectively.
On the other hand, the valves of the invention may not have the axial stem as depicted in the versions one, two and six (FIGS. 1 and 2; FIGS. 3 and 4; and 2; FIGS. 3 and 4; and FIGS. 11 and 12, respectively); or else they may have an axial stem. This axial stem, provided with a longitudinal groove, may be fixed or mobile with respect to the valve body. In the modalities three and seven, valves with fixed stem were described, and in the modalities five and eight, valves with a mobile stem were described.
Another important alternative of the invention is presented by the transfer means of control flow. These transfer means may consist in a traditional secondary valve, which is applicable in the modalities without axial stem or with a fixed axial stem; or, in the case of the valve with mobile axial stem, said transfer means of control flow may consist whether in a traditional secondary valve or in the particular interaction between the zone of the mobile stem with longitudinal groove and a secondary, axial cavity of the valve body, as described in the fifth modality and as already referred to in the eighth modality.
In the case of the valves of the invention with mobile axial stem, and with transfer means of control flow made up of the interaction of the axial stem with its longitudinal groove, and of the secondary chamber of the valve body, the longitudinal groove of the axial mobile stem may have a variable cross section, so that when said axial stem is commanded by axially moving, the groove shall define ports in the inlet of the secondary chamber, which areas shall depend on the cross section of the longitudinal groove in that sector, thus allowing to control the transfer rate of control flow from the chamber of the valve to the secondary cavity.
An obvious variant of the invention may consist in providing the external perimetrical mantle of the sealing zone of the elastomeric body with a rigid material, such as, for example, a tight metallic ring, which shall avoid the increase of the section of said sealing zone, when the pressure in the chamber of the valve significantly increases.
Another obvious variant of the invention may consist in providing the central hole of the sealing zone of the elastomeric body with regulating means of the opening, such as a screw with a longitudinal groove of variable section in order to allow the modification of the flow rate which is entering from the flow inlet of the valve to the chamber of the same, thus changing the answer speed of the valve, or the sensitivity of the same before variable pressures of flow.
Still another obvious variant of the invention may consist in providing the wall zone of the elastomeric body with several sections of thin axial wall, thus a valve being obtained which allows great displacements of the sealing element in order to control great volumes of flow.
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A flow valve operating by pressure differentials and by flow transfer means which regulate small flows of control. This valve is sensitive to small changes of pressure and resistant to great working pressures, having few components of a simple design. The valve of the invention basically consists in a rigid valve body with an opening for flow inlet and one opening for flow outlet, which are oriented in a substantially cross way to said flow opening. The body of the valve has a main cavity between the flow inlet and the flow outlet. A valve seat is in the limit of the main cavity and the flow inlet. In addition, the valve body has pipes for the inlet of the control flow and for the outlet of the control flow, which are associated with the flow transfer means for the control of the valve. The valve also has an elastomeric body in charge of regulating the flow of it, by opening or closing it, depending on the difference of pressures produced between the walls, which are modified by the flow transfer means for the control flow. The elastomeric body is located inside the main cavity of the valve, the same being hollow and open in one of its axial ends and has a central hole in the other end. This elastomeric body is at least made up of two coaxial zones: one sealing zone and a second zone of radial seal. Eventually, a third intermediate zone or a zone of thin wall. These zones of the elastomeric body meet specific functions during the operation of the valve, thus avoiding the participation of the separate components which make the design complex and increase the manufacture cost.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/121,797 filed on May 4, 2005, which is herein incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to an animal bed and in particular to a multiple function animal bed, which also serves as a storage location for objects, related to the animal, as a bench for humans and as an animal step for getting into a human bed.
[0005] 2. Background of the Invention
[0006] There have been many types of animal beds. These beds come in various designs. Some of the designs include beds shaped as different types of animals. Many beds in the form of animal designs are made of a cushion material to facilitate animal comfort.
[0007] One animal bed as disclosed in U.S. Pat. No. 5,662,065 describes an animal bed that includes an annular bed frame defining an interior chamber. A perforated top wall is supported at its periphery by the bed frame to receive and support the animal above the chamber. The perforated top wall is composed of a non-woven fabric material to provide a hammock like suspension for the animal and to permit small insects to fall through the top wall. The chamber is dimensioned to provide a space below the top wall sufficient to inhibit the insects from traveling upwardly through the top wall. An insect exterminating composition contained within the chamber receives the falling insects and destroys them.
[0008] U.S. Pat. d 288,970 describes a combined animal bed and housing unit. This design has a bed mat resting on a storage unit. The bed also has a canopy covering the mat. The animal would rest on the mat and would be covered by the canopy.
BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS
[0009] It is an objective of the present invention to provide a multiple purpose animal bed.
[0010] It is a second objective of the present invention to provide an animal bed with a storage area below the location where the animal rests.
[0011] It is a third objective of the present invention to provide a multiple purpose animal bed that can be used as a rest bench for humans.
[0012] It is a fourth objective of the present invention to provide a multiple purpose animal bed that can be used as a step for animals to jump to a higher human bed.
[0013] The present invention comprises a furniture bed having a shape that can be for example a square or rectangular shape design with four sides, a top surface and an optional bottom surface. One of the sides is open to allow for storing objects in the present invention. Doors can be included on the furniture bed as an option. The bottom of that open side has a lip element that extends the complete length of that side to prevent objects from rolling out of the furniture bed. Lips can also extend upward from each side to create an area in which to place a sleeping pad for an animal. The pad serves as the animal bed. The material for the animal bed element can be of any conventional material that is used in animal beds. The remaining walls of the furniture bed may be of any suitable composition and configuration suitable for use in the bed. In some instances, the multiple function animal bed may be positioned adjacent a human bed enabling humans to use the bed as a rest bench or as a step to enable animals to get into the human bed.
[0014] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
[0016] FIG. 1 illustrates a front view of the multiple function animal furniture bed;
[0017] FIG. 2 illustrates a top view of the multiple function animal furniture bed;
[0018] FIG. 3 illustrates a top view of the multiple function animal furniture bed adjacent a human bed;
[0019] FIG. 4 illustrates a side view of the multiple function animal furniture bed adjacent a human bed; and
[0020] FIG. 5 illustrates a top view of an alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to FIG. 1 , shown is the front view of the multiple function animal furniture bed 10 . The multiple function animal furniture bed 10 may have a generally rectangular shape, alternatively the multiple function animal furniture bed 10 may have any other shape suitable for a desired use. Sides 11 and 12 form the two ends of the multiple function animal furniture bed 10 . Side 13 is the front and open side of the multiple function animal furniture bed 10 . The back side, not shown, is a side similar to sides 11 and 12 . The back side may also have similar dimensions as the front side 13 . In alternative embodiments, the backside has different dimensions than the front side 13 . The multiple function animal furniture bed 10 has a top side 14 as shown in FIGS. 1 and 2 . The top side 14 supports the mat material 15 on which the animal may lay. This mat material 15 may be of any composition suitable for use with the multiple function animal furniture bed 10 . For instance, the mat material 15 may be a cushion, a padded material, and the like. In some embodiments, the top side 14 may be moveable (e.g., the top side 14 may be lifted up). As shown, the top side 14 may have tapered corners 14 ′. The multiple function animal furniture bed 10 may have an optional bottom side or floor (not illustrated).
[0022] Multiple function animal furniture bed 10 may be composed of any material suitable for the uses of multiple function animal furniture bed 10 . For instance, multiple function animal furniture bed 10 may be composed of wood, mesh, wire, plastic, metal, and the like. In an embodiment, multiple function animal furniture 10 includes sides (e.g., sides 11 , 12 , 13 , 14 , and back side) composed of a plurality of openings. The openings may be of any desired shape and configuration. Such sides composed of a plurality of openings may comprise wire, mesh, netting, weaving, and the like, preferably wire or mesh, and more preferably wire or wire-like material. Moreover, such sides may be composed of any porous material suitable for use as a side in an animal cage (e.g., porous metal or plastic siding). In an embodiment, such sides are composed of a plastic, wood, or metal wire or wire-like material. One or more sides of multiple function animal furniture bed 10 may be composed of such materials. In an embodiment (not illustrated), an outer covering may be disposed on the outside and/or inside surface of one or more sides of multiple function animal furniture bed 10 , preferably an outer covering is disposed on the outside of one or more sides of multiple function animal furniture bed 10 . In some embodiments, an outer covering is disposed on the outside of sides 11 , 12 . The outer covering may cover any desired portion of a side. The outer covering may comprise any suitable covering for use with animals. For instance, the outer covering may be composed of natural or synthetic woods, veneers, vinyl, wicker, plastic, ceramic, and the like. In alternative embodiments, at least one of the sides comprises a substantially solid material.
[0023] A lip element 16 is positioned at the bottom of the open front side 13 . This lip 16 extends the length of the front side 13 . In alternative embodiments, lip 16 extends a portion of the length of front side 13 . Without being limited by theory, lip 16 may prevent objects from rolling out of the storage area of the multiple function animal furniture bed 10 . For instance, many objects and toys for animals have rounded shapes and have a tendency to roll. This lip 16 may serve as a stop to prevent the objects from rolling out of the storage area (e.g., interior of multiple function animal furniture bed 10 ). In addition, sides 11 and 12 may have lips 17 and 18 that extend upward from these sides beyond the top side of the bed. Similar extensions may also extend from the front side 13 and back side in the same manner as the extensions 17 and 18 . Without being limited by theory, these extensions create an area in which to place the mat material 15 . For instance, some mats have the tendency to slide in response to the weight of an animal. These extensions may serve to help hold the mat in place. In alternative embodiments (not illustrated), multiple function animal furniture bed 10 may comprise no such lips or may comprise only a portion of such lips.
[0024] FIG. 3 shows the multiple function animal furniture bed 10 positioned adjacent a human bed 20 . Positioning the multiple function animal furniture bed 10 at the foot 40 of the human bed 20 may provide a step for an animal/pet to get into human bed 20 . For instance, many people have pets that sleep in the bedroom. In addition, this multiple function animal furniture bed 10 has the strength to serve as a bench for humans to use as well.
[0025] FIG. 4 gives a side view of the multiple function animal furniture bed 10 . Shown is a human bed 20 with a mattress 22 . By the animal climbing onto the top side 14 and mat material 15 of the multiple function animal furniture bed 10 , the animal may have sufficient elevation to move into the human bed 20 .
[0026] The multiple function animal furniture bed 10 may have various dimensions. In addition, the lip extensions (e.g., 16 , 17 , 18 ) may also have various dimensions. For example, the lip extension 16 may not have the same dimensions as lip extensions 17 and 18 . In a preferred embodiment, all lip extensions may be two to three inches in height.
[0027] FIG. 5 is a top view of an alternate embodiment in which only the side 23 adjacent the human bed 20 has a substantially straight design. The other portion of the bed may have a curved or convex shape as shown. The other previously described features would be the same as in the other embodiments (e.g., these features include an opening in the front side 13 and a lip extension 16 at the bottom).
[0028] In addition to the lip extensions 17 and 18 on the top side 14 , other attaching means may be used to secure the mat material 15 to the top of the multiple function animal furniture bed 10 . Without limitation, these means may include straps attached to the multiple function animal furniture bed 10 that may restrain the mat material 15 . Another means is an attaching or adhesive material such as VELCRO, which is commercially available from Velcro Industries B.V. Ltd. Liability Co. This material may be attached to a skirt that may be attached to the mat material 15 .
[0029] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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An animal furniture bed having one side open to allow for storing of objects in an area of the bed below the sleeping surface. The bottom of that open side has a lip element that extends the complete length of that side to prevent objects from rolling out of the furniture bed. Lips can also extend upward from each side to create an area in which to place a sleeping pad for an animal. The pad serves as the animal bed.
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This invention relates to security devices for articles such as wallets and the like, various items contained within wallets or pockets and, more particularly, this invention relates to security devices used to clip such articles to a desired location, such as within a pocket.
BACKGROUND OF THE INVENTION
Prior art teachings on security devices for articles carried on one's person disclose an array of measures taken to avoid the loss of an article, such as one stored within an article of clothing, like a slacks or breast pocket. These teachings attempt to address both accidental loss and intentional theft through pickpocketing. The prior art devices include a variety of security measures, including chains, strings, and friction devices, employing a variety of methodes such as magnetics, clips and teeth to inhibit removal. These devices have proven to be cumbersome to use and therefore ineffective.
The present invention improves upon the prior art in that the security component is integrally related to the article to be secured as opposed to being placed apart from the article for connecting it to the pocket or other clothing container unit. U.S. Pat. No. 4,825,922 discloses a security device which does teach the use of a security clip connected directly and immediately to a wallet by being clipped thereto, however, this reference teaches the need for a clip glued to the outside of a wallet. The configuration is problematic and ineffective partly because the acute angle configuration of the clip relative to the wallet provides minimal security effect, with the clip easily being disengaged with the use of minimal force and skill.
U.S. Pat. No. 4,241,476 also discloses a wallet security device with a theft guard system connected directly and immediately to a wallet for locking the wallet within a pocket. However, this device also is cumbersome to use and carry within a pocket because it requires the use of a bulky member having moveable locking arms to be inserted in a wallet held within a pocket. Thus, known pocket type security devices present cumbersome mechanics through the use of separate devices, such as clips, pivotable locking arms or cords, attached the article to be secured. This extra effort diminishes intended access incident to the devices use, and discourages users from implementing them.
It is therefore a principle object of the present invention to provide a device for securing an article on one's person, either within the pocket of an article of clothing or within a carrying bag worn or carried about the person, which device integrates the securing unit within its overall design and does not require independent placement or connection of the securing unit to the wallet, change-purse or other pocket type storage article.
Another object of the present invention is to provide a pocket-type security and storage device which is both attractive and easy to use to encourage continuous application of the security portion of the device without diminishing intended access of the storage portion of the device by clumsy or bulky security devices.
Yet another object of the present invention is to provide a subtle, attractive yet strong and effective security device having security means integral with a pocket-type storage article which securely holds the article within a pocket or other personal containment position and still allows for quick, uncomplicated disengagement from the secured position for removal from the pocket or other containment position.
These and other objects, features and advantages of the present invention will become apparent from the following description when considered in connection with the accompanying drawings.
SUMMARY OF THE INVENTION
The present invention is a device for securing articles to a desired location, generally on one's person such as in a coat, slacks or breast pocket of an article of clothing, or about one's person such as in a purse or carrying case. The device is comprised of a storage unit having an access end which opens and closes for accessing the storage space of the storage unit. In the preferred embodiment of the invention, the access end has a conventional zipper for opening and closing access to the storage unit, but other devices can be used for this purpose, such as ties, clips, hook-and-loop type fasteners known conventionally by the tradename "velcro", buckles, etc.
The storage unit of the present invention also has an insert end with a clip device cooperatively associated to the insert end or within the insert end for securely and releasably engaging a desired location. In a first preferred embodiment of the invention, the clip device is comprised of two clip arms pivotably associated to each other with each clip arm having a clip end and a pinch end. When the pinch ends are grasped and depressed together, the clip ends consequently are pivoted apart to allow for positioning of the desired security location between the clip ends and for gripping of the clip ends thereto when the pinch ends are released.
The desired location represented in the first preferred embodiment as shown is a clothes pocket such as that of a pair of slacks. In this embodiment, the clip ends protrude outwardly from the insert end of the storage unit, with the pinch ends being contained within the insert end and out of sight, the pinch ends being covered by the walls of the storage unit.
In the second preferred embodiment of the invention, the clip device is recessed further within the insert end of the storage unit such that the clip ends are concealed from view and not protruding outwardly as in the first embodiment. The insert end folds around each clip end of each clip arm to allow space for the grasping of the desired location between the clip ends contained within the insert end.
In the third preferred embodiment of the invention, the clip device is comprised of an expandable mouth formed of a pair of rigid members having interlocking gripping teeth. The members are longitudinally disposed in parallel alignment when the insert end is relaxed to a closed position. When the insert end is pinched at the ends, simultaneously, of the mouth, the members bow apart to form an opening for positioning of the desired security location between the gripping teeth of each of the members. When the pinching of the insert end is relaxed, the members grip the desired location as the mouth of the insert ends close into secured position. The desired location represented in the third preferred embodiment, as shown, is a breast pocket of an article of clothing, whereby pocket fabric is gripped between the members of the insert end mouth and thereby secured with the pocket.
Numerous other advantages and features of the invention will become readily apparent from the detailed description of the preferred embodiment of the invention, from the claims, and from the accompanying drawings, in which like numerals are employed to designate like parts throughout the same.
BRIEF DESCRIPTION OF THE DRAWINGS
A fuller understanding of the foregoing may be had by reference to the accompanying drawings, wherein:
FIG. 1 is a front elevational view of a pair of slacks showing the present invention secured within a pocket of the slacks.
FIG. 2 is an access end perspective view of the first embodiment of the present invention showing the clip ends protruded outwardly from the insert end and the clip arms concealed within the insert end.
FIG. 3 is a side elevational view of the present invention showing the first preferred embodiment in which the clip ends protrude outwardly from the insert end.
FIG. 4 is an elevational view of the access end of the invention.
FIG. 5 is an elevational view of the insert end of the first preferred embodiment of the present invention with the clip ends protruded outwardly from the insert end.
FIG. 6 is a cross-sectional view of the first embodiment of the invention showing the pinch ends of the clip arms being depressed to prepare for securing the invention to a desired location.
FIG. 7 is an access end perspective view of the second embodiment of the present invention showing the clip ends concealed within the insert end.
FIG. 8 is a side elevational view of the second embodiment of the present invention.
FIG. 9 is an elevational view of the insert end of the second embodiment of the present invention.
FIG. 10 is an elevational view of the access end of the second embodiment of the present invention.
FIG. 11 is a cross-sectional view of the second embodiment of the invention showing the pinch ends of the clip arms being depressed to prepare for securing the invention to a desired location.
FIG. 12 is a cut away front elevational view of a breast pocket showing the present invention secured therewithin.
FIG. 13 is an insert end perspective view of the third embodiment of the invention showing the mouth ends being depressed to bow the mouth members for securing the insert end to a desired location.
FIG. 14 is a side elevational view of the third preferred embodiment of the present invention.
FIG. 15 is an elevational view of the insert end of the third embodiment of the present invention.
FIG. 16 is an elevational view of the access end of the third embodiment of the present invention.
FIG. 17 is a cross-sectional view taken along line 17--17 of the third embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the invention is susceptible of embodiment in many different forms there is shown in the drawings and will be described herein in detail, the preferred embodiments of the invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit and scope of the invention and/or claims of the embodiments illustrated.
The embodiments of the present invention are shown in FIGS. 1 through 17. FIGS. 1 through 6 depict the first preferred embodiment.
Referring now to FIG. 1, a pair of slacks 5 is shown from a front elevational view. The slacks 5 have two front pockets 6 and 7, one of which is shown securing the pocket-type storage device 10 of the present invention which characterizes the first preferred embodiment. FIG. 2 shows a perspective view of the storage device 10 from its access end 20. The access end 20 opens and closes by access device 25. FIG. 2 depicts a conventional zipper 26 to provide the manner of access.
FIG. 2 also shows the insert end 30 of the storage device 10, with clip 40 protruding outwardly from the insert end 30. The clip 40 has clip arms 41 and 42. The clip arms 41 and 42 have clip ends 43 and 44, respectively, and pinch ends 45 and 46 respectively. The clip operates by pivot 47 which, as shown, employs a conventional spring biasing mechanism 48 to tense the clip 40 into a closed position 49a as shown in FIG. 2.
FIGS. 3 through 5 are elevational views of the device 10 of the first preferred embodiment of the invention. FIG. 3 is a side elevational view of the device 10. FIG. 4 is an access end 20 elevational view of the device 10 with the zipper 26 in a closed position. FIG. 5 is a side elevation view of the insert end 30 showing the clip 40 in the closed position 49a.
FIG. 6 shows a cross-sectional view of the storage device 10 taken along line 6--6 of FIG. 3, illustrating operation of the clip 40 by depressing the pinch ends 45 and 46 to pivot the clip 40 into an open position 49b to prepare for securing the storage device 10 to a desired location, such a within pocket 6 of slacks 5.
In the first preferred embodiment, the desired location of the device 10 is shown in FIG. 1 The storage device 10 is secured within the slacks pocket 6 of the slacks 5 by inserting the storage device 10 into the pocket 6, depressing the pinch ends 45 and 46 as shown in FIG. 6, pinching pocket 6 material between the clip ends 41 and 42 then releasing pinch ends 45 and 46 to secure the storage device 10 to the desired location.
FIG. 6 further shows exterior cover 15 wrapped around the storage device 10, including the clip 40, except for the clip ends 43 and 44, which remain exposed and protruding outwardly from the insert end 30. FIG. 6 also shows interior cover 16 which separates the clip 80 from the storage compartment 17 of the storage unit 10.
FIGS. 7 through 11 illustrate the second embodiment of the present invention. FIG. 7 shows a perspective view of the storage device 50 from its access end 60. The access end 60 opens and closes by access device 65, as in the first preferred embodiment. FIG. 7 depicts a conventional zipper 66 to provide the access within device 50.
FIG. 7 also shows the insert end 70 of the storage unit 50, with clip 80 contained within and concealed by insert end 70. The clip 80 has clip arms 81 and 82, respectively, and pinch ends 85 and 86, respectively. The clip 80 operates by a pivot 87 which, as shown, employs a conventional spring bias 88 to tense the clip 80 into a closed position 89a as shown in FIG. 7.
FIG. 8 is a side elevational view of the device 50. FIG. 9 is a side elevational view of insert end 70 showing the clip 80 in the closed position 89a. FIG. 10 is an access end 60 view of the device 10 with the upper 66 of access mean 65 in a closed position.
FIG. 11 shows a cross-sectional view of the storage device 50, taken along line 11--11 of FIG. 8, illustrating operation of the clip 80 by depressing the pinch ends 85 and 86 to pivot the clip 80 into an open position 89b, as done in the first preferred embodiment.
FIG. 11 also illustrates the exterior cover 55 wrapped around the storage unit 50, including the entirety of the clip 80 to cover the clip ends 83 and 84 which remain concealed within the insert end 70, but such that pinching of the desired security location still is possible. FIG. 11 also shows the interior cover 56 which separates the clip 80 from the storage compartment 57 of the storage unit 50.
FIGS. 12 through 17 depict the third embodiment of the invention. FIG. 12 shows the storage device 100 inserted and secured for storage within a breast pocket 95 of an article of clothing 90. FIG. 13 illustrates a perspective view of the storage unit 100 from its insert end 110. The insert end 110 has clip 120 which form a mouth 121, and is comprised of rigid members 122 and 123 which are toothed in this embodiment for enhanced gripping. The mouth 121 and insert end 110 are further defined by mouth ends 124 and 125, and a mouth opening 126 which is formed when mouth ends 124 and 125 are simultaneously depressed to cause the rigid members 122 and 123 to bow apart.
FIGS. 14 through 16 show side elevational, access end 105 elevational and insert end 110 views, respectively, of the third embodiment of the present invention. FIGS. 14 and 16 show access end 105, which opens and closes by access device 106. FIG. 14 and 16 depict a conventional zipper 107 to comprise the access device 106. FIG. 15 shows a side elevational view insert end 110, with clip 120 in closed position 127.
FIG. 17 shows a cross-sectional view of the storage device 100, taken along line 17--17 of FIG. 13. FIG. 17 illustrates operation of the clip 120 by depressing the mouth ends 124 and 125 to bow the rigid members 122 and 123 apart to form the opening 126 to prepare for securing the storage device 100 to a desired location.
In this third embodiment, the desired location is a breast pocket 95 shown in FIG. 12. The storage device 100 is secured thereby within by inserting the storage device 100 into the pocket 95, depressing the mouth ends 124 and 125 as shown in FIG. 17, pinching pocket 95 material between the ridged members 122 and 123, then releasing the mouth ends 124 and 125 to secure the storage device 100 to the desired location, with the mouth ends 124 and 125 relaxed to closed position 127.
The foregoing specification describes only the preferred embodiments of the invention as shown. Other embodiments besides the ones shown and described above may be articulated as well. The terms and expressions therefore serve to describe the invention by example only and not to limit the invention. It is expected that others will perceive differences which, while differing from the foregoing, do not depart from the spirit and scope of the invention herein described and claimed.
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A device for securing articles on or about the person, comprising a storage unit having an insert end and an access end, a zipper formed at the access end to access the storage space of the device, and a clip or mouth formed at the insert end for securely and releaseably engaging a desired storage location on or about the person.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to photoelectric conversion devices.
[0003] 2. Description of Related Art
[0004] A photoelectric conversion device includes a circuit board, a light emitting module, a light receiving module, and an optical coupling lens. The light emitting module and the light receiving module are mounted on the circuit board. The optical coupling lens includes a first converging lens and a second converging lens. The first converging lens is intended to be aligned with and optically coupled with the light emitting module, and the second converging lens is intended to be aligned with and optically coupled with the light receiving module. Light emitted from the light emitting module passes through the first converging lens, and light from the second converging lens reaches the light receiving module. The transmission efficiency of light depends on a precise alignment between the first converging lens and the light emitting module and between the second converging lens and the light receiving module. In particular, the higher the alignment precision is, the higher is the transmission efficiency. Therefore, it is important to design a photoelectric conversion device having an automatically precise alignment between the first converging lens and the light emitting module and between the second converging lens and the light receiving module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a schematic, isometric view of a photoelectric conversion device, according to an exemplary embodiment.
[0006] FIG. 2 is a partial, schematic, isometric view of the photoelectric conversion device of FIG. 1 .
[0007] FIG. 3 is a sectional view of the photoelectric conversion device of FIG. 1 , taken along the line III-III of FIG. 1 .
DETAILED DESCRIPTION
[0008] Referring to FIG. 1 , a photoelectric conversion device 100 , according to an exemplary embodiment, includes a circuit board 10 , a light emitting module 20 , a light receiving module 30 , and an optical coupling lens 40 .
[0009] The circuit board 10 includes a lower surface 12 and an upper surface 14 . The lower surface 12 and the upper surface 14 are positioned at opposite sides of the circuit board 10 , and the lower surface 12 is parallel to the upper surface 14 . Two protrusions 16 perpendicularly extend from the upper surface 14 . In this embodiment, the protrusions 16 are cylindrical. That is, if the protrusions 16 are cut in a plane parallel to the upper surface 14 , the cross-section of each of the protrusions 16 is perfectly circular.
[0010] The light emitting module 20 and the light receiving module 30 are mounted on the upper surface 14 and electrically connected to the circuit board 10 . In detail, the light emitting module 20 , the light receiving module 30 , and the two protrusions 16 are arranged in a straight line, and the two protrusions 16 are located between the light emitting module 20 and the light receiving module 30 . That is, centers of the light emitting module 20 , of the light receiving module 30 , and of the two protrusions 16 are arranged in a straight line. In this embodiment, the light emitting module 20 is a vertical cavity surface emitting laser (VCSEL) diode and is configured for emitting light. The light receiving module 30 is a photo diode and is configured for receiving light.
[0011] Referring to FIGS. 1-2 , the optical coupling lens 40 includes a transparent body portion 42 , a first converging lens 43 , a second converging lens 44 , a third converging lens 45 , a fourth converging lens 46 , two posts 48 , and two supports 49 .
[0012] The body portion 42 is a straight triangular prism and includes a light incident surface 422 , a reflection surface 424 , and a light output surface 426 . The light incident surface 422 is parallel to the upper surface 14 . The light output surface 426 perpendicularly extends from the light incident surface 422 . The reflection surface 424 is obliquely interconnected between the light incident surface 422 and the light output surface 426 . In this embodiment, an included angle between the light incident surface 422 and the reflection surface 424 is about 45 degrees, and an included angle between the light output surface 426 and the reflection surface 424 is about 45 degrees. A recess 420 is defined in the reflection surface 424 . The recess 420 includes a bottom surface 421 parallel to the light incident surface 422 and the upper surface 14 .
[0013] The first converging lens 43 and the second converging lens 44 are formed on the light incident surface 422 and arranged apart from each other. The third converging lens 45 and the fourth converging lens 46 are formed on the light output surface 426 and arranged apart from each other. The two posts 48 are located on the bottom surface 421 and arranged apart from each other. In this embodiment, the two posts 48 are cylindrical. That is, if the posts 48 are cut in a plane parallel to the upper surface 14 , the cross-section of each of the posts 48 is perfectly circular. The two supports 49 perpendicularly extend from the light incident surface 422 and are arranged apart from each other. In this embodiment, the first converging lens 43 , the second converging lens 44 , and the two supports 49 are arranged in a straight line, and the first converging lens 43 and the second converging lens 44 are located between the two supports 49 .
[0014] The first converging lens 43 , the second converging lens 44 , the protrusions 16 , the light emitting module 20 , and the light receiving module 30 can be observed along a direction perpendicular to and above the bottom surface 421 because the body portion 42 is transparent. The first converging lens 43 , the second converging lens 44 , and the two posts 48 are arranged in a straight line, and the two posts 48 are located between the first converging lens 43 and the second converging lens 44 .
[0015] The locational relationship between the first converging lens 43 and the two posts 48 is substantially the same as that of the light emitting module 20 and the two protrusions 16 , and the locational relationship between the second converging lens 44 and the two posts 48 is substantially the same as that of the light receiving module 30 and the two protrusions 16 . In detail, the distance between a center of the first converging lens 43 and a center of each of the posts 48 is equal to the distance between a center of the light emitting module 20 and a center of each of the protrusions 16 . The distance between a center of the second converging lens 44 and a center of each of the posts 48 is equal to the distance between a center of the light receiving module 30 and a center of each of the protrusions 16 . The diameter of each of the posts 48 is substantially equal to the diameter of each of the protrusions 16 , and the diameters of each of the posts 48 exceeds the diameters of the first converging lens 43 and the second converging lens 44 .
[0016] In alternative embodiments, the posts 48 may be may be triangular, rectangular, or elliptic and the cross-section of each of the protrusions 16 may accordingly be triangular, rectangular, or elliptic, the dimensions of each of the posts 48 always being the same as the dimensions of each of the protrusions 16 .
[0017] When the photoelectric conversion device 100 is assembled, the optical coupling lens 40 is adhered onto the upper surface 14 with adhesive. In detail, first, the optical coupling lens 40 is placed on the upper surface 14 . In this situation, the two supports 49 abut the upper surface 14 . Second, the optical coupling lens 40 is moved until the centers of the protrusions 16 are aligned with the centers of the posts 48 , while the location of the protrusions 16 can be observed along a direction perpendicular to and above the bottom surface 421 . In this situation, where the protrusions 16 completely coincide with the posts 48 , the light emitting module 20 is perfectly aligned with the first converging lens 43 , and the light receiving module 30 is thus perfectly aligned with the second converging lens 44 . Third, glue is applied to sidewalls of the supports 49 to fix the optical coupling lens 40 on the upper surface 14 . Thereby, the photoelectric conversion device 100 has a high alignment precision and thus a high transmission efficiency of light.
[0018] Referring to FIG. 3 , when in use, electrical power is applied to the light emitting module 20 and the light receiving module 30 through the circuit board 10 , thus light beams emitted from the light emitting module 20 enter into the first converging lens 43 and become parallel, and are then reflected about 90 degrees toward the light output surface 426 by the reflection surface 424 , and finally exit from the light output surface 426 . Accordingly, parallel light beams passing through the light output surface 426 are reflected about 90 degrees toward the second converging lens 44 , and are finally converged into the light receiving module 30 by the second converging lens 44 .
[0019] Even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in the matters of shape, size, and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A photoelectric conversion device includes a circuit board, a light emitting module, a light receiving module, and an optical coupling lens. Two protrusions apart from each other extend from the circuit board. The light emitting module and the light receiving module are mounted on the circuit board and apart from each other. The optical coupling lens includes an oblique reflection surface and a recess having a bottom surface parallel to the circuit board. Two distanced posts perpendicularly extend from the bottom surface and engage with the centers of the protrusions upon assembly to ensure automatic and alignment of the light emitting module with the first converging lens, and alignment of the light receiving module with the second converging lens.
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TECHNICAL FIELD
[0001] The present disclosure relates generally to decorative moldings for drop ceiling grids.
BACKGROUND
[0002] Current drop ceilings can comprise a series of interconnected supports for installing acoustic, insulating, or decorative tiles. The gridwork for suspended ceilings may comprise L-bars anchored to walls around a ceiling perimeter. T-bars may be suspended from anchors to extend latitudinally and longitudinally with respect to each other to create a grid. The L-bars and T-bars cooperate by overlapping and/or interlocking to provide support for tiles.
[0003] Many configurations of hardware are possible, including a system of main runners, cross grids, and perimeter wall runner grids, such as a system marketed by Armstrong World Industries.
[0004] Since the L-bars and T-bars are largely functional, their appearance can be characterized as plain or industrial. In addition, since the L-bars and T-bars tend to be metal, paint coatings can be marred during installation. Therefore, various prior art designs provide for interlocking tiles or other decorative means for concealing the L-bars and T-bars.
SUMMARY
[0005] In one embodiment, a clip-on molding for concealing gridwork in suspended ceilings may comprise two opposed clip assemblies. Each clip assembly comprises a vertical portion having a lower edge and an upper edge and a lower finger protruding horizontally from the lower edge of the vertical portion and towards the opposed clip assembly. An upper finger protrudes horizontally from the vertical portion and towards the opposed clip assembly. Upward projecting arms extend from the upper edges of the vertical portions, the upward projecting arms having upward edges. Horizontal arms extend from the upward edges of the upward projecting arms, and the horizontal arms extend away from the clip assemblies and have distal ends. A decorative portion spans between distal ends of the horizontal arms. The lower surfaces of the upper fingers may be parallel to the upper surfaces of the lower fingers, thereby forming grooves. The grooves may be configured to accept opposed edges of gridwork.
[0006] In yet another embodiment, a snap-on molding may conceal perimeter gridwork in suspended ceilings. A first horizontal arm may abut a lower portion of a horizontal surface. A second horizontal arm may be parallel to the first horizontal arm. A first leg may connect to a first end of the second horizontal arm. A second leg may connect to a second end of the second horizontal arm, with the second leg configured to abut an upper, distal portion of the horizontal surface near a hem on the horizontal surface. Serially connected connecting arms may span between an upper end of the second leg to an end of the first horizontal arm.
[0007] A molding system may conceal peripherally, longitudinally and/or laterally extending gridwork in suspended ceilings. The system may comprise at least one clip-on molding and at least one snap-on molding.
[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention.
[0010] FIG. 1A is an example of a front-view profile of a main or cross piece molding according to one embodiment of the invention.
[0011] FIG. 1B is an alternate example of a front-view profile of a main or cross piece molding according to a second embodiment of the invention.
[0012] FIG. 2A is an example of a front-view profile of a perimeter molding according to a third embodiment of the invention.
[0013] FIG. 2B is an example of a front-view profile of a perimeter molding according to a fourth embodiment of the invention.
[0014] FIG. 2C is an example of a front-view profile of a perimeter molding according to a fifth embodiment of the invention.
[0015] FIG. 2D is an example of a front-view profile of a perimeter molding according to a sixth embodiment of the invention.
[0016] FIG. 3 is an enlarged example of a front-view profile of a main or cross piece molding shown in FIG. 1B .
[0017] FIG. 4 is a side view of a main piece molding.
[0018] FIG. 5A is a side view of a first cross piece molding for spanning between parallel main piece moldings.
[0019] FIG. 5B is a side view of a second cross piece molding for spanning between a perimeter molding and a main piece molding.
[0020] FIG. 6 is a side view of a perimeter molding.
[0021] FIG. 7 is an example of an L-bar and T-bar drop ceiling assembly having a perimeter molding, two main piece moldings, a first cross piece molding, and a second cross piece molding.
DETAILED DESCRIPTION
[0022] Reference will now be made in detail to the present exemplary embodiments, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0023] In an effort to provide a lightweight and easily installed molding for concealing L-bars and T-bars, proposed herein is a clip-on extruded molding system. The system provides for a perimeter molding that can attach to L-bars and also provides cooperating main and cross piece moldings that can attach to the T-bars. The moldings abut one another to provide a substantially unitary appearance.
[0024] Since the proposed moldings are one-piece and clip-on in nature, it reduces the material content greatly over the prior art, resulting in a thin and lightweight product. Since the material can be uniform in composition in some embodiments, nicks and scratches in the molding are not as readily visible as they would be on powder-coated metal hardware. The design also eliminates the need for associated metal clips, magnetic or other tapes, or adhesives, thereby making installation simple. The one-piece design also reduces fabrication costs and time to market.
[0025] FIG. 1A shows an example of a profile 100 for a main or cross piece molding for attaching to a non-limiting example of a T-bar T. The example of a T-bar T, as shown, has a horizontal portion, a vertical portion, and a hollow portion. Hollow portion facilitates hanging the T-bar T from hangers anchored to the portion of the ceiling to be concealed. The vertical portion comprises a distance that allows sufficient room for positioning a tile in the grid. Horizontal portion traditionally supports a tile, but as shown in FIG. 1A , horizontal portion is clip-fit to decorative molding 100 , and decorative molding 100 supports a tile on upper edge 102 .
[0026] The profile 100 may comprise a first side and an opposite side. The first side comprises a clip assembly. The clip assembly may comprise a groove between a first finger 108 and a second finger 106 . First finger 108 and second finger 106 are integrally formed with a vertical surface 104 . Second finger 106 may have a triangular tab shape to assist with the alignment of T-bar T with the groove. The T-bar T may slide along the triangular tab shape of second finger 106 , thereby facilitating a snap-fit with T-bar T. The triangular tab shape also creates a strong grip on the T-bar since the material comprising the triangular tab shape prevents the finger from flexing.
[0027] Vertical surface 104 is a sufficient distance from upper edge 102 to provide space for the formation of the triangular tab shaped second finger. The vertical distance also enables a pressure-enhanced grip on T-bar T by transferring pressure exerted on upper edge 102 towards the clip assembly, thereby forcing clip assembly towards T-bar T. Upper edge 102 may receive a pressure load from the weight of tiles placed upon it. In addition, the molding may be designed to accommodate up to three tensile pounds without losing the grip capacity of the clip assembly.
[0028] The opposite side of profile 100 mirrors the first side, with a clip assembly, vertical surface and upper edge. The first side and opposite side are connected by a section of material that may comprise any one of a number of decorative designs which may include, for example, one or more ogees, bullnoses, roundovers, squares, semi-circles, groove patterns, chamfers, coves, rabbets, or flutings.
[0029] FIG. 1B shows an alternate profile 120 for a main or cross piece decorative molding. The molding grips T-bar T with a clip assembly comprising a groove, lower finger 128 and upper finger 126 . Upper finger 126 is integral with a diagonal surface 124 . The triangular tab shape of upper finger 126 transitions seamlessly to a surface of diagonal surface 124 .
[0030] The combination of the diagonal surface and the triangular tab shape assists with the alignment of T-bar T with the groove. The T-bar T may slide along diagonal surface 124 , along the triangular tab shape of upper finger 126 , and into the groove, thereby facilitating a snap-fit with T-bar T. The triangular tab shape also creates a strong grip on the T-bar since the material comprising the triangular tab shape prevents the finger from flexing.
[0031] Vertical surface 124 is a sufficient distance from an upper edge 122 to provide space for the formation of the triangular tab shaped second finger. The vertical distance also enables a pressure-enhanced grip on T-bar T by transferring pressure exerted on upper edge 122 towards the clip assembly, thereby forcing clip assembly towards T-bar T. Upper edge 122 may receive a pressure load from the weight of tiles placed upon it. In addition, the molding is designed to accommodate up to three tensile pounds without losing the grip capacity of the clip assembly.
[0032] The opposite side of profile 120 mirrors the first side, with a clip assembly, vertical surface and upper edge. The first side and opposite side are connected by a section of material that may comprise any one of a number of decorative designs which may include, for example, one or more ogees, bullnoses, roundovers, squares, semi-circles, groove patterns, chamfers, coves, rabbets, or flutings. An exemplary molding pattern is shown in FIG. 1B , and is used throughout the disclosure for consistency.
[0033] Turning now to FIGS. 2A-2D , alternative designs for perimeter profiles are shown. The perimeter profiles allow for a cohesive design throughout a ceiling assembly by providing a vertical distance between an L-bar and a ceiling tile that will comport with a vertical distance created between a T-bar and a ceiling tile. The exterior design of the perimeter profiles also allows for a smooth transition between cross-piece moldings and the perimeter of a room, as will be discussed in more detail below in reference to FIG. 7 .
[0034] A first perimeter profile 200 is shown attached to an L-bar L. The components of first perimeter profile 200 cooperate to exert pressure on a horizontal portion of L-bar L and to receive a hem H in a way that prevents the profile from slipping off of L-bar L.
[0035] A first vertical arm 202 contacts a first horizontal portion of L-bar L and connects to a first horizontal arm 204 . Second vertical arm 206 extends downward from first horizontal arm 204 and contacts a second horizontal portion of L-bar L. Vertical side 207 connects first horizontal arm 204 with a second horizontal arm 208 . Third vertical arm 210 extends towards second vertical arm 206 and contacts an opposite side of second horizontal portion of L-bar L. Second vertical arm 206 and third vertical arm 210 together cooperate to exert pressure on the second horizontal portion of L-bar L. Second vertical arm 206 and third vertical arm 210 also allow hem H of L-bar L to pass between them during installation and cooperate to prevent hem H from passing backwards out of the decorative molding. This cooperation secures a molding using the design of first perimeter profile 200 to a ceiling perimeter.
[0036] Second horizontal arm 208 also connects to fourth vertical arm 212 , which connects to third horizontal arm 214 . Third horizontal arm 214 abuts a horizontal length of L-bar L, including an opposite side of first horizontal portion of L-bar L. First vertical arm 202 and third horizontal arm 214 cooperate to press against L-bar L, thereby assisting with securing a molding using the design of first perimeter profile 200 to a ceiling perimeter.
[0037] The weight of a tile bearing down on first horizontal arm 204 also assists with providing pressure to press first vertical arm 202 and second vertical arm 206 against the L-bar L. When the molding is mounted, fourth vertical arm 212 abuts a wall thereby providing counter support to third horizontal arm 214 .
[0038] FIG. 2B shows an example of a second profile for a perimeter molding. First vertical arm 222 connects to first horizontal arm 224 . Second vertical arm 226 extends downward from first horizontal arm 224 . Vertical side 228 spans between first horizontal arm 224 and second horizontal arm 232 . Third vertical arm 230 and fourth vertical arm 234 extend upward from second horizontal arm 232 . Third horizontal arm 236 connects to fourth vertical arm.
[0039] First vertical arm 222 cooperates with third horizontal arm 236 to hold a portion of L-bar L. Third horizontal arm 236 can abut a horizontal distance of L-bar L.
[0040] Second vertical arm 226 and third vertical arm 230 extend towards each other to exert pressure on a second horizontal portion of L-bar L. Second vertical arm 226 and third vertical arm 230 also allow hem H of L-bar L to pass between them during installation and cooperate to prevent hem H from passing backwards out of the molding. The cooperation of first, second, and third vertical arms 222 , 226 , and 230 , and third horizontal arm 236 secures a molding using the design of second perimeter profile 220 to a ceiling perimeter.
[0041] The weight of a tile bearing down on first horizontal arm 224 also assists with providing pressure to press first vertical arm 2202 and second vertical arm 226 against the L-bar L. When the molding is mounted, fourth vertical arm 234 abuts a wall thereby providing counter support to third horizontal arm 236 .
[0042] FIG. 2C shows an example of a third profile for a perimeter molding. A diagonal leg 242 extends at an angle away from first horizontal arm 244 , which connects to vertical arm 246 . Vertical arm 246 connects to second horizontal arm 248 which connects to vertical side 250 . Third horizontal arm 252 spans vertical side 250 and second vertical arm 254 . Fourth horizontal arm 256 connects to second vertical arm 254 . Fourth horizontal arm 256 and first horizontal arm 244 may abut opposing horizontal surfaces of L-bar L and together may exert sufficient pressure on L-bar L to secure a perimeter molding to an L-bar. First horizontal arm 244 , first vertical arm 246 , and third horizontal arm 256 also cooperate to form a snap fit. The snap fit allows hem H of L-bar L to pass into the interior of the molding during installation while preventing hem H from passing backwards out of the molding.
[0043] Diagonal leg 242 provides a means for lifting first horizontal arm 244 and first vertical arm 246 a sufficient distance away from third horizontal arm 256 to permit hem H to exit the decorative molding. Thus, a perimeter molding having a design of third perimeter profile 240 is easy to remove and install.
[0044] Pressure caused by the weight of a tile bearing down on second horizontal arm 248 transfers to press first vertical arm 246 and first horizontal arm 244 against the L-bar L. When the molding is mounted, second vertical arm 254 abuts a wall thereby providing counter support to fourth horizontal arm 256 .
[0045] FIG. 2D shows an example of a fourth profile for a perimeter molding. A diagonal leg 262 extends at an angle away from first horizontal arm 264 . A diagonal arm 266 extends at an opposite angle away from first horizontal arm 264 . Second horizontal arm 268 spans second diagonal arm 266 and vertical side 270 . Third horizontal arm 272 spans vertical side 270 and first vertical arm 274 . A fourth horizontal arm 276 connects to second vertical arm 278 and to first vertical arm 274 . Fifth horizontal arm 280 also connects to an upper portion of first vertical arm 274 .
[0046] First horizontal arm 264 , fifth horizontal arm 280 , first vertical arm 274 , and diagonal arm 266 cooperate to form a snap fit. The snap fit allows hem H of L-bar L to pass into the interior of the molding during installation while preventing hem H from passing backwards out of the decorative molding. First horizontal arm 264 and fifth horizontal arm 280 also press against opposing surfaces of L-bar L to provide a secure and stable connection of a molding to L-bar L.
[0047] Diagonal leg 262 provides a means for lifting first horizontal arm 264 and diagonal arm 266 a sufficient distance away from fifth horizontal arm 280 to permit hem H to exit the molding. Thus, a perimeter molding having a design of fourth perimeter profile 260 is easy to remove and install.
[0048] Pressure caused by the weight of a tile bearing down on second horizontal arm 268 transfers to press first vertical arm 266 and first horizontal arm 264 against the L-bar L. When the molding is mounted, second vertical arm 278 abuts a wall thereby providing counter support.
[0049] FIG. 3 provides a front view for a main or cross-piece molding profile 120 of FIG. 1B . Lower finger 128 , groove 130 , and upper finger 126 share a common rear segment 132 . Rear segment 132 is shown as vertical, but may also be at an incline.
[0050] FIG. 3 also shows a side edge 134 and a bottom edge 136 connected by a decorative pattern. The shape of the side edge 134 , decorative pattern, and bottom edge 136 may vary with aesthetics. However, the vertical distance of the combination, including upper edge 122 , comports with the vertical distance of the vertical edges 207 , 228 , 250 , and 270 of the perimeter moldings so that the main and cross piece moldings can aesthetically abut the perimeter moldings while also maintaining a substantially uniform ceiling height.
[0051] FIG. 4 shows a side view of a main molding piece 400 . The main molding piece 400 may be approximately six feet in length. When a standard size ceiling tile is used in a drop ceiling design, notches 406 or rabbets should be placed along the length of the upper edge 122 ′ of the main molding piece at sufficient distances to accommodate the overlap areas of main runners and cross T grids. The depth of notches 406 should be sufficient to accept the overlap areas without affecting the grip of the clip assembly. The notches may be formed, for example, by a dado blade.
[0052] As one non-limiting example, the main piece molding may have the following dimensions so as to accommodate standard two foot by two foot tiles. The material thickness may be 0.060+/−0.005 inches. The depth of the notch along notch wall 404 may be approximately 0.300 inches. First notches may be approximately 11.438 inches from opposing ends of the six foot length. At least one additional notch may be spaced 22.875 inches away from the inner ends of the first notches, while the notches may be 1.125 inches in width. A reasonable engineering tolerance of approximately 0.030 may be implemented for the notch widths, notch spacings, and overall molding lengths. However, the notch depth may benefit from having a minimum depth of 0.300 inches with a maximum overcut of 0.010 inches.
[0053] As shown in FIG. 4 , main piece molding 400 may be butt cut on the end 408 to allow the main piece molding 400 to abut facing ends of other main piece moldings or to abut vertical sides 207 , 228 , 250 , or 270 of perimeter piece moldings. Bottom edge 136 ′ may be flush with the lower edges of other molding pieces in the ceiling assembly.
[0054] FIG. 5A shows an example of a side view of a cross piece molding 500 . Upper edge 122 ″ does not include notches since the cross piece molding 500 typically spans between parallel main piece moldings 400 , which are typically a set distance apart. First end 506 and second end 508 are formed with coped ends to smoothly abut the decorative pattern of main piece moldings 400 . The coping may follow an inverse of the decorative portion pattern that allows first end 506 and second end 508 to receive a face of the decorative portion. Bottom edge 136 ″ is also at a vertical distance that is flush with other lower edges of other molding pieces in the ceiling assembly.
[0055] FIG. 5B shows a side view of a peripheral cross piece molding 520 . Upper edge 122 ′″ does not include notches since the cross piece molding 500 typically spans between a main piece molding 400 and a perimeter molding, such as third perimeter molding 240 . The peripheral cross piece molding 520 typically spans between overlaps of suspension hardware, such as the joint formed when an L-bar intersects with a T-bar, or when a cross T-bar intersects with a main T-bar.
[0056] First end 526 is formed with a butt cut end to smoothly abut a perimeter molding. The butt cut end may be formed during installation of the peripheral cross piece molding 520 since the distance between main piece moldings 400 and perimeter moldings 200 , 220 , 240 , or 260 may vary. In addition, two peripheral cross piece moldings 520 may be abutted at their butt cut ends to span a section between main piece moldings 400 .
[0057] Second end 528 is formed with a coped end to smoothly abut the decorative pattern of main piece moldings 400 . The coping may follow an inverse of the decorative pattern that allows second end 528 to receive a face of the decorative portion. Bottom edge 136 ′″ is at a vertical distance that is flush with other lower edges of other molding pieces in the ceiling assembly.
[0058] FIG. 6 shows an example of a side view of a perimeter molding, such as third perimeter molding 240 . As an example, the perimeter molding 240 may be approximately six feet in length. An upper edge, formed by second horizontal arm 248 includes spaced notches 608 that also cut into vertical side 250 . The notches 608 are spaced at sufficient distances to accommodate the overlap areas of perimeter wall runner grids with cross T grids, which may comprise inter-fitting L-bars and T-bars. The depth of notches 608 should be sufficient to accept the overlap areas without affecting the grip of the snap-on assembly. Or, in the case of first and second perimeter molding designs 200 and 220 , the depth of the notches 608 should not interfere with the cooperation of respective vertical and horizontal arms. The notches may be formed, for example, by a dado blade.
[0059] As one non-limiting example, the perimeter molding may have the following dimensions. The material thickness may be 0.060+/−0.005 inches. The depth of the notch along notch wall 606 may be approximately 0.245 inches. First notches may be approximately 11.438 inches from opposing ends of the six foot length. At least one additional notch may be spaced 22.875 inches away from the inner ends of the first notches, while the notches may be 1.125 inches in width. A reasonable engineering tolerance of approximately 0.030 may be implemented for the notch widths, notch spacings, and overall molding lengths. However, the notch depth may benefit from having a minimum depth of 0.300 inches with a maximum overcut of 0.010 inches.
[0060] As shown in FIG. 6 , perimeter piece molding 240 may be butt cut on the end 610 in order to abut facing ends of other perimeter piece moldings or to abut butt cut ends 526 of peripheral piece moldings. Lower edge, here formed by third horizontal surface 252 , may be flush with the lower edges of other molding pieces in the ceiling assembly.
[0061] FIG. 7 shows an example of a ceiling assembly in the process of installation. For simplicity, installed tiles, walls, and suspension means for T-bars are not shown.
[0062] In the example of FIG. 7 , third perimeter piece molding 240 is snap-fit to L-bar L. Upper surface, at second horizontal arm 248 , extends upwards into the area concealed by the ceiling assembly. Lower edge, formed by third horizontal arm 252 , faces downward from the ceiling assembly.
[0063] Notches 608 permit T-bar T to pass through a portion of perimeter molding. Notch wall 606 abuts T-bar T, or is reasonably close to prevent a visual gap in the final installation.
[0064] The exterior of perimeter piece molding 240 is shown with substantially flat surfaces to allow butt cut ends of other perimeter piece moldings to abut the exterior. Butt cut ends of peripheral piece moldings 520 may also smoothly abut the flat surfaces of perimeter piece molding 240 .
[0065] FIG. 7 shows a peripheral piece molding 520 in the process of being installed. Upper surface 122 ′″ will extend upwards into the area concealed by the ceiling assembly. Bottom edge 136 ′″ will face downward from the ceiling assembly. First butt cut end 526 will abut vertical side 250 of perimeter molding and second coped end 528 will abut a portion of main piece molding 400 . Butt cut end 408 may, in other embodiments, connect to other portions of a ceiling assembly.
[0066] For instance, the length of peripheral piece molding 520 may be cut to a custom length to accommodate non-uniformly cut tiles or custom-cut tiles, such as may occur at the edges of a ceiling installation. The butt cut end 408 may abut a perimeter molding, or it may abut another butt cut end of a peripheral piece molding to accommodate a custom tile size in between main ceiling grids.
[0067] Cross piece molding 500 extends between first main piece molding 400 and second main piece molding 400 ′. First coped end 506 abuts first main piece molding 400 , and second coped end 508 abuts second main piece molding 400 ′. Bottom edge 136 ″ faces downward in the ceiling assembly.
[0068] FIG. 7 also shows a T-bar T extending through a notch in first main piece molding 400 and a notch 406 in second main piece molding. Notch wall 404 abuts T-bar T, or is reasonably close to prevent a visual gap in the final installation.
[0069] Turning now to formation methods for the molding system, while other formation methods may be used, the decorative molding may be extruded against a die to create a one-piece molding unit. The material for the molding may comprise composite wood, a synthetic composite, or a plastic such as PVC.
[0070] While the groove for the clip assemblies may be created during the molding process, the groove can be formed more precisely by cutting or etching the groove into the extruded molding to form the clip assembly.
[0071] The main piece molding can be fabricated to custom length, or it can be created to longer lengths and cut down to appropriate sizes, such as by sawing. For example, the main piece molding may be extruded to an initial 73 inch length and processed to create the clip assembly. Several pieces, for example, five, may be placed into a machining nest and fed into a set of saws that cut the extruded grooved pieces down to a 72 inch finished length. Simultaneously, three dado blade sets, or other cutting tools, may also cut the required notches.
[0072] The cross-piece molding 500 may be cut from an extruded grooved piece to a finished length of, for example 23.13 inches. The piece may then be cycled back and forth between two aligned punch units, which are connected by a rail, to form the opposed coped first and second ends 506 and 508 . Other alternatives are available to form the coped edges, such as a CNC machine equipped with a router bit, laser cutting, etc.
[0073] The peripheral edge molding 520 may be cut from an extruded grooved piece to a finished length of, for example 22.79 inches. The cutting may form a butt cut surface on butt cut end 526 , and the piece may then be punched to form coped end 528 . Other alternatives are available to form the coped end 528 , such as a CNC machine equipped with a router bit, laser cutting, etc
[0074] The perimeter molding can be fabricated to custom length, or it can be created to longer lengths and cut down to appropriate sizes, such as by sawing. For example, the perimeter molding may be extruded to an initial 73 inch length. Several pieces, for example, five, may be placed into a machining nest and fed into a set of saws that cut the extruded pieces down to a 72 inch finished length. Three dado blade sets, or other cutting tools, may then cut the required notches.
[0075] In the preceding specification, various preferred embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various other modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.
[0076] For instance, the dimensions of the moldings may be adjusted to accommodate two foot by four foot tiles, or other tile sizes. The adjustment would entail adjusting notch spacings and may entail adjusting the finished lengths of the moldings. Other gridwork configurations can also be accommodated, and the L-bar and T-bar shown are not meant to be limiting.
[0077] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims.
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A molding system conceals gridwork in suspended ceilings. A main or cross piece molding comprises two opposed clip assemblies for attaching to inverted T-bars. The clip assemblies comprise a vertical portion. Upper and lower fingers protrude horizontally from the vertical portion and towards the opposed clip assembly. Upward projecting arms extend from upper edges of the vertical portions and have upward edges. Horizontal arms extend from the upward edges and extend away from the clip assemblies. A decorative portion spans between distal ends of the horizontal arms. A perimeter molding for attaching to L-bars comprises a first horizontal arm configured to abut a lower portion of a horizontal surface and a second horizontal arm that is parallel to the first horizontal arm. First and second legs connect to the second horizontal arm. The second leg abuts an upper, distal portion of the horizontal surface near a hem.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 13/335,749, now U.S. Pat. No. 9,027,287, and claims the benefit of priority to Provisional Patent Application No. 61/428,778 filed Dec. 30, 2010.
TECHNICAL FIELD OF INVENTION
[0002] The present invention relates to a new rig mast, substructure, and transport trailer for use in subterranean exploration. The present invention provides rapid rig-up, rig-down and transport of a full-size drilling rig. In particular, the invention relates to a self-erecting drilling rig in which rig-up of the mast and substructure may be performed without the assistance of a crane. The rig components transport without removal of the drilling equipment including top drive with mud hose and electrical service loop, AC drawworks, rotary table, torque wrench, standpipe manifold, and blow out preventers (BOP), thus reducing rig-up time and equipment handling damage.
BACKGROUND OF THE INVENTION
[0003] In the exploration of oil, gas and geothermal energy, drilling operations are used to create boreholes, or wells, in the earth. Drilling rigs used in subterranean exploration must be transported to the locations where drilling activity is to be commenced. These locations are often remotely located. The transportation of such rigs on state highways requires compliance with highway safety laws and clearance underneath bridges or inside tunnels. This requirement results in extensive disassembly of full-size drilling rigs to maintain a maximum transportable width and transportable height (mast depth) with further restrictions on maximum weight, number and spacing of axles, and overall load length and turning radius. These transportation constraints vary from state to state, as well as with terrain limitations. These constraints can limit the size and capacity of rigs that can be transported and used, conflicting with the subterranean requirements to drill deeper, or longer reach horizontal wells, more quickly, requiring larger rigs.
[0004] Larger, higher capacity drilling rigs are needed for deeper (or horizontally longer) drilling operations, since the hook load for deeper operations is very high, requiring rigs to have a capacity of 500,000 lbs. and higher. Constructing longer, deeper wells requires increased torque, mud pump capacity and the use of larger diameter tubulars in longer strings. Larger equipment is required to handle these larger tubulars and longer strings. All of these considerations drive the demand for larger rigs. Larger rigs require a wider base structure for strength and wind stability, and this requirement conflicts with the transportability constraint and the time and cost of moving them. Larger rigs also require higher drill floors to accommodate taller BOP stacks. Once transported to the desired location, the large rig components must each be moved from a transport trailer into engagement with the other components located on the drilling pad. Moving a full-size rig and erecting a conventional mast and substructure generally requires the assistance of large cranes at the drilling site. The cranes will be required again when the exploration activity is complete and it is time to take the rig down and prepare it for transportation to a new drilling site.
[0005] Once the cranes have erected the mast and substructure, it is necessary to reinstall much of the machinery associated with the operation of the drilling rig. Such machinery includes, for example, the top drive with mud hose and electrical service loop, AC drawworks, rotary table, torque wrench, standpipe manifold, and BOP.
[0006] Rigs have been developed with mast raising hydraulic cylinders and with secondary substructure raising cylinders for erection of the drilling rig without the use, or with minimal use, of cranes. For example, boost cylinders have been used to fully or partially raise the substructure in combination with mast raising cylinders. These rigs have reduced rig transport and rig-up time; however, substructure hydraulics are still required and the three-step lifting process and lower mast lifting capacity remain compromised in these configurations. Also, these designs incorporate secondary lifting structures, such as mast starter legs which are separated completely from the mast for transportation. These add to rig-up and rig-down time, weight, and transportation requirements, encumber rig floor access, and may still require cranes for rig-up. Importantly, the total weight is a critical concern.
[0007] Movement of rig masts from transport trailers to engagement with substructures remains time consuming and difficult. Also, rig lifting supports create a wider mast profile, which limits the size of the structure support itself due to transportation regulations, and thus the wind load limit of the drilling rig. In particular, it is very advantageous to provide substructures having a height of less than 8 (eight) feet to minimize the incline and difficulty of moving the mast from its transport position into its connectable position on top of the collapsed substructure. However, limiting the height of the collapsed substructure restricts the overall length of retracted raising cylinders in conventional systems. It further increases the lift capacity requirement of the raising cylinder due to the disadvantageous angle created by the short distance from ground to drilling floor in the collapsed position.
[0008] For the purpose of optimizing the economics of the drilling operation, it is highly desirable to maximize the structural load capacity of the drilling rig and wind resistance without compromising the transportability of the rig, including, in particular, the width of the lower mast section, which bears the greatest load.
[0009] Assembly of drilling rigs for different depth ratings results in drilling rig designs that have different heights. Conventional systems often require the use of different raising cylinders that are incorporated in systems that are modified to accommodate the different capacity and extension requirements that are associated with drilling rigs having different heights from ground to drill floor. This increases design and construction costs, as well as the problems associated with maintaining inventories of the expensive raising cylinders in multiple sizes.
[0010] It is also highly desirable to devise a method for removing an equipment-laden lower mast section from a transport trailer into engagement with a substructure without the use of supplemental cranes. It is also desirable to minimize accessory hydraulics, and the size and number of telescopic hydraulic cylinders required for rig erection. It is also desirable to minimize accessory structure and equipment, particularly structure and equipment that may interfere with transportation or with manpower movement and access to the rig floor during drilling operations. It is also desirable to ergonomically limit the manpower interactions with rig components during rig-up for cost, safety and convenience.
[0011] It is also highly desirable to transport a drilling rig without unnecessary removal of any more drilling equipment than necessary, such as the top drive with mud hose and electrical service loop, AC drawworks, rotary table, torque wrench, standpipe manifold, and BOP. It is highly desirable to transport a drilling rig without removing the drill line normally reeved between the travelling block and the crown block. It is also highly desirable to remove the mast from the transport trailer in alignment with the substructure, and without the use of cranes. It is also desirable to maintain a low height of the collapsed substructure. It is also desirable to have a system that can adapt a single set of raising cylinders for use on substructures having different heights.
[0012] Technological and economic barriers have prevented the development of a drilling rig capable of achieving these goals. Conventional prior art drilling rig configurations remain manpower and equipment intensive to transport and rig-up. Alternative designs have failed to meet the economic and reliability requirements necessary to achieve commercial application. In particular, in deeper drilling environments, high-capacity drilling rigs are needed, such as rigs having hook loads in excess of 500,000 lbs., and with rated wind speeds in excess of 100 mph. Quick rig-down and transportation of these rigs have proven to be particularly difficult. Highway transport regulations limit the width and height of the transported mast sections as well as restricting the weight. In many states, the present width and height limit is 14 feet by 14 feet. Larger loads are subject to additional regulations including the requirement of an escort vehicle.
[0013] In summary, the preferred embodiments of the present invention provide unique solutions to many of the problems arising from a series of overlapping design constraints, including transportation limitations, rig-up limitations, hydraulic raising cylinder optimization, craneless rig-up and rig-down, and static hook load and rated wind speed requirements.
SUMMARY OF THE INVENTION
[0014] The present invention provides a substantially improved drilling rig system. In one embodiment, a drilling mast transport skid is provided comprising a frame positionable on a transport trailer. A forward hydraulically actuated slider, and a rear hydraulically actuated slider are located on the frame. The sliders are movable in perpendicular relationship to the frame. An elevator is movably located between the rear slider and the mast supports (or equivalently between the rear slider and frame) for vertically elevating the mast relative to the frame. A carriage is movably located between the frame and the forward slider for translating the forward slider along the length of the frame. A mast section of a drilling rig may be positioned on the sliders, such that controlled movement of the sliders, the elevator and the carriage can be used to position the mast section for connection to another structure.
[0015] In another embodiment, a slide pad is located on an upper surface of at least one of the sliders, so as to permit relative movement between the mast section and the slider when articulating the slider.
[0016] In another embodiment, an elevator is located on each side of the rearward slider, between the rearward slider and the mast support, such that each elevator is independently movable between a raised and lowered position for precise axial positioning of the mast section.
[0017] In another embodiment, a roller set between the carriage and the frame provides a rolling relationship between the carriage and the frame. A motor is connected to the carriage. A pinion gear is connected to the motor. A rack gear is mounted lengthwise on the frame, and engages the pinion gear, such that operation of the motor causes movement of the forward slider lengthwise along the frame.
[0018] In one embodiment, a drilling rig is provided, comprising a collapsible substructure including a base box, a drill floor and a pair of raising cylinders pivotally connected at one end to the base box and having an opposite articulating end. The raising cylinders are selectively extendable relative to their pivotal connection at the base box. A mast is provided, and has a lower mast section comprising a framework having a plurality of cross-members that define a transportable width of the lower mast section. The lower mast section has a plurality of legs, having an upper end attached to the framework, and an opposite lower end. A connection on the lower end of at least two legs is provided for pivotally connecting the lower mast section to the drill floor.
[0019] A pair of wing brackets is deployably secured to the lower mast section framework. The wing brackets are pivotal or slidable between a stowed position within the transport width of the lower mast section and a deployed position that extends beyond the transport width of the lower mast section. The raising cylinder is connectable to the wing brackets and extendable to rotate the lower mast section from a generally horizontal position to a raised position above the drill floor to a substantially vertical position above the drill floor, or to a desired angle that is less than vertical.
[0020] In another embodiment, each wing bracket of the drilling rig further comprises a frame having a pair of frame sockets on its opposite ends. The frame sockets pivotally connect the frame to the lower mast section. The wing brackets pivot to fit substantially within a portal in the lower mast section in the stowed position.
[0021] In another embodiment, the pivotal connection of the frame to the mast defines a pivot axis of the wing bracket about which the wing bracket is deployed and stowed. The pivotal connection between the lower mast section legs and the drill floor defines a pivot axis of the mast. In a preferred embodiment, the pivot axis of the wing bracket is substantially perpendicular to the pivot axis of the mast.
[0022] In another embodiment, each wing bracket of the drilling rig further comprises a frame and an arm extending from the frame towards the interior of the lower mast section. An arm socket is located on the end of the arm opposite to the frame. A bracket locking pin is attached to the lower mast section and is extendable through the arm socket to lock the wing bracket in the deployed position.
[0023] In another embodiment, each wing bracket of the drilling rig further comprises a frame and a lug box attached to the frame. The lug box is receivable of the articulating end of the raising cylinder. A lug socket is located on the lug box. A raising cylinder lock pin is extendable through the articulating end of the raising cylinder and the lug socket to lock the raising cylinder in pivotal engagement with the wing bracket.
[0024] In another embodiment, each wing bracket of the drilling rig further comprises a wing cylinder attached between the interior of the lower mast section and the arm of the wing bracket. Actuation of the wing cylinder moves the wing bracket between the deployed and stowed positions, without the need to have workers scaling the mast to lock the wing in position.
[0025] In one embodiment, a drilling rig assembly is provided comprising a collapsible substructure that is movable between the stowed and deployed positions. The collapsible substructure includes a base box, a drill floor framework and a drill floor above the drill floor framework, and a plurality of legs having ends pivotally connected between the base box and the drill floor. The legs support the drill floor above the base box in the deployed position. A raising cylinder has a lower end pivotally connected at one end to the base box and an opposite articulating end. The raising cylinder is selectively extendable relative to the pivotal connection at the base box. A cantilever is provided, having a lower end and an upper end, and being pivotally connected to the drill floor framework, the upper end movable between a stowed position below the drill floor and a deployed position above the drill floor. The upper end of the cantilever is connectable to the articulating end of the raising cylinder when the cantilever is in the deployed position, such that extension of the raising cylinder raises the substructure into the deployed position.
[0026] In one embodiment, the raising cylinder can be selectively connected to a lower mast section of a drilling mast that is pivotally connected above the drill floor such that extension of the raising cylinder raises the lower mast section from a generally horizontal position to a generally vertical position above the drill floor. In another embodiment, the raising cylinder raises the lower mast section from a generally horizontal position to a position above the drill floor that is within 50 degrees of vertical to permit slant drilling operations.
[0027] In another embodiment, a cantilever cylinder is pivotally connected at one end to the drill floor framework and has an opposite end pivotally connected to the cantilever. The cantilever cylinder is selectively extendable relative to its pivotal connection at the drill floor framework. Extension of the cantilever cylinder rotates the cantilever from the stowed position below the drill floor to the deployed position above the drill floor. Refraction of the cantilever cylinder refracts the cantilever from the deployed position above the drill floor to the stowed position below the drill floor.
[0028] In another embodiment, the substructure includes a box beam extended horizontally beneath the drill floor and a beam brace affixed to the box beam. The cantilever engages the beam brace upon rotation of the cantilever into the fully deployed position. Extension of the raising cylinder transfers the lifting force for deployment of the substructure to the box beam through the cantilever and beam brace.
[0029] In another embodiment, when the substructure is in the collapsed position and the raise cylinder is connected to the cantilever, the centerline of the raise cylinder forms an angle to the centerline of a substructure leg that is greater than 20 degrees. In another embodiment, when the substructure is in the collapsed position, the distance from the ground to the drill floor is less than 8 feet.
[0030] In another embodiment, connection of the upper end of the cantilever to the articulating end of the raising cylinder forms an angle between the cantilever and the raising cylinder of between 70 and 100 degrees, and extension of the raising cylinder to deploy the substructure reduces the angle between the cantilever and the raising cylinder to between 35 and 5 degrees.
[0031] In another embodiment, an opening is provided in the drill floor that is sufficiently large so as to permit passage of the cantilever as it moves between the stowed and deployed positions. A backer panel is attached to the cantilever and is sized for complementary fit into the opening of the drill floor when the cantilever is in the stowed position.
[0032] In another embodiment, the mast has front legs and rear legs. The front legs are connectable to front leg shoes located on the drill floor. The rear legs are connectable to rear leg shoes located on the drill floor. In another embodiment, the lower end of the raising cylinder is pivotally connected to the base box at a location beneath and between the front leg shoes and the rear leg shoes of the drill floor of the erected substructure. The lower end of the cantilever is pivotally connected to the drill floor framework at a location beneath the drill floor.
[0033] In one embodiment, a drilling rig assembly is provided, comprising a collapsible substructure movable between the stowed and deployed positions. The collapsible substructure includes a base box and a drill floor framework having a drill floor above the drill floor framework. The substructure further includes a plurality of legs having ends pivotally connected to the base box and drill floor framework, such that the legs support the drill floor above the base box in the deployed position of the substructure. A mast is included, having a lower mast section pivotally connected above the drill floor and movable between a generally horizontal position to a position above the drill floor.
[0034] A cantilever has a lower end and an upper end, the lower end being pivotally connected to the drill floor framework. The upper end is movable between a stowed position below the drill floor and a deployed position above the drill floor. A raising cylinder is pivotally connected at one end to the base box and has an opposite articulating end. The raising cylinder is selectively extendable relative to the pivotal connection at the base box. The articulating end of the raising cylinder is connectable to the mast such that extension of the raising cylinder moves the mast from a generally horizontal position above the drill floor to a generally vertical position above the drill floor. The articulating end of the raising cylinder is also connectable to the upper end of the cantilever such that extension of the raising cylinder raises the drilling substructure into the deployed position.
[0035] In another embodiment, the raising cylinder can be selectively connected to a lower mast section of a drilling mast that is pivotally connected above the drill floor such that extension of the raising cylinder raises the lower mast section from a generally horizontal position to a generally vertical position above the drill floor. In another embodiment, the partial extension of the raising cylinder is selectable for raising the mast to an angular position of at least 50 degrees of the vertical for slant drilling operations.
[0036] In another embodiment, a pair of wing brackets is pivotally attached to the lower mast section and capable of attachment to the raising cylinder. The raising cylinder may be connected to the wing brackets and extended to rotate the lower mast section from a generally horizontal position to a generally vertical position above the drill floor. In another embodiment, the partial extension of the raising cylinder is selectable for raising the mast to an angular position of at least 50 degrees of the vertical for slant drilling operations.
[0037] In another embodiment, the wing brackets are pivotal between a deployed position and a stowed position. A lug socket is located on each bracket and is connectable to the raising cylinder. In the stowed position, the wing brackets are contained within the width of the lower mast section. In the deployed position, the wing brackets extend beyond the width of the lower mast such that the sockets are in alignment with the articulating end of the raising cylinder.
[0038] In one embodiment, a drilling rig assembly is provided comprising a raising cylinder. The raising cylinder has a first angular position for connection to a deployable wing bracket connected to a mast section. The raising cylinder has a second angular position for detachment from the deployable wing bracket at the conclusion of raising a mast into the vertical position. The raising cylinder has a third angular position for connection to a retractable cantilever connected to a substructure in a stowed (collapsed) position. The raising cylinder has a fourth angular position for detachment of the raising cylinder from the retractable cantilever at the conclusion of raising a subsection into the deployed (vertical) position. In a preferred embodiment, the first angular position is located within 10 degrees of the fourth angular position, and the second angular position is located within 10 degrees of the third angular position.
[0039] In another embodiment, the raising cylinder has a pivotally connected end about which it rotates and an articulating end for connection to the deployable wing bracket and the retractable cantilever. The articulating end of the raising cylinder forms a first lifting arc between the first angular position and the second angular position. The articulating end of the raising cylinder forms a second lifting arc between the first angular position and the second angular position. The first and second lifting arcs intersect substantially above the pivotally connected end of the raising cylinder.
[0040] In another embodiment, the raising cylinder rotates in a first rotational direction while raising the mast sections. The raising cylinder rotates in a second rotational direction opposite to the first rotational direction while raising the substructure.
[0041] In another embodiment, the raising cylinder is a multi-stage cylinder having a maximum of three stages. In another embodiment, the wing brackets are deployed about a first pivot axis. The cantilevers are deployed about a second pivot axis that is substantially perpendicular to the first pivot axis.
[0042] In one embodiment, a drilling rig assembly is provided comprising a collapsible substructure movable between the stowed and deployed positions. The collapsible substructure includes a base box and a drill floor framework with a drill floor above the drill floor framework. A plurality of substructure legs have ends pivotally connected to the base box and the drill floor for supporting the drill floor above the base box in the deployed position.
[0043] A lower mast section of a drilling mast is provided comprising a lower section framework having a plurality of cross-members that define a transportable width of the lower mast section. A plurality of legs is pivotally connected to the lower section framework for movement between a stowed position and a deployed position. A connection is provided on the lower end of at least two legs for pivotally connecting the lower mast section above the drill floor.
[0044] A raising cylinder is pivotally connected at one end to the base box and has an opposite articulating end. The raising cylinder is selectively extendable relative to the pivotal connection at the base box. A wing bracket is pivotally connected to the lower mast section of a drilling mast and movable between a stowed position and a deployed position. The wing bracket is connectable to the articulating end of the raising cylinder when the cantilever is in the deployed position, such that extension of the raising cylinder raises the lower mast section into a generally vertical position above the drill floor.
[0045] In another embodiment, the legs are movable between a stowed position within the transport width and a deployed position external of the transport width. The wing brackets are also movable between a stowed position within the transport width and a deployed position external of the transport width.
[0046] In another embodiment, the legs are pivotally movable about a first axis. The wing brackets are pivotally movable about a second axis that is substantially perpendicular to the first axis.
[0047] In another embodiment, a cantilever is pivotally connected to the drill floor and is movable between a stowed position below the drill floor and a deployed position above the drill floor. The cantilever is connectable to the articulating end of the raising cylinder when the cantilever is in the deployed position, such that extension of the raising cylinder raises the drill floor into the deployed position.
[0048] In another embodiment, the cantilever is deployed about a third pivot axis substantially perpendicular to each of the first pivot axis and the second pivot axis.
[0049] In one embodiment, a method of assembling a drilling rig provides for steps comprising: setting a collapsible substructure onto a drilling site; moving a lower mast section into proximity with the substructure; pivotally attaching the lower mast section to a drill floor of the substructure; pivotally deploying a pair of wings outward from a stowed position within the lower mast section to a deployed position external of the lower mast section; connecting an articulating end of a raising cylinder having an opposite lower end to the substructure to each wing; extending the raising cylinder so as to rotate the lower mast section from a substantially horizontal position to an erect position above the drill floor; pivotally deploying a pair of cantilevers upward from a stowed position beneath the drill floor to a deployed position above the drill floor; connecting the articulating end of the raising cylinder to each deployed cantilever; and extending the raising cylinder so as to lift the substructure from a stowed, collapsed position to a deployed, erect position.
[0050] In another embodiment, the raising cylinders are adjusted as a central mast section and an upper mast section are sequentially attached to the lower mast section.
[0051] As will be understood by one of ordinary skill in the art, the sequence of the steps disclosed may be modified and the same advantageous result obtained. For example, the wings may be deployed before connecting the lower mast section to the drill floor (or drill floor framework).
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements.
[0053] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
[0054] FIG. 1 is an isometric view of a drilling system having certain features in accordance with the present invention.
[0055] FIG. 2 is an isometric exploded view of a mast transport skid having certain features in accordance with the present invention.
[0056] FIG. 3 is an isometric view of the mast transport skid of FIG. 2 , illustrated assembled.
[0057] FIG. 4 is an isometric view of a first stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0058] FIG. 5 is an isometric view of a second stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0059] FIG. 6 is an isometric view of a third stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0060] FIG. 7 is an isometric view of a fourth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0061] FIG. 8 is an isometric view of the wing bracket illustrated in accordance with an embodiment of the present invention.
[0062] FIG. 9 is an isometric view of the wing bracket of FIG. 8 , illustrated in the deployed position relative to a lower mast section.
[0063] FIGS. 10 , 11 and 12 are side views illustrating a fifth, sixth and seventh stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0064] FIG. 13 is a side view of an eighth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0065] FIG. 14 is a side view of a ninth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0066] FIG. 15 is an isometric view of a retractable cantilever, shown in accordance with the present invention.
[0067] FIG. 16 is a side view of a tenth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0068] FIG. 17 is a side view of an eleventh stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0069] FIG. 18 is a side view of a twelfth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0070] FIG. 19 is a side view of a thirteenth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
[0071] FIG. 20 is a diagram of the relationships between the mast and substructure raising components of the present invention.
[0072] FIG. 21 is a diagram of certain relationships between the raising cylinder, the deployable cantilever, and the substructure of the present invention.
[0073] FIG. 22 is a diagram of drilling rig assemblies of three different sizes, each using the same raising cylinder pair in combination with the deployable cantilever and deployable wing bracket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0074] The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
[0075] FIG. 1 is an isometric view of a drilling rig assembly 100 including features of the invention. As seen in FIG. 1 , drilling assembly 100 has a lower mast section 220 mounted on top of a substructure 300 .
[0076] Mast leg pairs 230 are pivotally attached to lower mast section 220 at pivot connections 226 . Mast leg cylinders 238 may be connected between lower mast section 220 and mast legs 230 for moving mast legs 230 between a transportable stowed position and the illustrated deployed position. The wider configuration of deployed mast legs 230 provides greater drilling mast wind resistance and more space on a drilling floor for conducting drilling operations.
[0077] A pair of wing brackets 250 is pivotally connected to lower mast section 220 immediately above pivot connections 226 . Wing brackets 250 are movable between a transportable stowed position and the illustrated deployed position.
[0078] Collapsible substructure 300 supports mast sections 200 , 210 (not shown) and 220 . Substructure 300 includes a base box 310 located at ground level. A drill floor framework 320 is typically comprised of a pair of side boxes 322 and a center section 324 . A plurality of substructure legs 340 is pivotally connected between drill floor framework 320 and the base box 310 . A box beam 326 (not visible) spans side boxes 322 of drill floor framework 320 for structural support. A drill floor 330 covers the upper surface of drill floor framework 320 .
[0079] A pair of cantilevers 500 is pivotally attached to drill floor framework 320 . Cantilevers 500 are movable between a transportable stowed position and a deployed position. In the stowed position, cantilevers 500 are located beneath drill floor 330 . In the deployed position, cantilevers 500 are raised above drill floor 330 .
[0080] A pair of raising cylinders 400 is provided for raising connected mast sections 200 , 210 and 220 into the vertical position above substructure 300 , and also for raising substructure 300 from a transportable collapsed position to the illustrated deployed position. Raising cylinders 400 are also provided for lowering substructure 300 from the illustrated deployed position to a transportable collapsed position, and for lowering connected mast sections 200 , 210 and 220 into the horizontal position above collapsed substructure 300 .
[0081] Raising cylinders 400 raise and lower connected mast sections 200 , 210 and 220 by connection to wing brackets 250 . Raising cylinders 400 raise and lower substructure 300 by connection to cantilevers 500 .
[0082] FIG. 2 is an isometric exploded view of an embodiment of transport skid 600 . Transport skid 600 is loadable onto a standard low-boy trailer as is well known in the industry. Transport skid 600 has a forward end 602 and a rearward end 604 . Transport skid 600 supports a movable forward slider 620 and a rearward slider 630 .
[0083] Forward slider 620 is mounted on a carriage 610 . A forward hydraulic cylinder 622 is connected between carriage 610 and forward slider 620 . A pair of front slider pads 626 may be located between forward slider 620 and frame sides 606 .
[0084] Carriage 610 is located on skid 600 and movable in a direction between forward end 602 and rearward end 604 , separated by skid sides 606 . In one embodiment, a roller set 612 provides a rolling relationship between carriage 610 and skid 600 .
[0085] A motor 614 is mounted on carriage 610 . A pinion gear 616 is connected to motor 614 . A rack gear 618 is mounted lengthwise on skid 600 . Pinion gear 616 engages rack gear 618 , such that operation of motor 614 causes movement of carriage 610 lengthwise along skid 600 .
[0086] Rearward slider 630 is mounted on a rearward base 632 . A rearward hydraulic cylinder 634 is connected between rearward slider 630 and rearward base 632 . A pair of rear slider pads 636 may be located between rearward slider 630 and skid sides 606 . In one embodiment, bearing pads 638 are located on the upper surface of rearward slider 630 for supporting mast section 220 .
[0087] In one embodiment, an elevator 640 is located on each side of rearward slider 630 , between rearward slider 630 and skid 600 , each being movable between a raised and lowered position.
[0088] FIG. 3 is an isometric view of mast transport skid 600 of FIG. 2 , illustrated assembled. Forward slider 620 is movable in the X-axis and Y-axis relative to skid 600 . Actuation of motor 614 causes movement of forward slider 620 along the X-axis. Actuation of forward cylinder 622 causes movement of forward slider 620 along the Y-axis.
[0089] Rearward slider 630 is movable independent of forward slider 620 . Rearward slider 630 is movable in the Y-axis and Z-axis relative to skid 600 . Actuation of rearward cylinder 634 causes movement of rearward slider 630 along the Y-axis. Actuation of elevators 640 causes movement of rearward slider 630 along the Z-axis. In one embodiment, elevators 640 are independently operable, thus adding to the degrees of freedom of control of rearward slider 630 .
[0090] FIGS. 4 through 7 illustrate the initial stages of the rig-up sequence performed in accordance with the present invention. FIG. 4 is an isometric view of a first stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. Lower mast section 220 is carried on forward slider 620 and rearward slider 630 of transport skid 600 . Transport skid 600 is mounted on a trailer 702 connected to a tractor 700 .
[0091] A plurality of structural cross-members 222 (not shown) defines a mast framework width 224 (not shown) of lower mast section 220 . At this stage of the sequence, mast legs 230 are in the retracted position, and within framework width 224 . Also at this stage, wing brackets 250 are in the retracted position, and also within framework width 224 . By obtaining a stowed position of mast legs 230 and wing brackets 250 , the desired transportable framework width 224 of lower mast section 220 is achieved. Substructure 300 is in the collapsed position, on the ground, and being approached by tractor 700 and transport skid 600 .
[0092] FIG. 5 is an isometric view of a second stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. At this stage, tractor 700 and trailer 702 are backed up to a position of closer proximity to substructure 300 , which is on the ground in a collapsed position. Having moved mast legs 230 past the point of interference with raising cylinders 400 , legs 230 are deployed by mast leg cylinders 238 (not shown), which rotates legs about the axis Z of pivot connection 226 .
[0093] Each mast leg pair 230 has a front leg 232 and a rear leg 234 . Shoe connectors 236 are located at the base of legs 230 . Front shoes 332 and rear shoes 334 are located on drilling floor 330 for receiving shoe connectors 236 of front legs 232 and rear legs 234 , respectively. A pair of inclined ramps 336 is located on drilling floor 330 , inclining upwards towards front shoes 332 .
[0094] Elevators 640 are actuated to raise rearward slider 630 and thus mast legs 230 of lower mast 220 along the Z-axis ( FIG. 3 ) above obstacles related to substructure 300 as tractor 700 and trailer 702 are backed up to a position of closer proximity to substructure 300 (see FIG. 4 ). In this position (referring also to FIG. 2 ), forward cylinder 622 of forward slider 620 and rearward cylinder 634 of rearward slider 630 are actuated to finalize Y-axis ( FIG. 3 ) alignment of mast legs 230 of lower mast section 220 with inclined ramps 336 ( FIGS. 4 and 5 ). The option of like or opposing translation of forward slider 620 and rearward slider 630 along the Y-axis is especially beneficial for this purpose. Using this alignment capability, shoe connectors 236 of front legs 232 are aligned with inclined ramps 336 .
[0095] FIG. 6 is an isometric view of a third stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. In this stage, rearward slider 630 is lowered by elevators 640 (not visible), positioning shoe connectors 236 of front legs 232 onto inclined ramps 336 . This movement disengages rearward slider 630 from lower mast section 220 .
[0096] Carriage 610 is translated from forward end 602 towards rearward end 604 . In one embodiment, this movement is accomplished by actuating motor 614 . Motor 614 rotates pinion gear 616 which is engaged with rack gear 618 , forcing longitudinal movement of carriage 610 and forward slider 620 along the X-axis ( FIG. 3 ). As a result, lower mast section 220 is forced over substructure 300 , as shoe connectors 236 slide up inclined ramps 336 .
[0097] FIG. 7 is an isometric view of a fourth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. As shoe connectors 236 reach the top of inclined ramps 336 , they align with, and are connected to, front leg shoes 332 .
[0098] In the embodiment described, wing brackets 250 ( FIG. 9 ) are pivotally connected to lower mast section 220 proximate to, and above, pivot connections 226 ( FIG. 7 ). Wing brackets 250 are movable between a transportable stowed position and the illustrated deployed position.
[0099] A wing cylinder 252 ( FIG. 9 ) may be connected between lower mast section 220 and each wing bracket 250 for facilitating movement between the stowed and deployed positions. Connection sockets 254 are provided on the ends of wing brackets 250 for connection to raising cylinder 400 . As shown in FIGS. 7 and 9 , wing brackets 250 are moved into the deployed position by actuating wing cylinders 252 ( FIG. 9 ).
[0100] Raising cylinder 400 is pivotally connected to base box 310 . In a preferred embodiment, raising cylinder 400 has a lower end 402 pivotally connected to base box 310 at a location between the pivotal connections of substructure legs 340 to base box 310 (see FIG. 18 ). Raising cylinder 400 has an opposite articulating end 404 (see FIG. 9 ). In a preferred embodiment, raising cylinder 400 is a multi-stage telescoping cylinder capable of extension of a first stage 406 , a second stage 408 and a third stage 410 . A positioning cylinder 412 may be connected to each raising cylinder 400 for facilitating controlled rotational positioning of raising cylinder 400 .
[0101] In the stage of the rig-up sequence illustrated in FIG. 7 , raising cylinders 400 are pivotally moved into alignment with deployed wing brackets 250 for connection to sockets 254 . Notably, raising cylinders 400 bypass the transported framework width 224 of lower mast section 220 in order to connect to wing brackets 250 on the far side of lower mast section 220 . It is thus required that mast raising cylinders 400 be separated by a distance slightly greater than framework width 224 . Lower mast section 220 is now supported by wing brackets 250 . This is accomplished by the present invention without the addition of separately transported and assembled mast sections.
[0102] As described above, an embodiment of the invention further includes a retractable push point for raising substructure 300 significantly above drill floor 330 and significantly forward of lower mast section 220 .
[0103] Lower mast section 220 is lifted slightly by extension of first stage 406 of raising cylinder 400 , disengaging lower mast section 220 from transport skid 600 , allowing tractor 700 and trailer 702 to depart.
[0104] As seen in FIG. 7 , mast legs 230 are pivotally deployed about first pivot axis Z (at 226 ), and wing brackets 250 are pivotally deployed about second pivot axis 264 that is substantially perpendicular to first pivot axis Z (at 226 ).
[0105] FIG. 8 is an isometric view of wing bracket 250 in accordance with an embodiment of the present invention. FIG. 9 is an isometric view of wing bracket 250 in the deployed position relative to lower mast section 220 . Referring to the embodiment of wing bracket 250 illustrated in FIG. 8 , wing bracket 250 is comprised of a framework 260 designed to fit within a portal 228 in lower mast section 220 (see FIG. 9 ). Frame 260 has a pair of sockets 262 for pivotal connection to lower mast section 220 within portal 228 . The pivotal connection defines an axis 264 about which wing bracket 250 is deployed and stowed. In one embodiment, axis 264 is substantially perpendicular to first pivot axis Z (at 226 ) about which legs 230 are deployed and stowed.
[0106] A lug box 256 extends from frame 260 . Socket 254 is located on lug box 256 . An arm 270 extends inward towards the interior of lower mast section 220 . A bracket socket 272 is located near the end of arm 270 .
[0107] Referring to FIG. 9 , wing cylinder 252 extends between lower mast section 220 and arm 270 to deploy and stow wing bracket 250 . In the deployed position, a bracket locking pin 274 extending through portal 228 passes through bracket socket 272 ( FIG. 8 ) to lock wing bracket 250 in the deployed position. With wing bracket 250 locked in the deployed position, raising cylinder 400 is extended. Lug box 256 receives articulating end 404 of raising cylinder 400 . A raising cylinder locking pin 258 is hydraulically operable to pass through articulating end 404 and socket 254 to lock raising cylinder 400 to wing bracket 250 .
[0108] FIGS. 10 , 11 and 12 are side views illustrating a fifth, sixth and seventh stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. Referring to FIGS. 10 through 11 , it is seen that subsequent tractor 700 and trailer 702 carry central mast section 210 for connection to lower mast section 220 , and carry upper mast section 200 for connection to central mast section 210 . At this time, the weight of the collective mast sections is born by the raising cylinder 400 as transmitted through the wing brackets 250 . Raising cylinder 400 can be extended to align connected mast sections with each incoming mast section. For example, raising cylinder 400 can be extended to align connected mast sections 210 with 220 , and 200 with 210 .
[0109] FIGS. 13 and 14 are side views illustrating an eighth and ninth sequence for a drilling system, as performed in accordance with the present invention. In these steps, lower mast section 220 (and connected central and upper mast sections 210 and 200 ) is raised into a vertical position. In FIG. 13 , lower mast section 220 is illustrated pivoted upwards by extension of first stage 406 and second stage 408 of raising cylinder 400 . In FIG. 14 , lower mast section 220 is illustrated pivoted into the fully vertical position by extension of third stage 410 of raising cylinder 400 .
[0110] FIG. 15 is an isometric view of cantilever 500 , shown in accordance with the present invention. Cantilever 500 has a lower end 502 for pivotal connection to drill floor framework 320 of substructure 300 . Cantilever 500 has an upper end 504 for connection to articulating end 404 of raising cylinder 400 . A load pad 508 is provided for load bearing engagement with a beam brace 328 (not shown) located on substructure 300 . A backer panel 510 provides a complementary section of drill floor 330 when cantilever 500 is in the stowed position.
[0111] Cantilever 500 is movable between a transportable stowed position and a deployed position. In the stowed position, cantilever 500 is located beneath drill floor 330 . In the deployed position, upper end 504 of cantilever 500 is raised above drill floor 330 for connection to articulating end 404 of raising cylinder 400 . A cantilever cylinder 506 (not shown) may be provided for moving cantilever 500 between the transportable stowed position and the deployed position.
[0112] FIGS. 16 , 17 , 18 , and 19 are side views illustrating tenth, eleventh, twelfth, and thirteenth stages of the rig-up sequence for a drilling system, illustrating the erection of substructure 300 , as performed in accordance with the present invention. In FIG. 16 , raising cylinder 400 has been detached from wing brackets 250 , and articulating end 404 of raising cylinder 400 has been retracted. Wing brackets 250 may remain in the deployed position during drilling operations.
[0113] Cantilever 500 has been moved from the stowed position beneath drill floor 330 into the deployed position in which upper end 504 of cantilever 500 is above drill floor 330 . Cantilever 500 may be moved between the stowed and deployed positions by actuation of cantilever cylinder 506 . Upper end 504 of cantilever 500 is connected to articulating end 404 of raising cylinder 400 . In this position, load pad 508 of cantilever 500 is in complementary engagement with beam brace 328 for transmission of lifting force as applied by raising cylinder 400 .
[0114] FIG. 17 is a side view of an eleventh stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. In the view, first stage 406 of raising cylinder 400 is fully extended and second stage 408 ( FIG. 18 ) is being initiated. As a result of the force being applied on cantilever 500 , as transferred to beam brace 328 , drill floor framework 320 is raising off of base box 310 as substructure 300 is moved towards an erected position.
[0115] FIG. 18 is a side view of a twelfth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. In this view, first stage 406 and second stage 408 of raising cylinder 400 have been extended to lift drill floor framework 320 over base box 310 as substructure 300 is moved into the fully deployed position with substructure legs 340 supporting the load of mast sections 200 , 210 , 220 , and drill floor framework 320 . Conventional locking pin mechanisms and diagonally oriented beams are used to prevent further rotation of substructure legs 340 , and thus maintain substructure 300 in the deployed position.
[0116] FIG. 19 is a side view of a thirteenth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. In this view, articulating end 404 of raising cylinder 400 is disconnected from upper end 504 of cantilever 500 . Raising cylinder 400 is then retracted. Cantilever 500 is moved into the stowed position by actuation of cantilever cylinder 506 . In the stowed position, backer panel 510 of cantilever 500 becomes a part of drill floor 330 , providing an unobstructed space for crew members to perform drilling operations.
[0117] FIG. 20 is a diagram of the relationships between lower mast section 220 and substructure 300 raising components 250 , 400 and 500 of the present invention. More specifically, FIG. 20 illustrates one embodiment of preferred kinematic relationships between deployable wing bracket 250 , deployable cantilever 500 and raising cylinder 400 .
[0118] In one embodiment, upper end 504 of cantilever 500 is deployed to a location above drill floor 330 that is also forward of front leg shoes 332 . In one embodiment, pivotally connected end 402 of raising cylinder 400 is connected to substructure 300 at a location beneath and generally between front leg shoes 332 and rear leg shoes 334 of drill floor 330 of erected substructure 300 . Also in this embodiment, lower end 502 of cantilever 500 is pivotally connected at a location beneath drill floor 330 and forward of front leg shoes 332 .
[0119] As was seen in an embodiment illustrated in FIG. 7 , mast legs 230 are pivotally deployed about a first pivot axis, and wing brackets 250 are pivotally deployed about a second pivot axis that is substantially perpendicular to the first pivot axis of mast legs 230 . Cantilever 500 is deployed about a third pivot axis that is substantially perpendicular to the first and second pivot axes of mast legs 230 and wing brackets 250 , respectively.
[0120] As seen in FIG. 1 , there is a pair of raising cylinders 400 , each raising cylinder 400 connectable to a cantilever 500 and a wing 250 . In a preferred embodiment, the pair of raising cylinders 400 rotates in planes that are parallel to each other. In another preferred embodiment, cantilevers 500 rotate in planes that are substantially within the planes of rotation of the raising cylinders. This configuration has a number of advantages related to the alignment and connection of upper end 504 of cantilever 500 to articulating end 404 of raising cylinder 400 . This embodiment also optimizes accessibility of the deployed cantilevers 500 of sufficient size to carry the significant sub-lifting load beneath and above the very limited space on drill floor 330 and within drill floor framework 320 . This embodiment also provides deployed engagement of load pad 508 with a beam brace 328 located on substructure 300 , without placing a misaligned load of the pivotal connections of cantilevers 500 and cylinders 400 . It will be understood by one of ordinary skill in the art that a modest offset of the planes would behave as a substantial mechanical equivalent of these descriptions.
[0121] As was seen in an embodiment illustrated in FIGS. 4-8 , mast legs 230 are pivotally deployed about a first pivot axis Z (at 226 ), and wing brackets 250 are pivotally deployed about a second pivot axis 264 that is substantially perpendicular to first pivot axis Z (at 226 ) of mast legs 230 . Cantilever 500 is deployed about a third pivot axis that is substantially perpendicular to the first and second pivot axes of mast legs 230 and wing brackets 250 , respectively. This embodiment is advantageous in that mast legs 230 may be pivoted about an axis that reduces the transport width of the mast. It is further advantageous in that the wings remain gravitationally retracted during transportation, and when deployed.
[0122] One such plane of rotation is illustrated in FIG. 20 . As illustrated in FIG. 20 , when connected to deployed wing brackets 250 , articulating end 404 forms a first arc A 1 upon extension of raising cylinder 400 . Arc A 1 is generated in a first arc direction as mast sections 200 , 210 and 220 are raised.
[0123] When connected to deployed cantilever 500 , articulating end 404 forms a second arc A 2 upon extension of raising cylinder 400 . Arc A 2 is generated in a second arc direction opposite that of A 1 , as collapsed substructure 300 is raised.
[0124] A vertical line through the center of pivotally connected end 402 of cantilever 400 is illustrated by axis V. In a preferred embodiment, the intersection of first arc A 1 and second arc A 2 relative to axis V, is located within + or −10 degrees of axis V.
[0125] In one embodiment illustrated in FIG. 20 , the angular disposition of raising cylinder 400 has four connected positions. The sequential list of the connected positions is: a) retracted connection to wing brackets 250 ; b) extended connection to wing brackets 250 ; c) retracted connection to cantilever 500 ; and d) extended connection to cantilever 500 . In the embodiment illustrated in FIG. 20 , the angular disposition of raising cylinder 400 in position a is within 10 degrees of position d, and the angular disposition of raising cylinder 400 in position b is within 10 degrees of position c. The angular disposition of each position a, b, c, and d to vertical axis V is denoted as angles a′, b′, c′, and d′, respectively.
[0126] Having connected positional alignments within approximately 10 degrees optimizes the power and stroke of raising cylinder 400 . Also, having connected positional alignments b and c within approximately 10 degrees speeds alignment and rig-up of drilling system 100 .
[0127] FIG. 21 is a diagram of the relationship between raising cylinder 400 , deployable cantilever 500 and substructure leg 340 . In this diagram, substructure leg 340 is relocated for visibility of the angular relationship to raising cylinder 400 , as represented by angle w. Angle w is critical to the determination of the load capacity requirement of raising cylinder 400 . Without the benefit of the higher push point provided by deployable cantilever 500 , angle w would be approximately 21 degrees of lees for the embodiment shown. By temporarily raising the push point or pivotally connected end 402 above drill floor 330 , w is increased, lowering the load capacity requirement of raising cylinder 400 .
[0128] Provided in combination with deployable wing brackets 250 , the configuration of drilling rig assembly 100 of the present invention permits the optimal sizing of mast raising cylinders 400 , as balanced between retracted dimensions, maximum extension and load capacity, all within the fewest hydraulic stages. Specifically, mast raising cylinders 400 can achieve the required retracted and extended dimensions to attach to wing brackets 250 and extend sufficiently to fully raise mast sections 200 , 210 and 220 , while also providing an advantageous angular relationship between substructure legs 340 and raising cylinder 400 such that sufficient lift capacity is provided to raise substructure 300 . This is all accomplished with the fewest cylinder stages possible, including first stage 406 , second stage 408 and third stage 410 .
[0129] As seen in the embodiment illustrated in FIG. 21 , connection of upper end 504 of cantilever 500 to articulating end 404 of raising cylinder 400 , when substructure 300 is in the stowed position, forms an angle x between cantilever 500 and raising cylinder 400 of between 70 and 100 degrees. Extension of raising cylinder 400 to deploy substructure 300 reduces the angle between cantilever 500 and raising cylinder 400 to between 5 and 35 degrees.
[0130] FIG. 22 is a diagram of drilling rig assemblies 100 of three different sizes, each using the same raising cylinder pair 400 in combination with the same deployable cantilever 500 and deployable wing bracket 250 .
[0131] As seen in FIG. 22 , the configuration of drilling rig assembly 100 of the present invention has the further benefit of enabling the use of one size of raising cylinder pair 400 in the same configuration with wing brackets 250 and cantilever 500 to raise multiple sizes of drilling rig assemblies 100 . As seen in FIG. 22 , a substructure 300 for a 550,000 lb. hook load drilling rig 100 is shown having a lower ground to drill floor 330 height than does substructures 302 and 304 . Drilling rig designs for drilling deeper wells may encounter higher subterranean pressures, and thus require taller BOP stacks beneath drill floor 330 . As illustrated, the same wing brackets 250 , cantilever 500 and the raising cylinders 400 can be used with substructure 302 for a 750,000 lb. hook load drilling rig 100 , or with substructure 304 for a 1,000,000 lb. hook load drilling rig 100 .
[0132] As also illustrated in FIG. 22 , the configuration of drilling rig assembly 100 of the present invention has a drill floor 330 height to ground of distance “h” which is less than 8 feet. This has the significant advantage of minimizing the incline and difficulty of moving mast sections 200 , 210 , 220 along inclined ramps 336 from the transport position into connection with front shoes 332 on top of collapse substructure 300 . This is made possible by the kinematic advantages achieved by the present invention.
[0133] As described, the relationships between the several lifting elements have been shown to be extremely advantageous in limiting the required size and number of stages for raising cylinder 400 , while enabling craneless rig-up of masts ( 200 , 210 , 220 ) and substructure 300 . As further described above, the relationships between the several lifting elements have been shown to enable optimum positioning of a single pair of raising cylinders 400 to have sufficient power to raise a substructure 300 , and sufficient extension and power at full extension to raise a mast ( 200 , 210 , 220 ) without the assistance of intermediate booster cylinder devices and reconnecting steps, and to permit such expedient mast and substructure raising for large drilling rigs.
[0134] Referring back to FIGS. 4 through 7 , 9 , 13 through 14 , and 16 through 19 , a method of assembling a drilling rig 100 is fully disclosed. The disclosure above, including the enumerated figures, provides for steps comprising: setting collapsible substructure 300 onto a drilling site; moving lower mast section 220 into proximity with substructure 300 ( FIGS. 4-6 ); pivotally attaching lower mast section 220 to a drill floor 330 of substructure 300 ( FIG. 7 ); pivotally deploying a pair of wing brackets 250 outward from a stowed position within lower mast section 220 to a deployed position external of lower mast section 220 ( FIGS. 7 and 9 ); connecting articulating ends 404 of a pair of raising cylinders 400 (having opposite pivotally connected end 402 connected to substructure 300 ) to each wing bracket 250 ( FIG. 7 ); extending raising cylinders 400 so as to rotate lower mast section 220 from a substantially horizontal position to an erect position above drill floor 330 ; pivotally deploying a pair of cantilevers 500 upward from a stowed position beneath drill floor 330 to a deployed position above drill floor 330 ; connecting articulating ends 404 of raising cylinders 400 to each deployed cantilever 500 ; and extending raising cylinders 400 so as to lift substructure 300 from a stowed, collapsed position to a deployed, erect position.
[0135] In another embodiment, shown in FIGS. 10 through 12 , raising cylinders 400 are adjusted as central mast section 210 and upper mast section 200 are sequentially attached to lower mast section 220 .
[0136] As will be understood by one of ordinary skill in the art, the sequence of the steps disclosed may be modified and the same advantageous result obtained. For example, the wing brackets may be deployed before connecting the lower mast section to the drill floor (or drill floor framework).
[0137] 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 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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The present invention discloses a high-capacity drilling rig system that includes novel design features that alone and more particularly in combination facilitate a fast rig-up and rig-down with a single set of raising cylinders and maintains transportability features. In particular, a transport trailer is disclosed having a first support member and a drive member which align the lower mast portion with inclined rig floor ramps and translate the lower mast legs up the ramps and into alignment for connection. A pair of wing brackets is pivotally deployed from within the lower mast width for connection to the raising cylinder for raising the mast from a horizontal position into a vertical position. A cantilever is pivotally deployed from beneath the rig floor to a position above it for connection to the raising cylinder for raising the substructure from a collapsed position into the erect position.
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TECHNICAL FIELD
The invention relates to the accurate measurement of speech and noise levels in a transmission path, such as a telephone connection.
BACKGROUND OF THE INVENTION
The levels of noise and speech signals propagating through an in-service transmission path are used to determine the quality of the path. For example, the transmission quality of a path may be questionable if the level of the noise signals is high, or if the level of the speech signals is low (weak). It can be appreciated, therefore, that an accurate determination of the quality of a transmission path requires an accurate measurement of the levels of noise and speech signals as they propagate through the transmission path.
Prior measuring arrangements have been unable to achieve such accuracy, since they do not measure accurately the level of noise signals present in a transmission path. For example, one such prior measuring arrangement performs multiple measurements over respective 30 millisecond windows when noise signals are believed to be present on the transmission path. Noise signals are present when the levels of signals on the path fall below a predetermined threshold. At that point, the prior arrangement measures the levels of all signals that are present on the transmission path within the 30 millisecond window. The arrangement then determines an average noise value for the window. When the prior measuring arrangement has completed a number of such measurements it then outputs, as the noise level of the transmission path, the average having the lowest value.
SUMMARY OF THE INVENTION
I have realized that such a measurement is not accurate since speech signals could be present during a 30 millisecond window and, therefore, would bias the resulting average. I have further realized that the minimum of such averages most likely underestimates the actual noise level of a transmission path.
Accordingly, the art is advanced and the foregoing problems are obviated by providing a facility which obtains a nonintrusive measurement of speech and noise signals present on an in-service connections by determining whether samples of signals received from the connection correspond to speech or noise and then determining the speech and noise levels of the connection as a function of such samples. In this way a dynamic noise measurement is obtained, in accord with an aspect of the invention, by determining the median of a number of measurements of the average power levels of noise signals, in which the measurements are accumulated over respective periods of time when it is known that noise signals are present on the connection. A speech level measurement is obtained in a similar manner.
More specifically, an average power level is determined for succeeding groups of noise signals that are present on the connection within a predetermined period of time. When a predetermined number of such average power levels have been determined, then, in accord with an aspect of the invention, the median of such average power levels is outputted to an output terminal as the noise measurement. Accordingly, an actual average, rather than a minimum, measurement for noise signals is obtained.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 illustrates the manner in which signal level measuring equipment may be connected to an in-service network connection for the purpose of measuring the level of noise and/or speech signals propagating through the connection, and
FIGS. 2-4 illustrate in flow chart form the program which implements the invention in the digital signal processor of FIG. 1.
DETAILED DESCRIPTION
FIG. 1 illustrates a conventional telephone connection established between station sets S1 and S2 via Central Offices (COs) 200 and 250 and interexchange network 300. The way in which a telephone connection is established between telephone station sets is well-known and will not be discussed herein. However, it is seen from the FIG. that such a connection includes telephone line 201, which connects station set S1 to Central Office (CO) 200. At CO 200, a conventional hybrid arrangement converts 2-wire telephone line 201 to a so-called 4-wire transmission path comprising paths 203 and 204. Paths 203 and 204 are then connected through toll switch 305, intertoll connection 310 and toll switch 315 to CO 250 where another conventional hybrid arrangement converts paths 203 and 204 into a 2-wire telephone line extending to station S2.
As is well-known, interexchange network 300 may be of the type which transports speech signals via its associated intertoll network 310 in digital form. Accordingly, COs 209 and 250 include analog-to-digital and digital-to-analog converters in the interface that they present to network 300.
In order to gauge the quality of the transmission connection between station sets S1 and S2, copies (samples) of the digital speech signals traveling in the E and F directions along intertoll connection 310 are supplied to transmission measurement arrangement 100 via leads 101 and 102, respectively. Digital signals appearing on leads 101 and 102 are then presented to respective inputs of Digital Signal Processor (DSP) 115 via interface circuits 105 and 110, respectively. DSP 115, which may be, for example, the model DSP32 available from AT&T, analyzes the digital samples that it receives from the E and F directions to determine if they represent speech or noise. Specifically, if particular digital samples represent a level which equals or exceeds a predetermined threshold, for example, a threshold having a level of -37 dBm, then DSP 115 operating in accord with the principles of the invention concludes that the samples represent speech signals.
It is well-known that a speaker typically drops the level of his/her voice when completing a response. Accordingly, the level of a speaker's "trailing" voice signals may be below the aforementioned threshold. To account for that situation, DSP 115 is arranged in accord with an aspect of the invention so that when it detects a speech signal that equals or exceeds the threshold it then considers all succeeding samples that occur within a predetermined window--illustratively 200 milliseconds--to be speech signals, even though the levels of those signals may be below the threshold, as will be explained below.
More specially, DSP 115, is arranged to process a number of samples each second, e.g., 8000, for each of the E and F directions. To facilitate such processing, DSP 115, accumulates the values of a group of samples, e.g., 16, as they are received. DSP 115 then determines an average power value for the group. If the average value equals or exceeds the aforementioned threshold of -37 dBm, then DSP 115 considers the average power value and succeeding ones of such values occurring within the aforementioned window to represent speech. As an aspect of the invention, DSP 115 is arranged to accumulate a predetermined number--illustratively 7500--of such average power values for both the E and F directions. When it has concluded such processing, DSP 115 outputs via lead 103 the average value of the 7500 power values it accumulated for the E direction and for the F direction. The outputted averages respectively represent the speech level measurements for the E and F directions.
It can be appreciated that during the measurement speech signals traveling in either the E or F direction could be an echo, which, if included in the speech measurement, could bias the overall speech measurement that DSP 115 outputs to lead 103. To guard against such a possibility, DSP 115 is arranged, in accord with an aspect of the invention, to determine if a group of speech samples that it receives represents an echo. If DSP 115 finds that to be the case, then it discards the group. In particular, if DSP 115 receives simultaneously a group of speech samples from both the E and F directions, then DSP 115 determines if one of the groups represents an echo. If that is the case, then, as mentioned above, DSP 115 discards the average power level determined for that group, as will be explained below.
In addition, if DSP 115 finds that the average power level of a group of samples received from either the E or F direction is below -37 dBm and is not within the aforementioned speech window, then DSP 115 considers the group to be noise. If that is the case, then DSP 115 accumulates (sums) that average power level with the average power levels determined for succeeding groups of samples obtained from the same direction within a 200 millisecond window. However, if any one of such succeeding average power levels equals or exceeds -37 dBm, then DSP 115 discards the accumulation. DSP 115 does so since a power level of -37 dBm most likely represents speech and, therefore, would affect adversely the noise measurement represented by the accumulation, as will be explained below.
Turning now to FIGS. 2 through 4, there is shown in flow chart form the program which implements the principles of the invention in DSP 100. Specifically, when the program is entered at block 500 it clears a number of flags, counters and accumulators (identified below) and then proceeds to block 501. At block 501, the program accepts a sample of a signal traveling in the F direction over intertoll transmission path 310 (FIG. 1), and then proceeds to block 502. At block 502, the program calculates in a conventional manner the absolute value of the voltage level represented by the received sample. The program then adds the result of the calculation to a running sum (accumulation) designated FDSUM. The program then increments a counter designated SUMCTR by a value of one. The program uses SUMCTR to determine when it has acquired a group of N samples from both the E and F directions, as will be seen below. In an illustrative embodiment of the invention, the value of N may be, for example, 16. Similarly, at blocks 503 and 504, the program acquires a sample of a signal traveling in the E direction and then determines the absolute value of the voltage level of that sample. The program then adds the latter result to a running sum designated EDSUM. The program then proceeds to block 505.
At block 505, the program returns to block 501 if the value contained in SUMCTR indicates that it has not acquired N samples (e.g., 16 samples) for each of the two oppositely directed transmission paths. Otherwise, the program proceeds to block 506 where it clears (sets to zero) the contents of SUMCTR and then proceeds to block 507. At block 507, the program squares the average voltage level represented by FDSUM/16 (EDSUM/16) to obtain a value designated FDVAL (EDVAL), which is proportional to the average power level of the group of samples acquired from the F (E) direction. The program then proceeds to block 508 where it clears FDSUM and EDSUM and increments two counters respectively designated FDHANGOVER and EDHANGOVER by a value of one. The program then proceeds to block 509. (The purpose of the latter counters will be made clear below. However, it suffices to say at this point that those counters represents a particular period of time which is defined herein as being a "hangover" time.)
Program blocks 509, 510 and 518 through 520 represent a program module which determines if the value of FDVAL determined at block 507 represents speech. Program blocks 511, 512 and 521 through 523 perform a similar function on EDVAL.
Specifically, at block 509, the program compares the value FDVAL with a threshold (TH) having a predetermined value--illustratively -37dBm. If the program finds that the value of FDVAL equals or exceeds the value of TH, then it proceeds to block 510. Otherwise, the program proceeds to block 518. At block 510, the program sets the contents of counter FDHANGOVER to zero and sets a flag FDSTATE to equal a value of one to indicate that the value of FDVAL represents speech. The program then proceeds to block 511.
As an aspect of the invention, the program classifies as speech signals, samples of signals acquired within 200 milliseconds of a group of samples whose power value, e.g., FDVAL, exceeds TH. Accordingly, the program uses a "hangover" time to include samples of weak speech signals which follow, within 200 milliseconds, a strong speech signal. The program implements the foregoing by incrementing hangover counter FDHANGOVER by a value of one each time it passes through block 508, in which, in accord with the aforementioned sampling rate, a value of one represents two milliseconds. In addition, the program clears counter FDHANGOVER at block 510 to ensure that the F-direction samples that are acquired within the next 200 milliseconds are classified as speech signals.
In particular, when the program arrives at block 518, it compares the value represented by the contents of counter FDHANGOVER with a predetermined value M, e.g., 100, representing 200 milliseconds. The program proceeds to block 519 if the comparison indicates that the former value is less than the latter value, otherwise, the program proceeds to block 520. At block 519, the program sets flag FDSTATE to a value of one to indicate that the current value of FDVAL represents speech. At block 520, the program sets the value of FDSTATE to zero to indicate that the value of FDVAL does not represent speech, since that value is below TH and was derived from samples that were received after the expiration of the hangover time. The program then proceeds to block 511 (FIG. 3).
As mentioned above, blocks 511, 512 and 521 through 523 perform a similar function with respect to EDVAL. As such, when the program arrives at block 513, the value of flag EDSTATE will be set to a one or zero, indicating that the value of EDVAL represents speech or nonspeech (noise) signals, respectively.
Blocks 513, 514 and 524 represent a program module which determines if (a) speech signals were detected in one direction only, E or F, or both directions, or (b) nonspeech signals were detected in both the E and F directions. If speech is detected in both directions, then the program (blocks 526 and 527) determines, in accord with an aspect of the invention, if either the E- or F-direction speech is an echo. If that is the case, then the program retains the power level derived from the true speech samples and discards the power level derived from the echo. The program discards the latter power level, since it represents a reflection of true speech signals. If the module determines that EDVAL and FDVAL both represent speech then the module nevertheless discards those values, since the level of speech signals represented by one of those values could have been "boosted" by an echo, thereby making the level of such signals somewhat higher than the actual level of speech signals.
Specifically, the program at block 513 proceeds to block 514 if it finds that FDSTATE is set to a value of one, which, as mentioned above, is indicative of speech. Otherwise, the program proceeds to block 524 where it proceeds to block 531 if it finds that EDSTATE is set to a value of zero, which, as mentioned above, is indicative of nonspeech signals (i.e., noise). Otherwise, the program proceeds to block 525.
At block 514 (525), the program clears two values, EDNOISE and FDNOISE, which it uses to accumulate the power level value determined for each of a number of successive groups of samples that are found to represent noise and obtained from the E direction and/or F direction, respectively. The program also clears a counter, NSCTR, that it uses to track the number of successive groups of E-and F-direction samples that are found to be noise. The purpose of the EDNOISE and FDNOISE values and NSCTR counter will be made clear below. Following the foregoing, the program then proceeds to block 515.
At block 515, the program proceeds to block 526 if it finds that EDSTATE is also set to a value of one. Otherwise, the program proceeds to block 516.
At block 516 (528) the program determines whether or not it has processed a predetermined number--illustratively 7500--groups of F-direction (E-direction) speech samples. To make that determination, the program maintains a counter, FDCTR (EDCTR), which it increments following the processing of a group of F-direction (E-direction) speech samples. If the program finds that the value of FDCTR (EDCTR) equals or exceeds a value of 7500 (noted in the FIG. as P) then it proceeds to block 519 (530). Otherwise, the program proceeds to block 517 (529). At block 519 (530), the program sets a flag designated FDDONE (EDDONE) to indicate that it has processed 7500 groups of F-direction (E-direction) speech samples. The program then proceeds to block 536. At block 517 (529), the program adds the value of FDVAL (EDVAL) (i.e., the power level that the program derived from the current group of samples obtained from the F (E) direction) to an accumulation, FDSPEECH (EDSPEECH), of such power levels. The program then increments counter FDCTR (EDCTR) by a value of one and then returns to block 501 to repeat the foregoing process.
At block 526, the program checks to see if FDVAL is at least 10 dB greater than EDVAL. If that is the case, then the program concludes that FDVAL represent speech and that EDVAL possibly represents an echo. As such, the program proceeds to block 516 to process FDVAL. In doing so, the program discards EDVAL. If that is not the case, then the program proceeds to block 527. At block 527, the program checks to see if EDVAL is at least 10 dB greater than FDVAL. If the program finds that to be the case, then it proceeds to block 528 to process EDVAL and discard FDVAL. Otherwise, the program concludes that both EDVAL and FDVAL represent speech and, therefore, discards those values and returns to block 501.
At block 531 the program determines if the value of a pointer, APTR, which is used to index a first and second array, is less than a predetermined value i, for example, a value of 20. The first array (FD.A) is used to store the average value of 100 FDVALs derived from 100 consecutive groups of F-direction noise samples. Similarly, the second array (ED.A) is used to store the average value of 100 EDVALs derived from 100 consecutive groups of E-direction noise samples. The program uses the aforementioned NSCTR counter to track 100 consecutive FDVALs and EDVALs that represent noise power levels, in which an NSCTR value of 100 represents approximately 200 milliseconds. In this way, the program stores the average power level of consecutive samples obtained within a 200 millisecond window from both the E and F transmission paths in respective ED.A and FD.A array locations.
In particular, if the program finds that the value of APTR is less than 20 then it proceeds to block 532. Otherwise, it proceeds to block 535 as a result of having filled each location forming the ED.A and FD.A arrays. At block 532, the program (a) adds the values of FDVAL and EDVAL (which represent noise) to accumulators FDNOISE and EDNOISE, respectively, and (b) increments counter NSCTR by a value of one. The program then proceeds to block 533 where checks to see if the value of NSCTR equals 100. If that is the case, then the program proceeds to block 534. Otherwise, it returns to block 501. At block 534, the program sets counter NSCTR to zero. The program then determines the average value contained in accumulators FDNOISE and EDNOISE and stores the results in their respective arrays, FD.A and ED.A, at a location determined by the current value of pointer APTR. The program then (a) clears accumulators FDNOISE and EDNOISE, (b) increments pointer APTR by a value of one and then (c) returns to block 501.
At block 535, the program sets a flag, NSDONE to indicate that it has accumulated sufficient data to calculate an accurate noise level measurement for the E and F transmission paths. At blocks 536 through 538, the program determines if it has accumulated the required data to generate speech and noise measurements for both the E and F transmission paths and proceeds to block 539 if it finds that to be the case. Otherwise, the program returns to block 501 via one of the NO branches of blocks 536 through 538.
The program arrives at block 539 as a result of having accumulated in each accumulator FDSPEECH and EDSPEECH the average power values for 7500 groups of respective speech samples and has stored in each of the arrays FD.A and ED.A twenty average power values relating to noise samples. As mentioned above, each of the latter power values represents the average power contained in a 200 millisecond window of noise signal samples. More particularly, the program at block 539 determines the average power level for the aforementioned 7500 (i.e., P) groups obtained from the F direction path. The program makes that determination by dividing the contents of accumulator FDSPEECH by 7500. The program then converts the resulting value to dBm and outputs that result to lead 103 (FIG. 1) as the speech measurement for the F direction. The program then proceeds to block 540 where it similarly generates a speech measurement for E direction and outputs that result to lead 103. The program then proceeds to block 541 where it determines in a conventional manner the median of the twenty values stored in array FD.A. The program converts that median value to dBrn and outputs that result to lead 103 as the noise measurement for the F direction. The program then proceeds to block 542 where it determines in a similar manner the noise measurement for the E direction and then outputs that result to lead 103. The program then exits via block 543.
The foregoing is merely illustrative of the principles of the invention. Those skilled in the art will be able to devise numerous arrangements, which, although not explicitly shown or described herein, nevertheless embody those principles that are within the spirit and scope of the invention.
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A digital signal processor is provided with the facility to measure accurately, and nonintrusively, the levels of noise and/or speech signals appearing on an in-service network connection.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a color image processing apparatus which digitally processes a color image.
2. Description of the Prior Art
Recently, the color image processing apparatus, such as a digital color copying machine and the like, has been demanded to perform the process for making the image as excellent as possible and to be equipped with a multifunctional performance.
A gradation correction performed in the conventional digital color copying machine, called a γ correction, is used for correcting gradations of digital signals which are outputted from an image scanner for reading out an original and which are corresponding to three primary colors respectively (the magnitude of each of the digital signals is proportional to the light quantity of a corresponding primary color) to match the gradation characteristic of a printer (Japanese patent publication No. 59-161979).
Since the conventional digital color copying machine has the output gradation characteristic of the printer corrected directly by a conversion of color-separated signals from the image scanner, if a distortion of the output gradation characteristic of the printer becomes larger, the limited number of bits for quantizing the color-separated signals in the image reading unit results in a situation in which the distortion correction of the output gradation characteristic of the printer causes quantization steps to be more coarse. Thus, even if the color correction (MASKING) processing is performed, the exact color reproduction is impossible.
If the ground of the original copy is colored, the conventional digital color copying machine cannot reproduce the color of the ground to be white and the colors of an image other than the ground to be exactly as they are.
When setting the copying machine to a monochromatic copying mode, gray components are extracted from a plurality of color image signals, so that the image obtained by the monochromatic copying of the colored original becomes unnatural.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a color image processing apparatus for performing exact color reproduction of an original by converting the color image signal which is proportional to the quantity of light into a data which is linear in a density scale, i.e. which is visually linear, performing a color correction (MASKING) processing of such data, and thereafter correcting the output gradation characteristic of the printer just prior to an execution of pseudo half tone processing (dither processing and the like).
Another object of the present invention is to provide a color image processing apparatus with multifunctional performances capable of performing a tone adjustment, a ground-color removal, and a contrast adjustment, when converting the color image signal which is proportional to the quantity of light into a data which is linear in the density scale.
Still another object of the present invention is to provide a color image processing apparatus capable of generating a monochromatic image signal which is visually natural from a plurality of color image signals.
A color image processing apparatus in an embodiment according to the present invention is equipped with a density conversion circuit for converting an input signal into a density signal, a masking circuit for performing color correction, and a selector for selecting one signal out of a plurality of outputs from the masking circuit. The density conversion circuit is equipped with a plurality of memories having stored therein data for performing a density conversion of a plurality of color image data including an ground-color removal of the input data. The density conversion circuit is further equipped with means for making a level of the ground-color removal variable, independently for each color.
Furthermore, a color image processing apparatus in another embodiment according to the present invention is equipped with a density conversion circuit for converting an input signal into a density signal, a masking circuit for performing a color correction of a color image data using a plurality of color image data, a binary circuit for performing a pseudo half tone processing of multivalued image signals, and a gamma (γ) correction circuit for performing a correction of the gradation characteristic of the printer. The gamma correction circuit is connected between the masking circuit and the binary circuit, and located just before the binary circuit. The gamma correction circuit comprises a memory into which correction data are stored, and means for selecting one of the correction data.
Still further, a color image processing apparatus in still another embodiment according to the present invention is equipped with a density conversion circuit for converting an input signal into a density signal, a masking circuit for performing a color correction, a density detecting circuit for generating one color signal out of a plurality of image signals issued from the density conversion circuit, a selector for selecting one signal from a plurality of outputs from the masking circuit and from the output of the density detecting circuit, a binary circuit for transforming value of the image signal into a binary value, and a printer. A plurality of image signals from the density conversion circuit correspond to the three primary colors, R, G, B, respectively. The density detecting circuit is equipped with means for operating a formula, [(signal corresponding to R)×2 I +(signal corresponding to G)×2 J +(signal corresponding to B)×2 K ]/2 L , wherein I, J, K, L are integergers which meet the requirement of 2 I +2 J +2 K =2 L More simply, the formula may be [(signal corresponding to R) +2×(signal corresponding to G)+(signal corresponding to B)]/4.
The density detecting circuit may be equipped with a memory into which data for converting a plurality of color image signals into one image signal are stored.
Such a construction as above,, enables output of a natural image, which is fit to the characteristics of the human visual sensitivity, when generating a monochromatic signal from a plurality of color signals.
In addition, the present invention can process image signals with an influence of the number of steps for quantizing the input image signals being minimized by means of performing the gamma correction of the printer and select the correction data for the output gradation characteristic of the printer under various kinds of conditions.
Even in the case where the ground of an original which has been read out by an image scanner and the like is colored, the present invention can cause the ground-color to be white by the ground-color removable function of the density conversion circuit which allows the image signal data, to become 0.
The above and other objects, features and advantages of the present invention will be apparent from the following description taken in connection with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating a digital color copying machine in an embodiment according to the present invention;
FIG. 2 is a block diagram of the density conversion circuit shown in FIG. 1;
FIG. 3 is an illustration representing each bit function of the signal 22 from the control circuit 21 shown in FIG. 1;
FIGS. 4(a)-(c) are illustrations respectively representing contents of table data of ROMs 30, 31, 32 shown in FIG. 2;
FIG. 5 is a block diagram of the masking circuit 8 shown in FIG. 1;
FIGS. 6(a)-(b) are block diagrams of the density detection circuit 13 in FIG. 1;
FIG. 7 is a block diagram of the gamma correction circuit and the binary circuit shown in FIG. 1; and
FIG. 8 is an illustration of bits of the signal 24 for selecting the table data of ROM 60.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A description of the color image processing apparatus according to the present invention is made in conjunction with the drawings as follows:
FIG. 1 is a block diagram of a digital color copying machine embodying a color image processing apparatus according to the present invention. Signal 1 denotes a red color signal R which is outputted from an image scanner 70, 2 denotes a green color signal G, and 3 denotes a blue color signal B. The color signals 1, 2, 3 are converted into density data by a density conversion circuit 4 which outputs a signal 5 corresponding to cyan (C), a signal 6 corresponding to magenta (M), and a signal 7 corresponding to yellow (Y). A control circuit 21, which is a circuit for selecting and setting various kinds of modes of the copying machine, comprises a microcomputer with I/O ports. A peak detecting circuit 27 detects and outputs a peak value 28 of the R.G.B signals in each line during a pre-scanning.
The scanner 70 pre-scanns the original, and during such pre-scanning the control circuit 21 repeated by sample of the output of the peak detecting circuit 27, to obtain a histogram of the peak values, and determines the ground level of each of R, G, B of the original from the histogram. At this time the color of a original cover of the scanner is black. A signal 22 from the control circuit 21 causes the density conversion circuit 4 to change over its mode.
The output signals 5, 6, 7 from the density conversion circuit 4 enter into a masking circuit 8, which performs a ground-color removal, an extraction of the black component, and a masking for correcting turbidness in ink in a printer 20. The masking circuit 8 outputs color signals including a black (Bk') signal 9, a cyan (C') signal 10, a magenta (M') signal 11 and an yellow (Y') signal 12. A signal 23 from the control circuit 21 causes the masking circuit 8 to change over its mode.
The signals 5, 6, 7 are inputted also into a density detecting circuit 13, which generates one monochromatic signal (D) 14 from the three color signals 5, 6, 7. A selector 15 selects one signal from signals 9, 10, 11, 12 and 14, and outputs it as a signal 16. In the case of making an output to the printer in a form of four color lapping, the selector 15 sequentially selects the signals 9, 10, 11 and 12. The selector 15 selects signal 14 in a monochromatic printing mode. Such selections are determined by a signal 26 from the control circuit 21. A gamma (γ) correction circuit 17 for correcting the output gradation characteristic of the printer 20 outputs a signal 18. A signal 24 from the control circuit 21 controls the gamma correction circuit 17. A binary circuit 19 for performing a pseudo half tone processing of the signal 18 outputs a signal which has been transformed into a binary value to the printer 20. A signal 25 from the control circuit 21 causes the binary circuit 19 to select a mode of the pseudo half tone processing. The printer 20 performs consecutively the printing process using black, cyan, yellow and magenta inks to obtain a copy.
The density conversion circuit 4 will be described with reference to FIG. 2. FIG. 2 is a block diagram of the density conversion circuit 4. The color signals (R) 1, (G) 2 and (B) 3, each being an 8-bit data, are supplied from the image scanner 70. Signals 22a, 22b and 22c are components of the signal 22 issued from the control circuit 21, and each of them is a 7-bit data. Signals 1, 22a, signals 2, 22b and signals 3, 22c are respectively applied to address inputs of ROMs 30, 31 and 32. The ROMs 30, 31 and 32 output the signals 5, 6 and 7 respectively which are the data being read out by the ROMs 30, 31, 32. Signals 22a, 22b, 22c determine which one of the conversion table data of the ROMs 30, 31, 32 is to be selected.
Next, a description of content, of the data of the ROMs shown in FIG. 2 will be made with reference to FIGS. 3 and 4(a)-(b) FIG. 3 is an illustration representing the function of each bit of each of the signals 22a, 22b, 22c issued from the control circuit 21. The lower 3 bits control variably the density, the following 2 bits perform the contrast adjustment, and the upper 2 bits set the level of the ground-color removal.
FIG. 4 is an illustration representing the content of the table data of the ROMs 30, 31, 32. Transverse axes represent the color signals being inputted into the addresses A0-A7 of the ROMs, in which 'FF'H stands for maximum brightness. Ordinate axes represent the output data from the ROMs, in which 'FF'H stands for maximum density. As shown by a solid line in FIG. 4(a), the basic conversion function of the ROMs 30-32 aims at conversion to the density As shown by a broken line in FIG.4 (a), a parallel movement of the conversion table data in a vertical direction allows 8 sets of table data (000-111) to be made. Setting the lower 3 bits as shown in FIG. 3 permits one of 8 sets of density conversion table data to be selected. FIG. 4(b) is an illustration representing the table data having the ground-color removal function. As shown in FIG. 4(b), the afore-mentioned table data is to output 0 when the value of the input data is larger than predetermined fixed value. Therefore, even in the case where the ground-color of the original which the scanner reads out is colored, forcing the density of the data whose value is larger than the predetermined fixed value to be changed into 0 enables the output to become 0 . One of 4 sets of table data (00-11) for changing the ground-color removal level is selected by the upper 2 bits as shown in FIG. 3. FIG. 4(c)is an illustration representing the table data which perform the contrast adjustment. As shown by the broken line in FIG. 4(c), changing of an inclination of the table data belonging to a medium density area permits contrast characteristics to be changed. Anyone of 4 sets of table data (00-11) is selected by the middle 2 bits as shown in FIG. 3.
Thus, 128 (obtained by 8 for the density adjustment×4 for the ground-color removal level ×4 for the contrast adjustment) different selections of the table data are possible. Since such a selection can be made independently for each of the ROMs 30, 31, 32, even if the ground is not gray but colored the ground-color removal is possible. At the same time, the contrast adjustment can be carried out for each color, and the density adjustment can be performed for each of the R, G, B colors to effect the tone adjustment.
A description of the masking circuit 8 will be made with reference to FIG. 5. FIG. 5 is a block diagram of the masking circuit 8. ROMs 40, 41 and 42 have stored therein table data for performing the masking, while a ROM 43 has stored therein table data for extracting the black component. As shown in FIG. 5, the outputs 5, 6 and 7 from the density conversion circuit enter into the address input of each of the ROMs 40-43. Masking table data for performing the color adjustment of the output from the printer are stored in the table data of the ROMs 40-42. The addresses A14 of the ROMs 40-43 are used for selection of the table data of the masking and the black generation, and such selection is made by the signal 23 from the control circuit 21. In the case of changing a method of the pseudo half tone processing which will be described later, a selection of masking table data and black generating table data which are suitable for such processing is made. The ROMs 40, 41, 42 and 43 output signals 47, 48, 49 and 9 respectively. Subtractors 44-46 perform subtractions of the output 9 of the ROM 43 from the outputs 47, 48, 49 from the ROMs 40-42, respectively, to obtain the 10, 11, 12.
FIG. 6(a) is a block diagram of an example of the density detecting circuit 13. Blocks 51 and 52 are 8-bit full adders. Each of 8-bit signals (C) 5 and (Y) 7 from the density conversion circuit 4 is inputted into the adder 51. Upper 8 bits including a carry from the full adder 51 and 8-bit signal (M) 6 are inputted into the full adder 52, and the monochrome, upper 8 bits including a carry from the full adder 52, is outputted as the signal 14. Namely, the density detecting circuit 13 performs an operation, (C+2M+Y)/4. Correspondingly to the fact that a peak location of the human visual spectral sensitivity lies in green, the density detecting circuit 13 performs the operation in which a weight twice -as large as those of the other two colors C, Y is applied to the signal M corresponding to the green, whereby a simple circuit generates the density signal possibly near to the human spectral sensitivity.
FIG. 6(b) is a block diagram of another example of the density detecting circuit 13. Block 50 is a ROM which, receiving the signals 5 for (C), 6 for (M), 7 for (Y) from the density conversion circuit 4 as the address input, and outputs the monochromatic signal 14. The output being memorized by the ROM 50 is the data for performing, for example, such an operation as (C+3.2×M+0.9×Y)/5.1. The data can be generally expressed as (2 I ×C+2 J ×M+2 K ×Y)/2 L where I, J, K and L are integers satisfying 2I+2J+2 K =2 L . Considering the characteristics of human visual spectral sensitivity and the spectral characteristics of color separation by the image scanner, the multiplication coefficients of C, M and Y and the divisor of the formula may be optimized.
A description of the gamma correction circuit 17 and the binary circuit 19 will be made with reference to FIG. 7 is a block diagram of the printer gamma correction circuit 17 and the binary circuit 19. A ROM 60 has stored therein table data for the γ correction of the printer. The signal 16 is the output signal from the selector 15, and the signal 24 is the signal for selecting the ROM table data from the control circuit 21. As shown in FIG. 7, the signals 16 and 24 enter into the address input of the ROM 60. The output signal 18 from ROM 60 is fed to an error diffusion processing circuit 61, a dither processing circuit 62, and a simple binary circuit 63. The signal 25 from the control circuit 21 causes a selector 64 to select any of the output signals from the circuits 61, 62 and 63 to obtain an output to the printer 20.
The signal 24 from the control circuit 21, 3 bits in width, is determined by the signal to be selected by the selector and a printing mode of the printer. FIG. 8 represents a relation between bits of the signal 24 and the selected table data for γ correction of the printer in the ROM 60. When any of the signals 9-12 shown in FIG. 1 is selected by the selector 15 or the output from the simple binary circuit 63 is selected by the selector 64, the table data for γ correction of the printer selects "linear" which means a table data that does not perform the γ correction, because the masking processing has already permitted the γ correction of the printer to be executed. As shown in FIG. 7, a selection of the table data for Y correction of the printer is made according to how many colors are printed out under a monochromatic copying mode and which of the output signals from the binary processing circuit is selected to be outputted to the printer.
In the case where only one method of binary processing is used, or where the γ correction of the monochromatic signal is not needed, the gamma correction circuit may be omitted.
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An image processing apparatus is for exactly reproducing color originals. The apparatus includes a circuit for removing a ground color contained in an input color signal by forcibly changing an input signal having a level larger than a predetermined level to white. The apparatus may include a gamma correction circuit having therein a plurality of selectable gamma collection data. The apparatus may also include a circuit for producing a natural monochromatic signal from signals corresponding to three primary color signals R, G and B by performing an operation expressed as [(signal corresponding to R)×2 I +(signal corresponding to G)×2 I +(signal corresponding to B)×2 K ]/2 L wherein I, J, K and L are integers and 2 I +2 J +2 K =2 L .
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Continuation Application of U.S. application Ser. No. 11/488,066 filed on Jul. 18, 2006, which is a Continuation Application of U.S. application Ser. No. 11/008,113 filed on Dec. 10, 2004, now issued U.S. Pat. No. 7,077,496, which is a Continuation Application of U.S. application Ser. No. 10/296,526, filed Nov. 23, 2002, now issued U.S. Pat. No. 6,893,109, which is a 371 of PCT/AU00/00596, filed May 24, 2000, all of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a printhead capping arrangement for a printer.
More particularly, though not exclusively, the invention relates to a printhead capping arrangement for an A4 pagewidth drop on demand printhead capable of printing up to 1600 dpi photographic quality at up to 160 pages per minute.
The overall design of a printer in which the arrangement can be utilized revolves around the use of replaceable printhead modules in an array approximately 8 inches (20 cm) long. An advantage of such a system is the ability to easily remove and replace any defective modules in a printhead array. This would eliminate having to scrap an entire printhead if only one chip is defective.
A printhead module in such a printer can be comprised of a “Memjet” chip, being a chip having mounted thereon a vast number of thermo-actuators in micro-mechanics and micro-electromechanical systems (MEMS). Such actuators might be those as disclosed in U.S. Pat. No. 6,044,646 to the present applicant, however, there might be other MEMS print chips.
The printhead, being the environment within which the printhead capping arrangement of the present invention is to be situated, might typically have six ink chambers and be capable of printing four color process (CMYK) as well as infra-red ink and fixative.
Each printhead module receives ink via a distribution molding that transfers the ink. Typically, ten modules butt together to form a complete eight inch printhead assembly suitable for printing A4 paper without the need for scanning movement of the printhead across the paper width.
The printheads themselves are modular, so complete eight inch printhead arrays can be configured to form printheads of arbitrary width.
Additionally, a second printhead assembly can be mounted on the opposite side of a paper feed path to enable double-sided high speed printing.
CO-PENDING APPLICATIONS
Various methods, systems and apparatus relating to the present invention are disclosed in the following co-pending applications filed by the applicant or assignee of the present invention simultaneously with the present application:
PCT/AU00/00518, PCT/AU00/00519, PCT/AU00/00520, PCT/AU00/00521, PCT/AU00/00522, PCT/AU00/00523, PCT/AU00/00524, PCT/AU00/00525, PCT/AU00/00526, PCT/AU00/00527, PCT/AU00/00528, PCT/AU00/00529, PCT/AU00/00530, PCT/AU00/00531, PCT/AU00/00532, PCT/AU00/00533, PCT/AU00/00534, PCT/AU00/00535, PCT/AU00/00536, PCT/AU00/00537, PCT/AU00/00538, PCT/AU00/00539, PCT/AU00/00540, PCT/AU00/00541, PCT/AU00/00542, PCT/AU00/00543, PCT/AU00/00544, PCT/AU00/00545, PCT/AU00/00547, PCT/AU00/00546, PCT/AU00/00554, PCT/AU00/00556, PCT/AU00/00557, PCT/AU00/00558, PCT/AU00/00559, PCT/AU00/00560, PCT/AU00/00561, PCT/AU00/00562, PCT/AU00/00563, PCT/AU00/00564, PCT/AU00/00565, PCT/AU00/00566, PCT/AU00/00567, PCT/AU00/00568, PCT/AU00/00569, PCT/AU00/00570, PCT/AU00/00571, PCT/AU00/00572, PCT/AU00/00573, PCT/AU00/00574, PCT/AU00/00575, PCT/AU00/00576, PCT/AU00/00577, PCT/AU00/00578, PCT/AU00/00579, PCT/AU00/00581, PCT/AU00/00580, PCT/AU00/00582, PCT/AU00/00587, PCT/AU00/00588, PCT/AU00/00589, PCT/AU00/00583, PCT/AU00/00593, PCT/AU00/00590, PCT/AU00/00591, PCT/AU00/00592, PCT/AU00/00584, PCT/AU00/00585, PCT/AU00/00586, PCT/AU00/00594, PCT/AU00/00595, PCT/AU00/00596, PCT/AU00/00597, PCT/AU00/00598, PCT/AU00/00516, PCT/AU00/00517, PCT/AU00/00511, PCT/AU00/00501, PCT/AU00/00502, PCT/AU00/00503, PCT/AU00/00508, PCT/AU00/00509, PCT/AU00/00510, PCT/AU00/00512, PCT/AU00/00513, PCT/AU00/00514, PCT/AU00/00515
The disclosures of these co-pending applications are incorporated herein by cross-reference. Each application is temporarily identified by its docket number. This will be replaced by the corresponding PCT Application Number when available.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide an arrangement for reducing of print nozzles during non-use of a printer.
It is another object of the present invention to provide an arrangement for reducing nozzle blockage during non-use, suitable for the pagewidth printhead assembly as broadly described herein.
It is another object of the present invention to provide an arrangement for reducing nozzle blockage for a printhead assembly on which there is mounted a plurality of print chips, each comprising a plurality of MEMS printing devices.
SUMMARY OF THE INVENTION
The present invention provides an inkjet printer, including a printhead having a plurality of print nozzles for selectively ejecting drops of ink towards a print medium passing said nozzles, the printhead further having a structure that defines a space adjacent said nozzles, and a capping mechanism; such that,
when the printer is in an operational mode, the structure allows drops of ink ejected from the nozzles to strike the print medium while preventing contact between the nozzles and foreign bodies larger than a threshold size; and,
when the printer is in a non-operational mode, the capping mechanism is engageable with the structure to provide a closed atmosphere in the space.
Preferably, the structure includes a nozzle guard the space being defined between the nozzle guard and the nozzles, the nozzle guard having a plurality of apertures aligned with the nozzles so that ink drops ejected from the nozzles pass through the apertures to be deposited on the paper or other print medium.
Preferably, the nozzles are arranged in an array extending across at least an A4 pagewidth, the nozzles preferably comprising MEMS devices. Preferably, the nozzles are arranged on a plurality of print modules of the printhead each with a respective nozzle guard and space.
Preferably, air valve means shuts off air supply to the spaces when the printer is in a non-printing operational mode.
Preferably, said capping mechanism covers the nozzle guard to seal the nozzle from atmosphere by moving to a capping position when said printer is in said non-printing mode.
Preferably also, the capping member is located on a rotatable platen member of the printer, and includes a seal member contacting said printhead in a locus surrounding said nozzle guard apertures.
As used herein, the term “ink” is intended to mean any fluid which flows through the printhead to be delivered to a sheet. The fluid may be one of many different coloured inks, infra-red ink, a fixative or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
FIG. 1 is a front perspective view of a print engine assembly
FIG. 2 is a rear perspective view of the print engine assembly of FIG. 1
FIG. 3 is an exploded perspective view of the print engine assembly of FIG. 1 .
FIG. 4 is a schematic front perspective view of a printhead assembly.
FIG. 5 is a rear schematic perspective view of the printhead assembly of FIG. 4 .
FIG. 6 is an exploded perspective illustration of the printhead assembly.
FIG. 7 is a cross-sectional end elevational view of the printhead assembly of FIGS. 4 to 6 with the section taken through the centre of the printhead.
FIG. 8 is a schematic cross-sectional end elevational view of the printhead assembly of FIGS. 4 to 6 taken near the left end of FIG. 4 .
FIG. 9A is a schematic end elevational view of mounting of the print chip and nozzle guard in the laminated stack structure of the printhead
FIG. 9B is an enlarged end elevational cross section of FIG. 9A
FIG. 10 is an exploded perspective illustration of a printhead cover assembly.
FIG. 11 is a schematic perspective illustration of an ink distribution molding.
FIG. 12 is an exploded perspective illustration showing the layers forming part of a laminated ink distribution structure according to the present invention.
FIG. 13 is a stepped sectional view from above of the structure depicted in FIGS. 9A and 9B ,
FIG. 14 is a stepped sectional view from below of the structure depicted in FIG. 13 .
FIG. 15 is a schematic perspective illustration of a first laminate layer.
FIG. 16 is a schematic perspective illustration of a second laminate layer.
FIG. 17 is a schematic perspective illustration of a third laminate layer.
FIG. 18 is a schematic perspective illustration of a fourth laminate layer.
FIG. 19 is a schematic perspective illustration of a fifth laminate layer.
FIG. 20 is a perspective view of the air valve molding
FIG. 21 is a rear perspective view of the right hand end of the platen
FIG. 22 is a rear perspective view of the left hand end of the platen
FIG. 23 is an exploded view of the platen
FIG. 24 is a transverse cross-sectional view of the platen
FIG. 25 is a front perspective view of the optical paper sensor arrangement
FIG. 26 is a schematic perspective illustration of a printhead assembly and ink lines attached to an ink reservoir cassette.
FIG. 27 is a partly exploded view of FIG. 26 .
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1 to 3 of the accompanying drawings there is schematically depicted the core components of a print engine assembly, showing the general environment in which the laminated ink distribution structure of the present invention can be located. The print engine assembly includes a chassis 10 fabricated from pressed steel, aluminum, plastics or other rigid material. Chassis 10 is intended to be mounted within the body of a printer and serves to mount a printhead assembly 11 , a paper feed mechanism and other related components within the external plastics casing of a printer.
In general terms, the chassis 10 supports the printhead assembly 11 such that ink is ejected therefrom and onto a sheet of paper or other print medium being transported below the printhead then through exit slot 19 by the feed mechanism. The paper feed mechanism includes a feed roller 12 , feed idler rollers 13 , a platen generally designated as 14 , exit rollers 15 and a pin wheel assembly 16 , all driven by a stepper motor 17 . These paper feed components are mounted between a pair of bearing moldings 18 , which are in turn mounted to the chassis 10 at each respective end thereof.
A printhead assembly 11 is mounted to the chassis 10 by means of respective printhead spacers 20 mounted to the chassis 10 . The spacer moldings 20 increase the printhead assembly length to 220 mm allowing clearance on either side of 210 mm wide paper.
The printhead construction is shown generally in FIGS. 4 to 8 .
The printhead assembly 11 includes a printed circuit board (PCB) 21 having mounted thereon various electronic components including a 64 MB DRAM 22 , a PEC chip 23 , a QA chip connector 24 , a microcontroller 25 , and a dual motor driver chip 26 . The printhead is typically 203 mm long and has ten print chips 27 ( FIG. 13 ), each typically 21 mm long. These print chips 27 are each disposed at a slight angle to the longitudinal axis of the printhead (see FIG. 12 ), with a slight overlap between each print chip which enables continuous transmission of ink over the entire length of the array. Each print chip 27 is electronically connected to an end of one of the tape automated bond (TAB) films 28 , the other end of which is maintained in electrical contact with the undersurface of the printed circuit board 21 by means of a TAB film backing pad 29 .
The preferred print chip construction is as described in U.S. Pat. No. 6,044,646 by the present applicant. Each such print chip 27 is approximately 21 mm long, less than 1 mm wide and about 0.3 mm high, and has on its lower surface thousands of MEMS inkjet nozzles 30 , shown schematically in FIGS. 9A and 9B , arranged generally in six lines—one for each ink type to be applied. Each line of nozzles may follow a staggered pattern to allow closer dot spacing. Six corresponding lines of ink passages 31 extend through from the rear of the print chip to transport ink to the rear of each nozzle. To protect the delicate nozzles on the surface of the print chip each print chip has a nozzle guard 43 , best seen in FIG. 9A , with microapertures 44 aligned with the nozzles 30 , so that the ink drops ejected at high speed from the nozzles pass through these microapertures to be deposited on the paper passing over the platen 14 .
Ink is delivered to the print chips via a distribution molding 35 and laminated stack 36 arrangement forming part of the printhead 11 . Ink from an ink cassette 93 ( FIGS. 26 and 27 ) is relayed via individual ink hoses 94 to individual ink inlet ports 34 integrally molded with a plastics duct cover 39 which forms a lid over the plastics distribution molding 35 . The distribution molding 35 includes six individual longitudinal ink ducts 40 and an air duct 41 which extend throughout the length of the array. Ink is transferred from the inlet ports 34 to respective ink ducts 40 via individual cross-flow ink channels 42 , as best seen with reference to FIG. 7 . It should be noted in this regard that although there are six ducts depicted, a different number of ducts might be provided. Six ducts are suitable for a printer capable of printing four color process (CMYK) as well as infra-red ink and fixative.
Air is delivered to the air duct 41 via an air inlet port 61 , to supply air to each print chip 27 , as described later with reference to FIGS. 6 to 8 , 20 and 21 .
Situated within a longitudinally extending stack recess 45 formed in the underside of distribution molding 35 are a number of laminated layers forming a laminated ink distribution stack 36 . The layers of the laminate are typically formed of micro-molded plastics material. The TAB film 28 extends from the undersurface of the printhead PCB 21 , around the rear of the distribution molding 35 to be received within a respective TAB film recess 46 ( FIG. 21 ), a number of which are situated along a chip housing layer 47 of the laminated stack 36 . The TAB film relays electrical signals from the printed circuit board 21 to individual print chips 27 supported by the laminated structure.
The distribution molding, laminated stack 36 and associated components are best described with reference to FIGS. 7 to 19 .
FIG. 10 depicts the distribution molding cover 39 formed as a plastics molding and including a number of positioning spigots 48 which serve to locate the upper printhead cover 49 thereon.
As shown in FIG. 7 , an ink transfer port 50 connects one of the ink ducts 39 (the fourth duct from the left) down to one of six lower ink ducts or transitional ducts 51 in the underside of the distribution molding. All of the ink ducts 40 have corresponding transfer ports 50 communicating with respective ones of the transitional ducts 51 . The transitional ducts 51 are parallel with each other but angled acutely with respect to the ink ducts 40 so as to line up with the rows of ink holes of the first layer 52 of the laminated stack 36 to be described below.
The first layer 52 incorporates twenty four individual ink holes 53 for each of ten print chips 27 . That is, where ten such print chips are provided, the first layer 52 includes two hundred and forty ink holes 53 . The first layer 52 also includes a row of air holes 54 alongside one longitudinal edge thereof.
The individual groups of twenty four ink holes 53 are formed generally in a rectangular array with aligned rows of ink holes. Each row of four ink holes is aligned with a transitional duct 51 and is parallel to a respective print chip.
The undersurface of the first layer 52 includes underside recesses 55 . Each recess 55 communicates with one of the ink holes of the two centre-most rows of four holes 53 (considered in the direction transversely across the layer 52 ). That is, holes 53 a ( FIG. 13 ) deliver ink to the right hand recess 55 a shown in FIG. 14 , whereas the holes 53 b deliver ink to the left most underside recesses 55 b shown in FIG. 14 .
The second layer 56 includes a pair of slots 57 , each receiving ink from one of the underside recesses 55 of the first layer.
The second layer 56 also includes ink holes 53 which are aligned with the outer two sets of ink holes 53 of the first layer 52 . That is, ink passing through the outer sixteen ink holes 53 of the first layer 52 for each print chip pass directly through corresponding holes 53 passing through the second layer 56 .
The underside of the second layer 56 has formed therein a number of transversely extending channels 58 to relay ink passing through ink holes 53 c and 53 d toward the centre. These channels extend to align with a pair of slots 59 formed through a third layer 60 of the laminate. It should be noted in this regard that the third layer 60 of the laminate includes four slots 59 corresponding with each print chip, with two inner slots being aligned with the pair of slots formed in the second layer 56 and outer slots between which the inner slots reside.
The third layer 60 also includes an array of air holes 54 aligned with the corresponding air hole arrays 54 provided in the first and second layers 52 and 56 .
The third layer 60 has only eight remaining ink holes 53 corresponding with each print chip. These outermost holes 53 are aligned with the outermost holes 53 provided in the first and second laminate layers. As shown in FIGS. 9A and 9B , the third layer 60 includes in its underside surface a transversely extending channel 61 corresponding to each hole 53 . These channels 61 deliver ink from the corresponding hole 53 to a position just outside the alignment of slots 59 therethrough.
As best seen in FIGS. 9A and 9B , the top three layers of the laminated stack 36 thus serve to direct the ink (shown by broken hatched lines in FIG. 9B ) from the more widely spaced ink ducts 40 of the distribution molding to slots aligned with the ink passages 31 through the upper surface of each print chip 27 .
As shown in FIG. 13 , which is a view from above the laminated stack, the slots 57 and 59 can in fact be comprised of discrete co-linear spaced slot segments.
The fourth layer 62 of the laminated stack 36 includes an array of ten chip-slots 65 each receiving the upper portion of a respective print chip 27 .
The fifth and final layer 64 also includes an array of chip-slots 65 which receive the chip and nozzle guard assembly 43 .
The TAB film 28 is sandwiched between the fourth and fifth layers 62 and 64 , one or both of which can be provided with recesses to accommodate the thickness of the TAB film.
The laminated stack is formed as a precision micro-molding, injection molded in an Acetal type material. It accommodates the array of print chips 27 with the TAB film already attached and mates with the cover molding 39 described earlier.
Rib details in the underside of the micro-molding provides support for the TAB film when they are bonded together. The TAB film forms the underside wall of the printhead module, as there is sufficient structural integrity between the pitch of the ribs to support a flexible film. The edges of the TAB film seal on the underside wall of the cover molding 39 . The chip is bonded onto one hundred micron wide ribs that run the length of the micro-molding, providing a final ink feed to the print nozzles.
The design of the micro-molding allow for a physical overlap of the print chips when they are butted in a line. Because the printhead chips now form a continuous strip with a generous tolerance, they can be adjusted digitally to produce a near perfect print pattern rather than relying on very close toleranced moldings and exotic materials to perform the same function. The pitch of the modules is typically 20.33 mm.
The individual layers of the laminated stack as well as the cover molding 39 and distribution molding can be glued or otherwise bonded together to provide a sealed unit. The ink paths can be sealed by a bonded transparent plastic film serving to indicate when inks are in the ink paths, so they can be fully capped off when the upper part of the adhesive film is folded over. Ink charging is then complete.
The four upper layers 52 , 56 , 60 , 62 of the laminated stack 36 have aligned air holes 54 which communicate with air passages 63 formed as channels formed in the bottom surface of the fourth layer 62 , as shown in FIGS. 9 b and 13 . These passages provide pressurised air to the space between the print chip surface and the nozzle guard 43 whilst the printer is in operation. Air from this pressurised zone passes through the micro-apertures 44 in the nozzle guard, thus preventing the build-up of any dust or unwanted contaminants at those apertures. This supply of pressurised air can be turned off to prevent ink drying on the nozzle surfaces during periods of non-use of the printer, control of this air supply being by means of the air valve assembly shown in FIGS. 6 to 8 , 20 and 21 .
With reference to FIGS. 6 to 8 , within the air duct 41 of the printhead there is located an air valve molding 66 formed as a channel with a series of apertures 67 in its base. The spacing of these apertures corresponds to air passages 68 formed in the base of the air duct 41 (see FIG. 6 ), the air valve molding being movable longitudinally within the air duct so that the apertures 67 can be brought into alignment with passages 68 to allow supply the pressurized air through the laminated stack to the cavity between the print chip and the nozzle guard, or moved out of alignment to close off the air supply. Compression springs 69 maintain a sealing inter-engagement of the bottom of the air valve molding 66 with the base of the air duct 41 to prevent leakage when the valve is closed.
The air valve molding 66 has a cam follower 70 extending from one end thereof, which engages an air valve cam surface 71 on an end cap 74 of the platen 14 so as to selectively move the air valve molding longitudinally within the air duct 41 according to the rotational positional of the multi-function platen 14 , which may be rotated between printing, capping and blotting positions depending on the operational status of the printer, as will be described below in more detail with reference to FIGS. 21 to 24 . When the platen 14 is in its rotational position for printing, the cam holds the air valve in its open position to supply air to the print chip surface, whereas when the platen is rotated to the non-printing position in which it caps off the micro-apertures of the nozzle guard, the cam moves the air valve molding to the valve closed position.
With reference to FIGS. 21 to 24 , the platen member 14 extends parallel to the printhead, supported by a rotary shaft 73 mounted in bearing molding 18 and rotatable by means of gear 79 (see FIG. 3 ). The shaft is provided with a right hand end cap 74 and left hand end cap 75 at respective ends, having cams 76 , 77 .
The platen member 14 has a platen surface 78 , a capping portion 80 and an exposed blotting portion 81 extending along its length, each separated by 120°. During printing, the platen member is rotated so that the platen surface 78 is positioned opposite the printhead so that the platen surface acts as a support for that portion of the paper being printed at the time. When the printer is not in use, the platen member is rotated so that the capping portion 80 contacts the bottom of the printhead, sealing in a locus surrounding the microapertures 44 . This, in combination with the closure of the air valve by means of the air valve arrangement when the platen 14 is in its capping position, maintains a closed atmosphere at the print nozzle surface. This serves to reduce evaporation of the ink solvent (usually water) and thus reduce drying of ink on the print nozzles while the printer is not in use.
The third function of the rotary platen member is as an ink blotter to receive ink from priming of the print nozzles at printer start up or maintenance operations of the printer. During this printer mode, the platen member 14 is rotated so that the exposed blotting portion 81 is located in the ink ejection path opposite the nozzle guard 43 . The exposed blotting portion 81 is an exposed part of a body of blotting material 82 inside the platen member 14 , so that the ink received on the exposed portion 81 is drawn into the body of the platen member.
Further details of the platen member construction may be seen from FIGS. 23 and 24 . The platen member consists generally of an extruded or molded hollow platen body 83 which forms the platen surface 78 and receives the shaped body of blotting material 82 of which a part projects through a longitudinal slot in the platen body to form the exposed blotting surface 81 . A flat portion 84 of the platen body 83 serves as a base for attachment of the capping member 80 , which consists of a capper housing 85 , a capper seal member 86 and a foam member 87 for contacting the nozzle guard 43 .
With reference again to FIG. 1 , each bearing molding 18 rides on a pair of vertical rails 101 . That is, the capping assembly is mounted to four vertical rails 101 enabling the assembly to move vertically. A spring 102 under either end of the capping assembly biases the assembly into a raised position, maintaining cams 76 , 77 in contact with the spacer projections 100 .
The printhead 11 is capped when not is use by the full-width capping member 80 using the elastomeric (or similar) seal 86 . In order to rotate the platen assembly 14 , the main roller drive motor is reversed. This brings a reversing gear into contact with the gear 79 on the end of the platen assembly and rotates it into one of its three functional positions, each separated by 120°.
The cams 76 , 77 on the platen end caps 74 , 75 co-operate with projections 100 on the respective printhead spacers 20 to control the spacing between the platen member and the printhead depending on the rotary position of the platen member. In this manner, the platen is moved away from the printhead during the transition between platen positions to provide sufficient clearance from the printhead and moved back to the appropriate distances for its respective paper support, capping and blotting functions.
In addition, the cam arrangement for the rotary platen provides a mechanism for fine adjustment of the distance between the platen surface and the printer nozzles by slight rotation of the platen 14 . This allows compensation of the nozzle-platen distance in response to the thickness of the paper or other material being printed, as detected by the optical paper thickness sensor arrangement illustrated in FIG. 25 .
The optical paper sensor includes an optical sensor 88 mounted on the lower surface of the PCB 21 and a sensor flag arrangement mounted on the arms 89 protruding from the distribution molding. The flag arrangement comprises a sensor flag member 90 mounted on a shaft 91 which is biased by torsion spring 92 . As paper enters the feed rollers, the lowermost portion of the flag member contacts the paper and rotates against the bias of the spring 92 by an amount dependent on the paper thickness. The optical sensor detects this movement of the flag member and the PCB responds to the detected paper thickness by causing compensatory rotation of the platen 14 to optimize the distance between the paper surface and the nozzles.
FIGS. 26 and 27 show attachment of the illustrated printhead assembly to a replaceable ink cassette 93 . Six different inks are supplied to the printhead through hoses 94 leading from an array of female ink valves 95 located inside the printer body. The replaceable cassette 93 containing a six compartment ink bladder and corresponding male valve array is inserted into the printer and mated to the valves 95 . The cassette also contains an air inlet 96 and air filter (not shown), and mates to the air intake connector 97 situated beside the ink valves, leading to the air pump 98 supplying filtered air to the printhead. A QA chip is included in the cassette. The QA chip meets with a contact 99 located between the ink valves 95 and air intake connector 96 in the printer as the cassette is inserted to provide communication to the QA chip connector 24 on the PCB.
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A printing assembly has a chassis. A printhead assembly is mounted on the chassis and has printhead integrated circuits each with a plurality of micro-electromechanical nozzle arrangements for ejecting ink. An ink distribution assembly supports the integrated circuits. The distribution assembly defines a plurality of converging ink passages in fluid communication with respective ink nozzle arrangements. An ink reservoir is mounted to the ink distribution assembly and defines a plurality of parallel ink channels in fluid communication with respective groups of the passages, such that inks can be fed from the channels to respective groups of the nozzle arrangements. A paper feed mechanism operatively feeds paper past said printhead. A printed circuit board (PCB) has electronic components for controlling the feed mechanism and the integrated circuits.
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REFERENCE TO RELATED APPLICATIONS
[0001] This application claims one or more inventions which were disclosed in Provisional Application No. 61/021,482 filed Jan. 16, 2008, entitled “SERVO SYSTEM USING FEEDBACK”. The benefit under 35 USC §119(e) of the United States provisional application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention pertains to the field of servo systems. More particularly, the invention pertains to actuated servo systems using feedback.
[0004] 2. Description of Related Art
[0005] In U.S. Pat. No. 6,883,320, a servomechanism for a valve controlling engine intake uses a proportional solenoid operating a hydraulic valve to power a hydraulic actuator, setting the position of the control valve. An engine sensor and electric controller provide input to the proportional solenoid. Feedback from the position of the control valve is applied to the hydraulic valve by a cam and a spring applying a force in opposition to the proportional solenoid. The mechanical feedback in US'320 applies a direct force on the valve via the spring.
SUMMARY OF THE INVENTION
[0006] A servo control system comprising a hydraulic actuator, a position sensor and a hydraulic control valve. The hydraulic actuator is coupled to a gas controlled valve. The position sensor measures the position of the hydraulic actuator and sends the position of the actuator as an input to an engine control unit (ECU). The hydraulic control valve is coupled to a proportional solenoid coupled to the ECU. When the ECU senses the position of the hydraulic actuator and in response to a control input, the ECU commands the position of the hydraulic control valve by controlling the force of the proportional solenoid and the hydraulic fluid sent to the hydraulic actuator, actuating the hydraulic actuator to move to a desired position and actuate the gas controlled valve.
[0007] In an alternate embodiment, the hydraulic actuator may be coupled to a rack and a valve may be actuated through a pinion and a rotary shaft. The valve may be a butterfly or flapper valve.
BRIEF DESCRIPTION OF THE DRAWING
[0008] FIG. 1 shows a schematic of a hydraulically actuated servo system using electrical feedback and rotary output.
[0009] FIG. 2 shows a more detailed schematic of the control valve of FIGS. 1 and 3 .
[0010] FIG. 3 shows a schematic of a hydraulically actuated servo system for a poppet EGR valve.
[0011] FIG. 4 a shows a schematic of a control system in which a hydraulic actuator controls a gas operated poppet control valve with a hydraulic control valve in a stationary position. FIG. 4 b shows a schematic of a control system in which a hydraulic actuator controls a gas operated poppet control valve with a hydraulic control valve moving towards a first position. FIG. 4 c shows a schematic of a control system in which a hydraulic actuator controls a gas operated poppet control valve with a hydraulic control valve moving towards a second position.
[0012] FIG. 5 a shows a schematic of a control system in which a hydraulic actuator controls a rotary device with a hydraulic control valve in a closed position. FIG. 5 b shows a schematic of a control system in which a hydraulic actuator controls a rotary device with a hydraulic control valve in a mid position.
DETAILED DESCRIPTION OF THE INVENTION
[0013] FIGS. 4 a through 4 c show schematics of a proportional position feedback hydraulic servo system. FIG. 4 a shows a schematic of a control system in which a hydraulic actuator controls a gas operated poppet control valve with a hydraulic control valve in a stationary position. FIG. 4 b shows a schematic of a control system in which a hydraulic actuator controls a gas operated poppet control valve with a hydraulic control valve moving towards a first position. FIG. 4 c shows a schematic of a control system in which a hydraulic actuator controls a gas operated poppet control valve with a hydraulic control valve moving towards a second position.
[0014] Referring to FIGS. 4 a through 4 c a double acting hydraulic actuator in fluid communication with a hydraulic control valve 28 . The hydraulic control valve 28 includes a spool 40 with a plurality of lands that is actuated by a proportional solenoid 38 on one side and a spring 33 on the opposite side. The proportional solenoid 38 is in communication with an engine control unit (ECU) 10 . The double acting hydraulic actuator 64 operates a gas operated poppet valve 37 such as a poppet wastegate valve or a poppet EGR valve. The gas operated poppet valve 37 shown in FIGS. 4 a - 4 c is shown by a three position valve in which hot gas flow from a source is blocked 37 c , restricted 37 b , or allowed 37 a to flow to or from an exhaust gas component. The position of a piston 46 of the double acting hydraulic actuator 64 is monitored by a position sensor 56 . The position sensor 56 is in communication with the engine control unit (ECU) 10 . The position sensor 56 produces a feedback signal 51 in proportion to the hydraulic actuator position which gets sent to the ECU 10 . The ECU 10 uses the feedback signal 51 , other engine parameters, and a control input to generate a signal 53 that is sent to the proportional solenoid 38 to change the current, changing the position of the spool 40 , the hydraulic fluid sent to hydraulic actuator 64 , and the position of the gas operated poppet valve 37 .
[0015] Referring to FIG. 4 a , the position sensor 56 monitors the position of the piston 46 of the double acting hydraulic actuator 64 and sends a signal 22 to the ECU 10 . The ECU 10 uses the feedback signal 51 from the position sensor 56 , other engine parameters, and a control input and sends a signal 53 to the proportional solenoid 38 . In this case, the signal 53 sent from the ECU 10 did not alter the current being supplied to the proportional solenoid 38 . With the current remaining in a steady state, the spool 40 is not moved and remains in position, which happens to be in a middle position 40 b as shown. In this position, the lands of the spool 40 block the flow of fluid to or from the chambers 52 , 54 defined between the piston 46 and the housing 50 of the double acting hydraulic actuator 64 . Since fluid is prevented from flowing in or out of the chambers 52 , 54 formed between the piston 46 and the housing 50 of the double acting hydraulic actuator 64 , the gas operated poppet valve 37 also remains in position, which happens to be a middle position 37 b , in which hot gas flow from a source is restricted from flowing to or from an exhaust gas component. If the force of the spring 33 on the spool 40 increases or decreases and the force on the spool 40 from the proportional solenoid 38 remains the same, the spool 40 will move accordingly. If the force of the proportional solenoid 38 on the spool 40 increases or decreases and the force on the spool 40 from the spring 33 remains the same, the spool will move accordingly.
[0016] Referring to FIG. 4 b , the position sensor 56 monitors the position of the piston 46 of the double acting hydraulic actuator 64 and sends a signal 51 to the ECU 10 . The ECU 10 uses the feedback signal 51 from the position sensor 56 , other engine parameters and a control input and sends a signal 53 to the proportional solenoid 38 . The signal 53 from the ECU 10 increases the current to the proportional solenoid 38 , increasing the force on the one end of the spool 40 to be greater than the spring 33 force on the opposite end of the spool 40 , moving the spool 40 towards the spring 33 (towards the right in the figure) towards a first position 40 a until the spring force equals the force from the proportional solenoid 38 . Once the force of the spring equals the force of the proportional solenoid 38 , the spool 40 moves to an equilibrium position. If the force of the spring 33 on the spool 40 increases or decreases and the force on the spool 40 from the proportional solenoid 38 remains the same, the spool 40 will move accordingly. If the force of the proportional solenoid 38 on the spool 40 increases or decreases and the force on the spool 40 from the spring 33 remains the same, the spool will move accordingly. With the spool 40 moving towards the first position 40 a , fluid from a first chamber 52 formed between the piston 46 and the housing 50 of the double acting hydraulic actuator 64 receives fluid from a source 18 and the opposite second chamber 54 is exhausts fluid through the spool 40 to sump (not shown). By filling one chamber 52 and exhausting the other chamber 54 of the double acting hydraulic actuator 64 , the piston 46 moves towards the spring 35 (towards the right in the figure), against the force of the spring 35 on the gas operated poppet valve 37 , moving the poppet valve towards a first position 37 a in which hot gas flow is allowed from the source to or from an exhaust gas component until the force of the spring 35 on the gas operated valve 37 equals the force of the fluid acting on the piston 46 of the double acting hydraulic actuator 64 . When the force of the spring 35 equals the force of the fluid acting on the piston 46 of the double acting hydraulic actuator 64 , the gas operated poppet valve 37 moves to an equilibrium position. If the force of the spring 35 on the gas operated poppet valve 37 increases or decreases and the force on the gas operated poppet valve 37 from the hydraulic actuator 64 remains the same, the gas operated poppet valve 37 will move accordingly. If the force of the hydraulic actuator 64 on the gas operated poppet valve 37 increases or decreases and the force on the gas operated poppet valve 37 from the spring 35 remains the same, the gas operated poppet valve 37 will move accordingly.
[0017] Referring to FIG. 4 c , the position sensor 56 monitors the position of the piston 46 of the double acting hydraulic actuator 64 and sends a signal 51 to the ECU 10 . The ECU 10 uses the feedback signal 22 from the position sensor 56 , other engine parameters, and a control input and sends a signal 53 to the proportional solenoid 38 . The signal 53 from the ECU 10 has decreases the current to the proportional solenoid 38 , decreasing the force on the one end of the spool 40 to be less than the spring 33 force on the opposite end of the spool 40 , moving the spool 40 towards the proportional solenoid 38 (towards the left in the figure) towards a second position 40 c until the spring 33 force equals the force from the proportional solenoid 38 . Once the force of the spring 33 equals the force of the proportional solenoid 38 , the spool 40 moves to an equilibrium position. If the force of the spring 33 on the spool 40 increases or decreases and the force on the spool 40 from the proportional solenoid 38 remains the same, the spool 40 will move accordingly. If the force of the proportional solenoid 38 on the spool 40 increases or decreases and the force on the spool 40 from the spring 33 remains the same, the spool will move accordingly. With the spool 40 moving towards the second position 40 c , fluid from a second chamber 54 formed between the piston 46 and the housing 50 of the double acting hydraulic actuator 64 is receives fluid from a source 18 and the opposite first chamber 52 is exhausts fluid through the spool 40 to sump (not shown). By filling one chamber 54 and exhausting the other chamber 52 of the double acting hydraulic actuator 64 , the piston 46 moves towards the left in the figure, with the force of the spring 35 on the gas operated poppet valve 37 , moving the gas operated poppet valve towards a third position 37 c in which hot gas flow is blocked from a source to or from an exhaust gas component until the force of the spring 35 on the gas operated valve 37 equals the force of the fluid acting on the piston 46 of the double acting hydraulic actuator 64 . When the force of the spring 25 equals the force of the fluid acting on the piston 46 of the double acting hydraulic actuator 64 , the gas operated poppet valve 37 moves to an equilibrium position. If the force of the spring 35 on the gas operated poppet valve 37 increases or decreases and the force on the gas operated poppet valve 37 from the hydraulic actuator 64 remains the same, the gas operated poppet valve 37 will move accordingly. If the force of the hydraulic actuator 64 on the gas operated poppet valve 37 increases or decreases and the force on the gas operated poppet valve 37 from the spring 35 remains the same, the gas operated poppet valve 37 will move accordingly.
[0018] After the gas operated valve 37 is moved, the position sensor 56 monitors the position of the piston 46 of the double acting hydraulic cylinder and compares the position of the piston 46 to the control input sent to the ECU 10 .
[0019] It should be noted that the gas operated valve 37 is shown in the middle position in FIGS. 4 a - 4 c , and the arrow above the hydraulic actuator 64 indicates the direction in which the gas operated valve 37 is going to move.
[0020] FIG. 3 shows an example of the servo system shown in FIGS. 4 a - 4 c in which the double acting hydraulic actuator 64 is operating a gas operated poppet valve 37 , such as an EGR valve sealed by poppet valves 42 . FIG. 2 shows a more detailed schematic of the hydraulic control valve 40 used in FIGS. 1 and 3 . The gas operated poppet valve 37 in this example would be the poppet valve 42 .
[0021] The intake and the exhaust chambers 26 , 36 of an EGR valve are sealed by poppet valves 42 . The position of the poppet valves 42 are controlled by a spring 44 and hydraulically biased piston 46 attached to the poppet valves 42 via a rod 48 . The spring 44 and the hydraulically biased piston 46 is received within a housing 50 and forms fluid chambers 52 , 54 on either side of the piston 46 within the housing 50 . A position sensor 56 is present on the piston housing 50 and electrically sends signals regarding the piston 46 position to an ECU 10 . The ECU 10 then sends a signal 53 to a proportional solenoid 38 of a control valve 28 . The proportional solenoid 38 adjusts the spool 40 position.
[0022] When the spool 40 is in the position shown in FIG. 4 b , supply oil 18 flows as directed by the spool 40 to a first chamber 52 formed between the piston 46 and the housing 50 , and works in conjunction with the force of the spring 44 , opening the poppet valves 42 between the exhaust and the intake chambers 36 , 26 . The position sensor 56 electronically provides feedback of piston 46 position to the ECU 10 that sends an appropriate signal to the proportional solenoid 38 .
[0023] The proportional solenoid 38 shown is a variable force solenoid but a voice coil actuator or similar linear force motor may also be used. The control valve 28 may be located remotely as shown in FIG. 3 or may be packaged within the EGR housing 50 in any orientation.
[0024] FIG. 5 a shows a schematic of a control system in which a hydraulic actuator controls a rotary device with a hydraulic control valve in a closed position. FIG. 5 b shows a schematic of a control system in which a hydraulic actuator controls a rotary device with a hydraulic control valve in a mid position.
[0025] Referring to FIGS. 5 a and 5 b , the double acting hydraulic actuator 14 is connected to a rotary output shaft 12 that operates butterfly valve or a flapper valve 41 through a rack 34 and pinion 32 and is in fluid communication with a hydraulic control valve 28 . The hydraulic control valve 28 includes a spool 40 with a plurality of lands that is actuated by a proportional solenoid 38 on one side and a spring 33 on the opposite side. The proportional solenoid 38 is in communication with an engine control unit (ECU) 10 . The double acting hydraulic actuator 14 operates a flapper valve or butterfly valve 41 through a rack and pinion. The butterfly valve or flapper valve is indicated by reference number 41 shown in FIGS. 5 a and 5 b . The flapper and butterfly valve 41 have a closed position and an open position. The amount the flapper or butterfly valve 41 is open will vary and is not limited to the position shown in FIG. 5 b . The position of a piston 14 a of the double acting hydraulic actuator 14 is monitored by a position sensor 16 . The position sensor 16 is in communication with the engine control unit (ECU) 10 . The position sensor 16 produces a feedback signal 22 in proportion to the actuator position which gets sent to the ECU 10 . The ECU 10 uses the feedback signal 22 , other engine parameters, and a control input to generate a signal 24 that is sent to the proportional solenoid 38 to change the current, changing the position of the spool 40 , the hydraulic fluid sent to the hydraulic actuator 14 and the position of the butterfly or flapper valve 41 .
[0026] Referring to FIG. 5 a , the position sensor 16 monitors the position of the piston 14 a of the double acting hydraulic actuator 14 and a sends a signal 22 to the ECU 10 . The ECU 10 uses the feedback signal 22 from the position sensor 16 , other engine parameters, and a control input and sends a signal 24 to the proportional solenoid 38 . The signal 24 from the ECU 10 decreases the current to the proportional solenoid 38 , decreasing the force on the one end of the spool 40 to be less than the spring 33 force on the opposite end of the spool 40 , moving the spool 40 towards the proportional solenoid 38 (towards the left in the figure) towards a second position 40 c until the spring force equals the force from the proportional solenoid 38 . Once the force of the spring 33 equals the force of the proportional solenoid 38 , the spool 40 moves to an equilibrium position. If the force of the spring 33 on the spool 40 increases or decreases and the force on the spool 40 from the proportional solenoid 38 remains the same, the spool 40 will move accordingly. If the force of the proportional solenoid 38 on the spool 40 increases or decreases and the force on the spool 40 from the spring 33 remains the same, the spool will move accordingly. With the spool 40 in the second position 40 c , fluid from a second chamber 15 b formed between the piston 14 a and the housing 17 of the double acting hydraulic actuator 14 receives fluid from a source 18 and the opposite first chamber 15 a is exhausts fluid through the spool 40 to sump (not shown). By filling one chamber 15 b and exhausting the other chamber 15 a of the double acting hydraulic actuator 14 , the rack 34 on the second shaft 31 and coupled to the piston 14 a of the double acting hydraulic actuator is moved, and the pinion 32 meshed with the rack 34 and mounted to the rotary shaft 12 rotates, rotating the butterfly valve 41 mounted to the rotary shaft 31 to a closed position in which fluid is prevented from flowing to or form a source to an exhaust gas component. Once the spool 40 moves to an equilibrium position, the rack 34 on the second shaft 31 moves, rotating the pinion 32 and thus the butterfly valve 41 to an equivalent equilibrium position.
[0027] Referring to FIG. 5 b , the position sensor 16 monitors the position of the piston 14 a of the double acting hydraulic actuator 14 and a sends a signal 22 to the ECU 10 . The ECU 10 uses the feedback signal 22 from the position sensor 16 , other engine parameters, and a control input and sends a signal 24 to the proportional solenoid 38 . In this case, the signal 24 sent from the ECU 10 did not alter the current being supplied to the proportional solenoid 38 . With the current remaining in a steady state, the spool 40 is not moved and remains in a middle position in which 40 b as shown. In this position, the lands of the spool 40 blocks the flow of fluid to or from the chambers 15 a , 15 b defined between the piston 14 a and the housing 17 of the double acting hydraulic actuator 14 . Since fluid is prevented from flowing in or out of the chambers 15 a , 15 b formed between the piston 14 a and the housing 17 of the double acting hydraulic actuator 14 , the rack 34 and pinion 32 are not rotated by the double acting hydraulic actuator 14 and the butterfly or flapper valve remains in a middle position in which fluid may flow from a source to an exhaust gas component.
[0028] After the butterfly valve or flapper valve 41 is moved, the position sensor 16 monitors the position of the piston 14 a of the double acting hydraulic cylinder and compare the position of the piston 14 a to the control input sent to the ECU 10 .
[0029] FIGS. 1 and 2 show an example of the control system shown in FIGS. 5 a - 5 b , with the double acting hydraulic actuator being coupled to a rotary device. Referring to FIG. 1 , a cam 30 and pinion 32 are mounted on a rotary output shaft 12 . The pinion 32 meshes with a rack 34 on a second shaft 31 . The cam 30 on the rotary output shaft 12 contacts a position sensor 16 . The position sensor 16 is in communication with an engine control unit (ECU) 10 . At the end of the rack 34 , a piston 14 a of a double acting actuator 14 is attached. The double acting actuator 14 is in fluid communication with a hydraulic control valve 28 .The hydraulic control valve 28 includes a proportional solenoid 38 in communication with the engine control unit 10 and in contact with a spool valve 40 . The proportional solenoid 38 of the hydraulic control valve 28 adjusts the position of the spool 40 , determining the flow of fluid to the double acting actuator 14 .
[0030] Based on the movement of the cam 30 , the position sensor 16 sends a feedback signal 22 to an engine control unit (ECU) 10 . The ECU 10 then sends a signal 24 based on the feedback signal 22 , other engine parameters, and a control input to the proportional solenoid 38 of a hydraulic control valve 28 . The signal 24 may adjust the current supplied to the proportional solenoid 38 of a hydraulic control valve 28 . Depending on the adjustment to the current of the proportional solenoid 38 of the hydraulic control valve 28 , the spool 40 is moved as shown in FIGS. 5 a - 5 b . If the current is increased or decreased, the spool 40 is moved by the solenoid 38 and the flow of fluid to the double acting hydraulic actuator 14 is adjusted. By adjusting the flow to the double acting hydraulic actuator 14 , the piston 14 a of the double acting hydraulic actuator 14 is moved and thus the rack 34 in which the piston 14 a is attached is also moved. By moving the rack 34 on the second shaft 31 , the pinion 32 and cam 30 on the rotary output shaft 12 are also moved. The rotation of the rotary output shaft rotates the position of the butterfly or flapper valve. The position of the cam 30 is measured by the position sensor 16 .
[0031] The rotary output shaft 12 may be connected to a turbocharger wastegate, an EGR wastegate, a bypass valve, flapper valve, butterfly valve, or other modulated devices. The control valve 28 may be located remotely as shown in FIG. 1 or may be packaged within the actor assembly 20 housing.
[0032] The proportional solenoid 38 may be a variable force solenoid, a voice coil actuator or similar linear motor.
[0033] Alternatively, the position sensor 16 may be mounted directly to the flapper or butterfly valve 41 .
[0034] Other types of hydraulic actuators may also be used other the than the linear actuator shown.
[0035] Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.
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A servo control system comprising a hydraulic actuator, a position sensor and a hydraulic control valve. The hydraulic actuator is coupled to a gas controlled valve. The position sensor measures the position of the hydraulic actuator and sends the position of the actuator as an input to an engine control unit (ECU). The hydraulic control valve is coupled to a proportional solenoid coupled to the ECU. When the ECU senses the position of the hydraulic actuator and in response to a control input, the ECU commands the position of the hydraulic control valve by controlling the force of the proportional solenoid and the hydraulic fluid sent to the hydraulic actuator, actuating the hydraulic actuator to move to a desired position and actuate the gas controlled valve.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the covering of upholstered sofas and more particularly it concerns novel coverings for upholstered sofas and chairs as well as upholstered sofas and chairs as so covered.
[0003] 2. Description of the Related Art
[0004] United States Patent Publication US 2004/0095002 shows an adjustable slip cover for upholstered furniture such as chairs or sofas. The sofa or chair base is covered separately from the seat cushions, which themselves are individually covered. Elastic straps and clips are provided on the sofa or chair base cover to hold the material of the cover taut. Extra material in the sofa or chair base cover is also tucked under the cushions.
[0005] U.S. Pat. No. 2,367,450 also shows adjustable slip covers for upholstered chairs wherein the chair base cover is separate from the cushion cover. Excess material of the base cover is tucked beneath adjacent portions of the slip cover. The cushion cover is bag shaped and open along the rear edge for insertion of the cushion. The cushion cover is pulled tight and held by strings.
[0006] U.S. Pat. No. 2,921,625 show an adjustable slip cover for chairs and sofas. Here also the cover for the chair or sofa base is separate from the cover for the seat cushion The seat cushion cover extends over the top, front and sides of the cushion and appears to be held in place by an elasticized edging.
[0007] U.S. Pat. No. 2,884,993 relates to adjustable slip covers for chairs and sofas; and separate covers are provided for the sofa or chair base and for the seat cushion. The cushion covers comprise panels which form a pocket into which the cushions are inserted.
[0008] A particular problem involved in providing slipcovers to accommodate upholstered furniture of different sizes and configurations results from the fact that the seat cushions of such furniture are made with widely different shapes, sizes and thicknesses. Prior attempts to handle this problem have involved providing cushion covers that are pulled tight by a drawstring or an elastic band. However, these lack versatility, and they are not suited for use with multiple cushions such as in sofas. Also there is no assurance that the cushion covers will remain taut after someone has sat on the furniture
SUMMARY OF THE INVENTION
[0009] In one aspect of the invention there is provided an upholstered chair or sofa having a base on which are mounted, a horizontal seat cushion support, a back, and arms at each end of the cushion support. At least one removable seat cushion rests on the cushion support between the arms. A seat cushion slip cover covers the seat cushion or cushions. The seat cushion slip cover is pulled tight at the ends of the cushion or cushions which abut the arms. This conforms the cover to the shape of the cushion or cushions. The excess cover material which extends beyond the cushion or cushions at the arms is folded under them, whereby the weight of the cushion or cushions holds the cover taut along their upper side.
[0010] In another aspect, the invention involves a novel slip covered seat cushion for an upholstered chair or sofa. This novel covered seat cushion comprises an elongated bag-like cover; and at least one seat cushion contained within the cover. The cover itself has excess material extending beyond opposite ends of the seat cushion with the excess material being foldable under the seat cushion.
[0011] In a further aspect, the invention comprises a novel slip cover for covering the removable seat cushions of upholstered sofas or chairs. This novel slip cover comprises an elongated bag-like cover for containing the seat cushion or cushions, with substantial excess cover material extending beyond the ends of the cushion or cushions. This excess material at the ends of the slip cover can be folded under the cushion or cushions so that their weight will hold the slip cover tight along their upper surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a frontal view of a slip covered sofa according to the invention;
[0013] FIG. 2 is a frontal view similar to FIG. 1 but showing the sofa with the covered seat cushion removed;
[0014] FIG. 3 is a perspective view showing a cushion seat cover according to the invention; and
[0015] FIG. 4 is a perspective view of a slip covered seat cushion with portions of the slip cover folded over for installation of the seat cushion on a sofa.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] In the embodiment of FIG. 1 , a sofa 10 comprises a base section 11 and a separately slip covered cushion section 12 which contains one or more seat cushions. The base section 11 has a bottom portion 14 which supports a back 14 , a pair of arms 16 at opposite ends of the sofa, and a horizontal cushion support surface 18 between the arms. The cushion section 12 rests on this support surface. The cushion section 12 is removable from the base section 10 ; and a cushion slip cover 12 a covers the cushion section. A separate base section slip cover may be provided for the base section 11 .
[0017] FIG. 2 shows the base section 11 with the cushion section removed. The base section is shown to have a slip cover 11 a which is larger than the base section itself; and the excess material of the cover is folded over on the support surface 18 as indicated by the reference character 20 .
[0018] FIG. 3 shows the cushion slip cover 12 a in perspective and containing two T-shaped seat cushions 22 a and 22 b (shown in dashed outline). A cushion insertion opening 24 is provided in the back of the cover 12 a . This opening can be closed by a zipper, by Velcro® fasteners or by any suitable and well known closure means. It is also possible to provide the insertion opening at one end of the cushion cover 12 a . Although the ends of the cushion slip cover are shown as being open, they may be sewn closed
[0019] It will be seen that the ends of the cushion cover 12 a extend substantially beyond the ends and back of the cushion 22 a and 22 b . This allows the cover to accommodate cushions of different widths and depths. The excess material of the cushion slip cover that extends beyond the ends and back of the cushions is pulled tight and folded around the cushions so that the cover material takes on the shape of the cushions (in the present embodiment, a T-shape). The excess material is then pulled under the cushions so that when the cushions are placed on the cushion support 18 of the base 10 ( FIG. 1 ), their weight will hold the material of the cushion cover taut and maintain a smooth upper surface of the cover. In addition, the friction of the arms 16 and the weight of the persons occupying the sofa will add to the holding effect on the cushion slip cover 12 a.
[0020] FIG. 4 shows the covered seat cushions 22 a and 22 b inverted so that the folded over excess material of the cushion cover 12 a can be seen at 12 b . The excess material may not only be at the ends of the cover 12 a ; but additional excess material may be provided along its rear edge so as to accommodate seat cushions of different depths.
[0021] There may also be provided one or more elastic bands 28 which are attached to the excess cover material 12 b by means of clips 30 to assist in holding the cover taut. The clips may be any well known clips such as suspender type clips for example.
[0022] In installing the seat cushion cover 12 a , the cushion or cushions are inserted in the cover via the opening 24 . The opening is then closed. The cushion or cushions are then arranged to be substantially centered between the ends of the cover 12 a . Because the cushions can be moved with respect to the ends of the cover 12 a , it will be possible to have any pattern on the cushion cover 12 a aligned with a corresponding pattern on the base cover 10 a The cover 12 a is then pulled tight at its ends and back; and the excess material of the cover is folded under the cushions. The covered cushions are then positioned on the cushion support as shown in FIG. 1 .
[0023] The cushion cover of this invention can be made of any slip cover material and may be woven or knit fabric. As an example, the cushions 22 a and 22 b would have a depth, from the front elongated edge to the rear of 26 inches and would accommodate a cushion thickness of 6 inches. The length of the cushion cover would depend on the distance from one end of the cushion to the other while allowing sufficient excess material to be folded under the cushions. These dimensions are not critical and a wide range of dimensions may be employed for the cushion slip cover, provided that the cover is large enough to accommodate a wide range of cushion sizes while still leaving sufficient excess material of the cover to be folded under the cushions.
[0024] The cushion cover 12 a may be made to accommodate seat cushions of upholstered chairs as well as sofas. In addition elastic bands, Velcro® fasteners, etc. may be used to hold the excess material under the cushions.
[0025] The cushions with the cushion cover may be turned over in the event that the upper surface of the cover becomes worn or stained. In this case the excess material at the ends and back of the cover 12 a is folded in the reverse direction so that it remains between the cushions and the cushion support.
[0026] While this invention has been described in conjunction with T-shaped cushions, it is equally applicable with rectangular cushions or cushions of other shapes. Pulling the material of the cover and then folding it under the ends of the cushions will cause it to conform to whatever the shape of the cushion ends may be.
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A slip covered sofa having removable seat cushions which are separately slip covered by a single bag-like cover into which the seat cushions are inserted and which has excess material extending beyond the cushions, the excess material being and folded under the cushions at each end to hold the material on the upper surface of the cushions taut when the cushions are in place on the sofa.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to deployable structures whose shapes can be controlled and altered to modify their size, stiffness and/or damping characteristics. More particularly, this invention relates to a lightweight deployable structure that is capable of large displacements to achieve a variety of shapes with controlled precision, capable of being returned to a desired shape after being subjected to a disturbance force, and characterized by enhanced vibration isolation.
2. Description of the Prior Art
As used herein, deployable structures are generally characterized by a combination of trusses or struts that are interconnected in a manner that enables the structure to be articulated between a collapsed, retracted or stowed configuration and a deployed configuration. Such structures find uses in a wide variety of applications, including portable support structures such as platforms and bridges, vibration isolation for machinery, and structures for use in space that, because of their size, must be collapsible for transport to space. Advantages of deployable structures include improved efficiency because a deployable structure can be entirely assembled during manufacture rather than in the field, improved design performance because greater precision can typically be attained for units assembled during manufacture than for those requiring field assembly, and lower transportation costs because collapsed units are more compact for storage and shipping.
The existing technology for deployable structures is generally focused on two types of structures. A first type is the more traditional truss structure that employs heavy trusses which are mechanically interconnected with pins, welds or bolts. Because of the manner in which the trusses are secured directly together, this type of deployable structure tends to be relatively heavy for the degree of stiffness achieved, often requires powerful actuators to deploy and retract the structure, and readily transmits high frequency disturbances. Accordingly, truss structures are typically limited to applications in which weight, accuracy and vibration isolation are not paramount.
Another known type of deployable structure employs piezoelectric members to precisely control the dimension and damping of the structure. Because piezoelectric materials are brittle and therefore incapable of sustaining high loads, these deployable structures, often referred to as "smart structures," are generally limited to low load applications where minimal displacements are adequate.
A more recent deployable structure design of considerable experimental interest employs struts maintained in static equilibrium by a number of tension members, or "tendons," such that the struts do not touch each other. As discussed in the article "Double-Layer Tensegrity Grids as Deployable Structures," A. Hanaor, International Journal of Space Structures, Vol. 8, Nos. 1 & 2 (1993), such structures, referred to as "tensegrity structures," can be deployed and retracted by either elongating or shortening the struts and/or tendons. Notably, tensegrity structures are capable of larger displacements and higher loads than the above-noted "smart structures" and provide better vibration isolation as compared to the more traditional truss structures. Therefore, it would be desirable if a deployable structure characterized by the functional advantages of a tensegrity structure were available in a lightweight configuration whose shape could be precisely monitored and controlled, and whose stiffness could be modified, for use in a wide variety of applications in which weight, load capacity, accuracy and/or vibration isolation are important. In particular, it would be desirable if a tensegrity structure were available that was capable of responding to and counteracting disturbance forces in order to establish and maintain a structural or shape configuration.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a deployable structure capable of being articulated between a retracted configuration and a deployed configuration, and intermediate configurations therebetween.
It is a further object of this invention that such a deployable structure is composed of compression members subjected primarily to compression and interconnected with tension members that are subjected primarily to tension, such that the deployable structure is capable of large displacements and resists transmission of vibration.
It is another object of this invention that the tension members can be adapted to be manipulated in order to precisely articulate the compression members and thereby enable the deployable structure to attain a desired shape and/or achieve a desired stiffness.
It is still another object of this invention that the deployable structure includes sensors to monitor the compression and/or tension members in order to ascertain the shape of the deployed structure and thereby provide appropriate feedback for ascertaining the state of the structure and/or manipulating the tension members and articulating the compression members to resume a desired shape for the structure following a disturbance force.
In accordance with a preferred embodiment of this invention, these and other objects and advantages are accomplished as follows.
According to the present invention, there is provided a lightweight, deployable structure whose shape can be precisely monitored and controlled to acquire a wide variety of shapes and varying levels of stiffness, yet is also capable of large displacements and sustaining high loads. As such, the structure is highly suitable for use in applications in which information concerning the shape and/or stiffness of the structure can be employed to precisely attain a desired shape, precisely return the structure to a desired shape after being subjected to a disturbance force, or to increase or decrease the structural stiffness in response to changing environmental conditions. The deployable structure of this invention is generally composed of one or more structural units, each of which is generally a tensegrity structure. As such, each structural unit can be articulated between two extreme configurations, one of which will be termed the deployed configuration in which the deployable structure is fully extended. In one deployed configuration, each structural unit defines opposing first and second polygon-shaped ends and a polygon-shaped midsection. The first and second polygon-shaped ends each have "X" number of corners, while the midsection has "2X" number of corners so as to establish at the perimeter of the midsection "X" number of odd-numbered corners alternating with "X" number of even-numbered corners. Each structural unit is configured such that the odd-numbered corners of the midsection correspond with the corners of the first polygon-shaped end, and the even-numbered corners of the midsection corresponding with the corners of the second polygon-shaped end.
The corners of the polygon-shaped ends and the midsection of each structural unit is established by rigid compression members that are interconnected by elastic tension members to form two interconnected tiers. The compression and tension members are interconnected such that the compression members are subjected to essentially axial loads--i.e., essentially no bending loads are imposed on the compression members. The shape of the structural unit is controlled by loosening and tightening the tension members and/or shortening and lengthening the compression members. The number of compression and tension members and the manner in which the compression and/or tension members are manipulated enable the deployable structure to acquire a variety of shapes and levels of stiffness or rigidity. Multiple structural units can be interconnected through the use of both compression members and tension members in order to promote the stiffness of the deployable structure, or alternatively solely with tension members so as to achieve maximum maneuverability and control of the deployable structure.
Importantly, the deployable structure of this invention further includes one or more articulators for manipulating the compression and/or tension members in order to articulate the deployable structure between a retracted or collapsed configuration and the aforementioned deployed configurations, or any desired intermediate configuration. In addition, the deployable structure includes sensors for detecting the status of the deployed structure by detecting the condition at one or more of the compression and/or tension members, with feedback being communicated to the articulators in order to acquire or reacquire a desired shape or stiffness for the deployable structure. Because the compression members sustain only compression loads, the difficulty with which bending loads are analyzed is avoided, enabling reliable closed loop control of the deployable structure.
In view of the above, it can be seen that the deployable structure of this invention provides advantages generally associated with deployable structures. Such advantages include improved efficiency because the deployable structure can be entirely assembled during manufacture rather than in the field, and improved design performance because greater precision can typically be attained for units assembled during manufacture as compared to those requiring field assembly. Another advantage is that lower transportation costs are made possible, since the deployable structure is collapsible and therefore is made more compact for storage and shipping. In addition, large displacements and high loads can be sustained and a significant level of vibration isolation can be achieved because the deployable structure is composed of rigid compression members interconnected with elastic tension members.
Furthermore, considerable precision of the deployable structure's shape can be achieved through appropriate sensing of the compression and tension members to provide feedback that forms the basis for selectively and precisely altering the compression and/or tension members. Such capabilities enable the deployable structure to perform as a sensing device in which the compression and/or tension members are closely monitored in order to ascertain the shape or stiffness of the deployed structure in response to an external disturbance force, as well as reestablish a desired shape or stiffness for the structure after being subjected to a disturbance force. Alternatively, such capabilities enable the deployable structure to perform as an actuator in which the compression and/or tension members are selectively manipulated in order to retract and partially or fully deploy the structure.
Other objects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other advantages of this invention will become more apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a plan view of a single structural unit of a deployable structure in accordance with a preferred embodiment of this invention;
FIG. 2 is a side view of the structural unit of FIG. 1 taken along line 2--2;
FIG. 3 is a side view of a deployable structure incorporating multiple structural units of the type shown in FIG. 1 in accordance with a first embodiment of this invention;
FIG. 4 is a side view of a deployable structure incorporating multiple structural units of the type shown in FIG. 1 in accordance with a second embodiment of this invention;
FIG. 5 shows a tension adjusting and measuring device that can be used with the structural unit of FIG. 1 in accordance with one aspect of this invention; and
FIG. 6 is a schematic representation of a sensing structure incorporating the structural unit of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A deployable structure and a single structural unit 10 of the structure areillustrated in the Figures in accordance with the present invention. Shown in FIGS. 1 and 2 are a plan and side view, respectively, of the structuralunit 10, while FIGS. 3 and 4 illustrate deployable structures 100 and 200 that incorporate a plurality of the structural units 10. As shown in FIGS.1 and 2, the structural unit 10 is generally composed of multiple rigid compression members, or struts 12, interconnected with elastic tension members, or tendons 14. As used herein, the term "rigid" indicates that the struts 12 do not flex or elastically deform readily in order to sustain an axial compression load with bending, while the term "elastic" indicates that the tendons 14 elastically deform when subjected to an axial tensile load, and will return to their prestressed condition once the load is removed. As those skilled in the art will appreciate, a wide variety of materials can be used for the struts and tendons 12 and 14. Though six struts 12a-12f are shown, it will become apparent that greater numbers of struts 12 could be employed within a given structural unit configured in accordance with the invention. In addition, though the struts 12a-12f are shown to be of approximately equal length, their lengths could differ considerably to yield a structural unit 10 appearing substantially different from that shown in the Figures.
FIG. 1 is useful to illustrate the polygonal shape of the structural unit 10 when viewed from one of its longitudinal end. The unit 10 is shown deployed in FIG. 2, in which the outline of the unit 10 defines an operating envelope 16 having a polygonal shape when as viewed in FIG. 1. Though shown as a regular hexagon in the Figures, the envelope 16 could have any even number of sides, which may be of different lengths. The hexagonal-shaped envelope 16 shown in the Figures is characterized by opposing first and second triangular-shaped ends 18a and 18b, each defining three corners 24a-24c and 26d-26f, respectively. The envelope 16 further has a midsection 20 having a polygonal shape (when viewed from thelongitudinal end of the unit 10) with twice as many corners as the first and second ends 18a and 18b--here, a hexagonal shape defining six corners identified as 22a-22f. As viewed in FIG. 1, each of the corners 22a-22c issuperimposed with a corresponding one of the corners 24a-24c of the first end 18a and a corresponding one of the corners 26d-26f of the second end 18b. It will be useful to describe the midsection 20 as having at its perimeter a number of "odd" corners 22a-22c alternating with an identical number of "even" corners 22d-22f, with corresponding nomenclature being used for the corners 24a-24c and 26d-26f, respectively.
As is apparent from FIG. 2, the struts 12a-12c form a first tier 28a of thestructural unit 10, while the struts 12d-12f form a second tier 28b of the unit 10. Though the struts 12a-12c and 12d-12f within each tier 28a and 28b are shown to be all of the same length, the struts of different tiers and within each tier could have different lengths. Each of the struts 12a-12c has a first end 30a-30c and an oppositely-disposed second end 32a-32c, with the first ends 30a-30c being located at the odd corners 24a-24c of the first end 18a of the envelope 16. With reference to both FIGS. 1 and 2, it can also be seen that each of the second ends 32a-32c ofthe struts 12a-12c is disposed at one of the odd corners 22a-22c of the midsection 20, but not the same odd corner 22a-22c as its corresponding first end 30a-30c. In other words, each of the struts 12a-12c is inclined,such that their respective second ends 32a-32c are indexed to the next odd corner 22a-22c of the midsection 20. As shown, the second end 32a of the strut 12a is disposed at the odd corner 22b, the second end 32b of the strut 12b is disposed at the odd corner 22c, and the second end 32c of thestrut 12c is disposed at the odd corner 22a. Though FIG. 2 shows the struts12a-12c as being inclined in a counterclockwise direction, they could alternatively have been shown inclined in a clockwise direction. As is apparent from FIG. 2, the second ends 32a-32c of the struts 12a-12c are shown as being disposed in a plane displaced above the first end 18a of the envelope 16.
In a manner similar to that described for the struts 12a-12c, the struts 12d-12f are also arranged in the second tier 28b of the structural unit 10to have their first ends 30d-3Of located at different even corners 22d-22f of the midsection 20. Specifically, the first end 30d of the strut 12d is disposed at the even corner 22d, the first end 30e of the strut 12e is disposed at the even corner 22e, and the first end 30f of the strut 12f isdisposed at the even corner 22f. Furthermore, the second ends 32d-32f of the struts 12d-12f are located at one of the even corners 26d-26f of the second end 18b corresponding to a different even corner 22d-22f from that of their corresponding first ends 30d-30f. Specifically, the second end 32d of the strut 12d is disposed at the even corner 26e, the second end 32e of the strut 12e is disposed at the even corner 26f, and the second end 32f of the strut 12f is disposed at the even corner 26d.
As apparent from FIGS. 1 and 2, each of the first ends 30d-30f of the struts 12d-12f is disposed between two adjacent second ends 32a-32c of thestruts 12a-12c of the first tier 28a. In the embodiment of FIG. 2, the first ends 30d-30f of the struts 12d-12f are disposed in a second plane that is parallel to the plane containing the second ends 32a-32c of the struts 12a-12c, though these two planes need not be parallel. Importantly,the plane containing the first ends 30d-30f of the struts 12d-12f is disposed beneath the plane containing the second ends 32a-32c of the struts 12a-12c. In essence, the first ends 30d-30f are cradled by the tendons 14a between the second ends 32a-32c. According to the invention, the plane defined by the first ends 30d-30f must lie below the plane defined by the second ends 32a-32c in order for the unit 10 to be structurally stable, i.e., exhibit static equilibrium As such, the polygonal shape of the midsection 20 cannot lie in a single plane, but instead will be skewed in some manner, as is depicted in FIGS. 2, 3, 4 and6. FIG. 4 depicts the plane defined by the first ends 30d-30f as being disposed approximately half the distance between the plane defined by the second ends 32a-32c and the first end 18a of the structural unit 10. The different characteristics of the arrangements shown in FIGS. 3 and 4 will be discussed in greater detail below.
With reference again to FIGS. 1 and 2, the structural unit 10 is shown to include six tendons 14a, each of which interconnects one of the second ends 32a-32c of the struts 12a-12c with an adjacent one of the first ends 30d-30f of the struts 12d-12f. Furthermore, the second ends 32d-32f of thestruts 12d-12f are interconnected with three tendons 14b, and additional tendons 14c further interconnect the struts 12a-12c with the struts 12d-12f. Specifically, the tendons 14c are employed to interconnect:
(a) the first end 30a of the strut 12a with the first end 30d and the second end 32c;
(b) the first end 30b of the strut 12b with the first end 30f and the second end 32a;
(c) the first end 30c of the strut 12c with the first end 30e and the second end 32b;
(d) the first end 30d of the strut 12d with the second end 32f;
(e) the first end 30e of the strut 12e with the second end 32d;
(f) the first end 30f of the strut 12f with the second end 32e;
(g) the second end 32a of the strut 12a with the second end 32f;
(h) the second end 32b of the strut 12b with the second end 32e; and
(I) the second end 32c of the strut 12c with the second end 32d.
As shown in FIG. 1 (but omitted from FIGS. 2 through 6 for clarity), each of the tendons 14a are capable of being manipulated to alter their tensionso as to selectively articulate the structural unit 10 between its retracted and deployed configurations, as well as any intermediate configuration therebetween. The structural unit 10 of FIG. 1 is shown as being equipped with a centrally-disposed shaft 46 that is rotatably supported relative to the unit 10. The shaft 46 is interconnected to each of the tendons 14a with an appropriate number of tendons 48 or other suitable members, which serve to draw the tendons 14a toward the shaft 46 when the shaft 46 is rotated, resulting in an increase in the tension within the tendons 14a. In this manner, the tension in the tendons 14a canbe selectively increased or decreased in order to articulate the structuralunit 10 between its deployed and stowed configurations, or to control the rigidity (stiffness) of the unit 10 after deployment.
While a shaft and tendons are illustrated, numerous other techniques for altering the tension in the tendons 14a will be apparent to one skilled inthe art, and such techniques are within the scope of this invention. Alternatively, one or more of the struts 12a-12f shown in the Figures can have a telescoping design that enables the struts 12a-12f to be extended and retracted electrically, mechanically, pneumatically or hydraulically. As such, if the tension in the tendons 14 is increased and/or the struts 12a-12f are extended, the structural unit 10 is extended to acquire its deployed configuration, characterized by the shape of the envelope 16. In contrast, if the tension in the tendons 14 is decreased and/or the struts 12a-12f are retracted, the structural unit 10 is collapsed to acquire a stowed or collapsed configuration. Finally, if only a select few of the tendons 14 or struts 12a-12f are altered, the shape of the structural unit10 can be uniquely altered from that shown in the Figures.
According to this invention, the ability to deploy and stow the structural unit 10 shown in FIGS. 1 and 2 is useful when coupled with a system that enables the shape and/or stiffness of the unit 10 to be accurately detected, and then provides feedback to the struts and/or tendons 12 and 14 in order to enable the unit 10 to alter its configuration or stiffness,or to reestablish a desired configuration or stiffness. The manner in whichthe configuration of the unit 10 is sensed can be through sensing the tension in at least some of the tendons 14 and/or the compression or length of the struts 12. FIG. 5 schematically represents one such embodiment, in which the tension in a tendon 14 is detected by a piezoelectric strain gauge 36 equipped with a roller 38 and placed betweenany adjacent two of the struts 12. Those skilled in the art will appreciatethat alternative methods and devices for measuring stress or strain in the tendons 14 and/or the struts 12 could be employed, and all such methods and devices are within the scope of this invention.
Turning now to FIGS. 3 and 4, multiple units 10 are shown as being assembled to form deployable structures 100 and 200. The deployable structure 100 of FIG. 3 illustrates a configuration in which the plane containing the first ends 30d-30f of the struts 12d-12f is disposed beneath the plane containing the second ends 32a-32c of the struts 12a-12c, and less than half the distance between the latter plane and the first end 18a of the structure 100. As shown in FIG. 3, such an arrangement of units 10 results in each unit 10 being interconnected with its adjacent units 10 with only a set of the tendons 14c. For example, thesecond end 32c of the strut 12c of the bottom unit 10 is interconnected with a tendon 14c to the first end 30a of the strut 12a of the second unit10, and the second end 32b of the strut 12b of the bottom unit 10 is interconnected with a tendon 14c to the first end 30c of the strut 12c of the second unit 10 As such, the units 10 are vibrationally isolated from each other, such that the deployable structure 100 resists transmission ofvibrations between its upper and lower ends 18a and 18b. In addition, the maneuverability of the structure 100 is maximized, providing a maximum degree of freedom for the units 10. As such, the deployable structure 100 is of the type most suited for dynamic structures such as payload pointingstructures, vibration isolation of machinery, antennas, equipment that mustbe compactly stowed for transport to space, and robotic members.
In contrast, FIG. 4 depicts the plane containing the first ends 30d-30f of the struts 12d-12f as being disposed approximately half the distance between the plane containing the second ends 32a-32c of the struts 12a-12cand the first end 18a of the structure 200. As a result, the second ends 32a-32c of the struts 12a-12c are shown as contacting the first ends 30a-30c of the struts 12a-12c of the adjacent unit 10, instead of being interconnected with tendons as shown for the embodiment of FIG. 3. Preferably, the ends 30a-30c and 32a-32c are pivotably connected. In this manner, the deployable structure 200 is capable of being deployed and collapsed in essentially the same manner as the structure 100 of FIG. 3, but is characterized by greater stiffness. As such, the deployable structure 200 is of the type most suited for such structures as buildings,bridges, support platforms for space telescopes and antennae, and airfoils for aerospace applications. In particular, this invention is highly suitable to form the support structure for an airfoil, wherein the selective control of the shape and stiffness of the structural unit 10 enables the airfoil to be selectively and precisely altered in order to affect its aerodynamics.
With either arrangement depicted in FIGS. 3 and 4, a deployable structure in accordance with this invention must be operative to enable the shape and/or stiffness of its units 10, individually or in unison, to be alteredin order to achieve precise articulation of the deployable structure or achieve a desired level of stiffness for the structure. Such a capability can be advantageously exploited if the deployable structure is used as an actuator to precisely position a payload or a sensor that can respond to an external disturbance force to counteract the force or otherwise accommodate the force such that the desired shape and/or stiffness of the structure are not adversely affected. One such example is represented in FIG. 6, in which a deployable structure 300 incorporating the single structural unit 10 of FIG. 1 is adapted to respond to a disturbance force 40 applied to one of the corners 26f of the structure 300. Shown schematically is a feedback control 42 for communicating the output of sensors (not shown) coupled with one or more of the tendons 14, to a mechanism (not shown) for altering the tension in the tendons 14 and/or the lengths of one or more of the struts 12a-12f, so as to articulate the structure 300 in response to changes in the tension of the tendons 14 as aresult of the disturbance force 40. If the structure 300 is a building, such that the struts 12 and tendons 14 are beams and cables, respectively,within the building, examples of potential disturbances to the structure 300 include high winds and earthquakes. Through monitoring the output of the sensors coupled with the tendons 14, whose output will change as a result of the structure's configuration being forcibly altered by the disturbance force 40, rapid compensation can be made in the tension withinselected tendons 14 in order to counteract the disturbance and thereby appropriately modify the stiffness of the structure 300, reestablish the original configuration of the structure 300, or possibly reconfigure the structure 300 in order to attain a configuration better adapted to the newenvironment of the structure 300 or more readily capable of withstanding the disturbance.
The dynamics of the structural unit 10 or any of the deployable structures 100, 200 and 300 of this invention are complex and therefore not obvious to one skilled in the art. However, this difficulty is overcome by the availability of software, such as DYCOM available from Dynamic EngineeringCompany, Inc., of Palm Harbor, Fla., which develops equations of motion that are able to reliably model the structural unit 10 and deployable structures 100, 200 and 300 of this invention due to their construction--namely, the struts 12 and tendons 14 undergo only axial forces, such that the extreme difficulty of accurately modeling bending moments is completely avoided. Consequently, the simplicity of the axial forces within the structural unit 10 enables reliable modeling, and therefore reliable control of the struts 12 and/or tendons 14 through the use of analytical determinations using the feedback control 42.
In view of the above, it can be seen that a significant advantage of deployable structures configured in accordance with this invention is thatlarge displacements and high loads can be sustained and a significant levelof vibration isolation can be achieved due to the use of rigid struts 12 that are interconnected with elastic tendons 14. Operationally, considerable precision of a structure's shape and stiffness is achieved bysensing of the condition (e.g., tensile or compressive stress, length, etc.) of the struts 12 and tendons 14 to provide a feedback that enables one or more of the struts 12 and/or tendons 14 to be altered such that a desired configuration and/or stiffness for the structure is established, or reestablished if in response to an external disturbance force. Such capabilities enable a deployable structure to perform as a sensing device in which the struts 12 and/or tendons 14 are closely monitored in order toascertain the shape of the deployable structure in response to external disturbances, and perform appropriate alterations to the struts 12 and/or tendons 14 in order to counteract or compensate for the disturbance. Alternatively, such capabilities enable a deployable structure to perform as an actuator in which the struts 12 and/or tendons 14 are selectively manipulated in order to partially or fully deploy and retract the structure, as well as reestablish a desired shape for the structure after being subjected to an external disturbance force.
While our invention has been described in terms of a preferred embodiment, it is apparent that other forms could be adopted by one skilled in the art. For example, a different number of struts, tendons and/or structural units could be employed to construct a deployable structure, the physical and mechanical characteristics of the struts and tendons could be modified, and a deployable structure of the type disclosed could be adapted for applications and operating environments other than those noted. Accordingly, the scope of our invention is to be limited only by the following claims.
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A lightweight, deployable structure capable of large displacements and sustaining high loads, and whose shape can be precisely monitored and controlled to acquire a wide variety of shapes and varying levels of stiffness, and precisely returned to a desired shape after being subjected to a disturbance force. As such, the structure is highly suitable for use in applications in which information concerning the shape and/or stiffness of the structure can be employed to precisely attain a desired shape, precisely return the structure to a desired shape after being subjected to a disturbance force, or to increase or decrease the structural stiffness in response to changing environmental conditions. The deployable structure is generally composed of one or more structural units, each of which can be articulated between two extreme configurations, one of which is a deployed configuration in which the deployable structure is fully extended. The shape and stiffness of each structural unit is established by rigid compression members that are interconnected by elastic tension members to form two interconnected tiers. The compression and elastic members are interconnected such that the compression members are subjected to essentially axial loads. The shape and stiffness of the structural unit is controlled by loosening and tightening one or more of the tension members and/or shortening and lengthening one or more of the compression members.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part application of Patent Cooperation Treaty application PCT/US02/29422, filed Sep. 18, 2002, the entire disclosure of which is hereby incorporated herein by reference, which is a continuation of U.S. application Ser. No. 09/953,891, filed on Sep. 18, 2001, now U.S. Pat. No. 6,470,696, the entire disclosure of which is hereby incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to devices and methods for sensing condensation conditions and for preventing or removing such condensation from surfaces such as vehicle windscreens, eyewear, goggles, helmet visors, computer monitor screen, windows, electronic equipment, etc., and especially devices and methods that use a thermal sensor and a humidity sensor in an adjacent ambient space with respect to the surface, or in thermally conductive contact with a thermoelectric cooler (TEC), for automatically and dynamically sensing condensation conditions when condensation appears on a surface or before such condensation actually appears on a surface.
BACKGROUND
The level of moisture in air at any time is commonly referred to as relative humidity. Percent relative humidity is the ratio of the actual partial pressure of steam in the air to the saturation pressure of steam at the same temperature. If the actual partial pressure of steam in the air equals the saturation pressure at any given temperature, the relative humidity is 100 percent. If the actual partial pressure is half that of the saturation pressure, the relative humidity is 50 percent, and so forth.
Dew point temperature, also known as condensation temperature or saturation temperature, is a function of the level of moisture or steam that is present in the air, and is the temperature at which air has a relative humidity of 100 percent. Condensation of moisture on a surface occurs when the temperature of that surface is at or below the dew point temperature of air surrounding the surface.
When air having a relatively high content of moisture comes into contact with a surface having a temperature at or below the dew point temperature, steam will begin to condense out of the air and deposit as water droplets onto the surface. At this time, a thin layer of liquid water comprised of small water droplets forms on the surface, creating a visual hindrance or “fog” to an observer looking at or through the surface. Once, formed, the condensation can be dispersed and removed either by raising the temperature of the surface, thereby changing the water into steam, or by lowering the relative humidity of the air surrounding the surface, thereby allowing the droplets to evaporate.
Steam, as a gas, exists in a saturated state at pressures and corresponding temperatures that are predictable and measurable. Notably, the standard for steam's thermodynamic properties, including saturation pressures and temperatures, in the United States and arguably the world, is the ASME (American Society of Mechanical Engineers) Steam Tables. These thermodynamic property tables are readily obtainable from ASME, as well as from engineering texts.
In that steam possesses certain characteristics and traits as a saturated gas that are measurable and exact, equations have been developed that permit the engineer to approximate and predict the properties of steam at a desired set of conditions when its properties are known at a different, or datum, set of conditions. Such an equation, in the case of gas saturation pressures and temperatures, is entitled the Clausius-Clapeyron Equation. This equation, which may be described in several variations, may be best stated for the purposes at hand in the following form: ln [ P 2 sat P 1 sat ] = Δ H R * ( 1 T 1 - 1 T 2 )
where
P 1 sat is the saturation partial pressure at state 1 , in units of psia;
P 2 sat is the saturation partial pressure at state 2 , in units of psia;
ΔH is the heat of vaporization, equal to approximately 755,087.46 (ft−lbf)/lbm for steam;
R is the gas constant, equal to approximately 85.8 (ft−lbf)/(lbm−° R) for steam;
T 1 is the temperature at state 1 , in units of degrees Rankine; and
T 2 is the temperature at state 2 , in units of degrees Rankine.
Thus, using the Clausius-Clapeyron Equation, once steam 's saturation pressure and temperature are known (the saturation pressure and temperature defining state 1 of the steam), given any other desired temperature, the saturation pressure at this temperature can be calculated to a high degree of accuracy (the temperature and calculated saturation pressure defining state 2 of the steam). Conversely, given any known state 1 conditions, for any desired saturated gas pressure, the saturation temperature can be calculated (the saturation pressure and calculated temperature defining state 2 of the steam).
SUMMARY
The invention provides a device and method for sensing or predicting when condensation is present or imminent and for suppressing such condensation from a surface by preventing it or removing it. A first thermal sensor is in thermally conductive contact with the surface. A second thermal sensor is in an environment separated from the surface. A humidity sensor is in the environment of the second thermal sensor. A circuit causes a condensation suppression mechanism to be activated for preventing or removing condensation having the given physical state from the surface when a temperature sensed by the first thermal sensor, a temperature sensed by the second thermal sensor, and a humidity sensed by the humidity sensor indicate that a condensation condition is either present or likely and requires prevention or removal at the surface. As used herein and in the claims, the term “suppress” encompasses prevention or preclusion of condensation conditions as well as, in the alternative, removal of existing condensation conditions.
The invention provides a convenient and practical mechanism for detecting condensation conditions quickly, before they manifest themselves on the surface. In certain embodiments the condensation suppression mechanism can be activated automatically when a condensation condition is detected, thereby providing convenience and safety where the surface is a windscreen of a vehicle, for example, or goggles, a helmet visor, computer monitor screen, window, electronic equipment enclosure.
In one embodiment of the invention, the second thermal sensor is in thermally conductive contact with a cooling device, and a circuit activates the cooling device in order to maintain the second thermal sensor at a temperature that is lower than a temperature of the first thermal sensor. The humidity sensor is in thermally conductive contact with the cooling device. The circuit causes the condensation suppression mechanism to be activated when the humidity sensor indicates a presence of high humidity conditions or condensation at the temperature that is lower than the temperature of the first thermal sensor.
In alternative embodiments of the invention, the environment of the second thermal sensor is in an adjacent ambient space with respect to the surface. The circuit determines that the condensation condition requires suppression at the surface by determining, from the temperature sensed by the second thermal sensor and the humidity sensed by the humidity sensor, the pressure of steam in the environment of the second thermal sensor. Then, the circuit may either determine a ratio of the pressure of steam in the environment of the second thermal sensor to the saturated steam pressure at the temperature sensed by the first thermal sensor, or determine a difference between a temperature sensed by the first thermal sensor and a dew point temperature associated with the pressure of steam in the environment of the second thermal sensor.
Thus, in certain embodiments of the invention, instead of measuring RH at an intentionally lowered temperature relative to the surface in question, RH (and temperature) can be measured in the surrounding ambient air adjacent to and in the proximity of the surface itself. Through calculation, the measurements taken in the surrounding ambient air can be extrapolated using the Clausius-Clapeyron Equation or any of its derivatives to determine whether condensation conditions exist on the surface in question or are imminent. Thus, it is not necessary physically to create a simulated (state 2 ) temperature in which a (state 2 ) relative humidity (RH) value can be measured.
Numerous additional features, objects, and advantages of the invention will become apparent from the following detailed description, drawings, and claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a diagram of a surface in combination with a pair of thermal sensors in accordance with the invention.
FIG. 2 is a cross-sectional drawing of two options for incorporating a thermal sensor into a surface.
FIG. 3 is a cross-sectional drawing of thermoelectric cooler according to the invention in combination with a thermal sensor.
FIG. 4 is a block diagram of the electrical circuitry for an automatic sensing system according to the invention.
FIG. 5 is a block diagram of the electrical circuitry for two options of a condensation suppression system configured to be combined with the automatic sensing system of FIG. 4 .
FIG. 6 is a drawing of the thermoelectric cooler and thermal sensor of FIG. 3 within an air duct, the air duct being shown in partial cut-away view.
FIG. 7 is a flow diagram of a method for automatically sensing condensation conditions and for suppressing condensation from surfaces using the system illustrated in FIGS. 1-6.
FIG. 8 is a diagram of a surface in combination with a pair of thermal sensors and a humidity sensor in accordance with another embodiment of the invention
FIG. 9 is a cross-sectional drawing of two options for incorporating a thermal sensor into a surface.
FIG. 10 is a block diagram of electrical circuitry for automatic sensing systems according to the invention of the type shown in FIG. 8 .
FIG. 11 is a block diagram of the electrical circuitry for three embodiments of a condensation suppression system configured to be combined with the automatic sensing system of FIG. 10 .
FIG. 12 is a drawing of a condensation detection and suppression system, in accordance the invention, applied to a pair of goggles.
FIG. 13 is an exploded view of a portion of the electronic circuitry sensors juxtaposed relative to their protective hydrophobic cover as embodied in FIG. 12 .
FIG. 14 is a flow diagram of a method for automatically sensing condensation conditions and for suppressing such conditions from a surface using the system illustrated in FIGS. 10 and 11 .
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
With reference to FIG. 1, an automatic sensing and condensation prevention and removal system according to the invention includes two thermal sensors 2 and 6 . Thermal sensor 2 is mechanically affixed to or embedded within a surface 1 from which condensation conditions are to be sensed and/or condensation is to be removed, such as a windscreen, goggles, a visor for a military helmet, pilot helmet, space-suit helmet, or other type of helmet, a computer monitor screen (such as a screen for a commercial electron beam or LCD computer monitor placed outdoors or in a high-humidity environment, such as in an industrial panel), a window or other transparent or translucent pane or enclosure (such as common windows in office buildings or enclosures that may house documents or other sensitive materials such as artwork and artifacts in museums or historic works), including plastics, an electronic equipment enclosure (such as a transparent or non-transparent enclosure for computer equipment, telecommunications equipment, etc. that might be placed outdoors or in high-humidity environments in which condensation might appear on the inside surface of the enclosure).
Each of the thermal sensors is a thermocouple formed by the thermal fusion of two dissimilar but electrically insulated metal conductors. In particular, the thermal fusion of metal conductors 3 and 4 forms thermal sensor 2 and the thermal fusion of metal conductors 3 and 7 forms thermal sensor 6 . Conductors 4 and 7 are of the same electro-conductive material and are of the same length.
If the temperatures of the bodies sensed by thermal sensors 2 and 6 are exactly the same, the thermocouple circuit through conductors 4 and 7 creates no electrical current. If the temperatures are not identical, a current is generated through this thermocouple circuit through conductors 4 and 7 , this current being proportional to the temperature difference of the two thermocouple junctions, as was first discovered by Thomas Seebeck in 1821.
The integrated sensing and condensation prevention and removal device creates an intentional temperature difference between thermocouples 2 and 6 by the thermoelectric cooling effect of a thermoelectric cooler (TEC) onto which thermocouple 6 is mechanically affixed.
With reference to FIG. 2, thermal sensor 2 may be mechanically affixed to surface 1 by an adhesive 5 (Option 1 ), or thermal sensor 2 may be embedded within surface 1 (Option 2 ).
With reference to FIG. 3, thermal sensor 6 is mechanically affixed by means of an adhesive 17 to the exterior face of the cold junction side 9 of thermoelectric cooler (TEC) 8 . The exterior face of the hot side 10 of TEC 8 may be mechanically bonded or otherwise attached to an optional heat sink 12 . A humidity sensor 13 , illustrated as a thin-film capacitive sensor but which may be any other sensing device that performs a similar function, is bonded by a mechanical bond 18 to thermocouple 6 . Thus, TEC cold-side face 9 , thermocouple 6 , and capacitive sensor 13 will always be at the same temperature. With reference to FIG. 6, TEC 8 , thermal sensor 6 , and thin-film capacitive sensor 13 are placed within the recirculation or outside air duct 58 , with heat sink 12 being attached to air duct 58 .
With reference to FIG. 4, as the above-mentioned intentionally-created temperature difference is created between thermocouples 2 and 6 , and, consequentially, as current is developed within the thermocouple circuit, the resultant voltage difference across conductors 4 and 7 is measured and amplified by voltage amplifier circuit 19 . This voltage signal is adjusted and offset for any impressed thermocouple effects due to any dissimilar metal junctions created by the connection of conductors 4 and 7 to voltage amplifier circuit 19 itself. The voltage signal is thereafter fed to TEC controller circuit 20 , within which the signal is compared to a pre-established differential voltage set point. Thereafter, TEC controller circuit 20 , supplied with an electrical power source and electrically grounded at ground 28 , electrically modulates a voltage that is applied to TEC 8 by conductors 14 and 15 , in order to maintain the cold face of TEC 8 at a temperature level that is a predetermined amount below the temperature of the windscreen, goggles, helmet visor, computer monitor screen, window, electronic equipment enclosure, or other surface.
The integrated sensing and condensation prevention and removal device is operated in a manner such that a constant difference is dynamically maintained between the temperature established at thermal sensor 6 by the action of TEC 8 and the temperature measured at the surface by thermal sensor 2 . Therefore, regardless of the temperature of the surface, the temperature established at the cold-side face of TEC 8 onto which thermal sensor 6 is affixed will always be lower than that of the surface by a predetermined amount.
Ambient air or outside air flows over thin-film capacitive sensor 13 . The capacitance of capacitive sensor 13 will be proportional to the relative humidity of the surrounding air. Because capacitive sensor 13 is maintained at a temperature less than that of the windscreen, goggles, helmet visor, computer monitor screen, window, electronic equipment enclosure, or other surface, the humidity level sensed will always be greater than that at the surface, and any liquid condensation will always form on capacitive sensor 13 before it forms on the surface.
Thin-film capacitive sensor 13 is connected by conductors 22 and 23 to capacitance-to-voltage circuit 29 . Conductor 23 and capacitance-to-voltage circuit 29 are connected to a common electrical ground 40 . Capacitance-to-voltage circuit 29 is supplied regulated 2.5-volt DC power by conductor 27 from voltage regulator circuit 26 , which is in turn energized by an electrical power source and an electrical ground 28 . Capacitance-to-voltage circuit 29 includes two #7556 timing integrated circuits 30 and 33 , resistors 34 , 35 , 37 , and 39 , and filter capacitors 31 , 38 , and 41 . Timing integrated circuits 30 and 33 are electrically grounded at junctions 32 , 36 , 42 , and 44 .
Capacitance-to-voltage circuit 29 transforms the constant 2.5-volt DC supply voltage into a high-frequency AC signal. Thin-film capacitive sensor 13 is integrated into capacitance-to-voltage circuit 29 in a manner such that any capacitance of capacitive sensor 13 is transformed into a positive DC voltage relative to ground 44 , at conductor 43 of capacitance-to-voltage circuit 29 . The capacitance of capacitive sensor 13 increases as humidity increases, thereby resulting in an increased voltage at conductor 43 . The capacitance of capacitive sensor 13 is at a maximum when liquid moisture condenses onto capacitive sensor 13 . This condensation of liquid moisture onto capacitive sensor 13 , occurs when the temperature of capacitive sensor 13 is at or below the dew point of the ambient air.
With reference to FIG. 5, the output signal of the capacitance-to-voltage circuit is connected by conductors 45 and 46 to comparator circuit 47 . This output signal is compared to a set point voltage previously established in comparator circuit 47. If the signal is less than a pre-established set point, the signal is interpreted as meaning that fogging of the surface is not present or imminent. If the signal is equal to or greater to the pre-established set point, the signal is interpreted as meaning that fogging of the surface is present, imminent or likely to occur, in which case the system activates condensation suppression action.
If the signal from the capacitance-to-voltage circuit is equal to or greater than the pre-established set point, an electrical signal is directed to switching circuit 50 through conductors 48 and 49 , thereby causing the internal electronic or mechanical contactors of switching circuit 50 to close. Thereafter, electrical power is directed from switching circuit 50 through conductor 51 , which branches into conductors 53 and 54 . Conductor 53 is connected to a single-speed or multiple-speed fan 55 located within duct 58 . When fan 55 is energized, it rotates or increases its speed in order to generate or increase the volume of airflow directed toward the windscreen, goggles, computer monitor screen, window, electronic equipment enclosure, or other surface. The TEC, the thermal sensor mechanically bonded thereto, and the capacitive sensor are positioned within duct 58 upstream of fan 55 .
FIG. 5 illustrates a first option (Option 1 ), according to which electrical power is applied by conductor 54 to electrical heating coil 57 . Both fan 55 and heating coil 57 are electrically grounded by grounds 56 and 59 respectively. Energization of heating coil 57 raises the temperature of the air flowing over the heating coil element and thereafter flowing to and onto the face of the surface, thereby raising the temperature of the surface and the ambient space surrounding it so as to preclude condensation, or alternately if condensation is present, vaporizing water droplets deposited thereon.
According to a second option (Option 2), electrical power is applied by conductor 54 to an electric motor or solenoid actuator 60 , which is electrically grounded by ground 61 . Electric motor or solenoid actuator 60 is connected by linkage arm 63 to damper 62 , which moves as indicated in FIG. 5 so as to divert the airstream to an adjacent but interconnecting and parallel duct 65 within which a heater core 64 is mounted. Heater core 64 raises the temperature of the airstream passing through parallel duct 65 . Thereafter, the heated air is directed toward and onto the face of the surface, thereby raising the temperature of the surface and the ambient space surrounding it so as to preclude condensation, or alternately if condensation is present, vaporizing water droplets deposited thereon.
As a further option, the hot side face of the TEC may be used to provide heat, in lieu of the heating coil 57 or heater core 64 , to the air flowing toward and onto the face of the surface, thereby precluding condensation, or alternatively if condensation is present, vaporizing water droplets deposited thereon.
As yet a further option, since there will not be any ductwork per se in a helmet or goggles, or within certain other equipment having surfaces to be defogged, fan 55 , heating coil 57 and heater core 64 may be replaced by a heating coil embedded in or on the visor, etc., as micro-fine electro-resistive wires, or by an infrared source positioned so as to radiate onto the surface.
With reference to FIG. 7, once the automatic sensing and condensation prevention and removal system is powered up, the difference in temperature between the windscreen, goggles, helmet visor, computer monitor screen, window, electronic equipment enclosure, or other surface and the TEC is monitored to determine whether it is lower than a pre-established set point, and the TEC is energized to the extent necessary-to raise the difference to the set point. Also, the capacitive sensor is monitored to determine whether it indicates the presence of condensation. If the capacitive sensor indicates the presence of condensation a fan is energized, and either a heating coil or a damper actuator is activated.
With reference to FIG. 8, an alternative embodiment of an automatic sensing and condensation preclusion and removal system according to the invention includes two thermal sensors 68 and 71 . Thermal sensor 68 is mechanically affixed to or embedded within surface 66 , for which condensation conditions are to be monitored and/or from which condensate liquid is to be removed. Surface 66 can be, for example, a windscreen for a vehicle, a visor for a military helmet, pilot helmet, space-suit helmet, or other type of helmet, a visor for safety or non-safety apparatus, goggles, glasses, or other type of visor or goggle, a full-face air purifying respirator mask, a self-contained breathing apparatus (SCBA) mask, or other type of respirator mask, a computer monitor screen (such as a screen for a commercial electron beam or LCD computer monitor placed outdoors, in a cool or cold environment or in a high-humidity environment, such as in an industrial panel), a window or other transparent or translucent pane or enclosure (such as common windows in office buildings or enclosures that may house documents or other sensitive materials such as artwork and artifacts in museums or historic works), including plastics, an electronic equipment enclosure (such as a transparent or non-transparent enclosure for computer equipment, telecommunication equipment, cameras, projection equipment, transmitters, receivers, transceivers, or like components or objects that may be placed outdoors or in cool or cold environments or in high-humidity environments in which condensation might appear), optical equipment such as telescopes, binoculars, instrument bezels, viewing windows, eyeglasses and prescription lenses, electronic circuitry and circuit boards, and like components.
As schematically shown, the sensors may each be a thermocouple, formed by the fusion of two dissimilar metal conductors, a resistance temperature detector (RTD), a thermistor, or any electronic thermal measurement device performing the same function. Thermal sensor 68 is electrically connected to conductors 69 and 70 , while thermal sensor 71 , positioned adjacent to and in close proximity to surface 66 , at distance 72 , in the ambient surroundings 67 , is electrically connected to conductors 73 and 74 . Additionally, a humidity sensor 75 , illustrated as a thin-film capacitive relative humidity sensor, but which may be any other sensing device that performs a similar function is positioned immediately adjacent to thermal sensor 71 , but also may be mechanically affixed to or otherwise mechanically attached to thermal sensor 71 , it also being in close proximity to surface 66 , at distance 72 , in the ambient surroundings 67 . Capacitive sensor 75 is electrically connected to conductors 76 and 77 .
With reference to FIG. 9, thermal sensor 68 may be mechanically affixed to surface 66 by means of adhesive 78 (Option 1 ), or thermal sensor 68 may be imbedded within surface 66 (Option 2 ).
With reference to FIG. 10, in one embodiment of the circuitry for a condensation detection and suppression system of the type shown in FIG. 8, thermal sensor 79 , illustrated as a negative temperature coefficient (NTC) thermistor, but which may be any other temperature-sensing device that performs a similar function, is positioned within ambient space 81 . Thin-film relative humidity sensor 80 is also positioned within the ambient space 81 , in close proximity to thermal sensor 79 . A second thermal sensor 82 is embedded within or affixed to surface 83 . The first thermal sensor 79 is part of a voltage divider circuit, formed by a DC voltage source, resistor 86 , conductors 84 and 85 , and ground 87 . Similarly, the second thermal sensor 82 is part of a second voltage divider circuit, formed by a DC voltage source of the same potential, resistor 90 , conductors 88 and 89 , and ground 91 . As is illustrated in this embodiment, the resistance of each thermal sensor is proportional to the temperature of the material surrounding it. Thus, in the ambient space, the resistance of thermal sensor 79 , and hence the voltage across thermal sensor 79 , is proportional to the temperature of the air in the ambient space, resulting in a finite voltage input through conductor 84 to the analog-to-digital converter (ADC) 92 relative to ground 93 . ADC 92 is supplied power through conductor 104 by voltage regulator circuit 103 that is connected to a DC power source.
Similarly, the resistance of thermal sensor 82 , and hence the voltage across thermal sensor 82 , is proportional to the temperature of surface 83 , resulting in a finite voltage input to ADC 96 through conductor 94 relative to ground 95 . ADC 96 is supplied power through conductor 106 by a voltage regulator circuit 105 that is connected to a DC power source.
Ambient air or outside air flows over thin-film capacitive sensor 80 in the ambient space 81 . The capacitance of capacitive sensor 80 is proportional to the relative humidity of the surrounding air. Thin film capacitive sensor 80 is connected by conductors 97 and 98 to the capacitance-to-voltage circuit 99 , the relative humidity level thus resulting in a finite voltage input to ADC 101 through conductor 100 relative to ground 102 . The capacitance-to-voltage circuit 99 is supplied power through conductor 108 by a voltage regulator circuit 107 that is connected to a DC power source. ADC 101 is supplied power through conductor 110 by a voltage regulator circuit 109 that is connected to a DC power source.
Alternatively, a single voltage regulator connected to conductors 104 , 106 , and 110 and a single DC power source be may used instead of individual voltage regulators 103 , 105 and 109 .
The voltage level across ambient space thermal sensor 79 is converted in ADC 92 to a digital signal, thereafter being appropriately modified to account for any sensor error or non-linearity, as necessary, by calibration data 111 . Similarly, the voltage level across surface thermal sensor 82 is converted in ADC 96 to a digital signal, thereafter being appropriately modified to account for any sensor error or non-linearity, as necessary, by calibration data 112 . The voltage level across the output conductor 100 relative to ground 102 of the ambient space relative humidity sensor circuit 99 is converted in ADC 101 to a digital signal, thereafter being appropriately modified to account for any sensor error or nonlinearity, as necessary, by calibration data 113 .
Internal timer 114 sets the period of data sampling (or data polling) for sample-and-hold buffers 115 , 116 , and 117 , such that the acquisition of temperature and relative humidity data occurs concurrently. Each buffer may be configured to retain such data in flash memory or in a stack arrangement, such that the newest data replaces the data previously recorded. Subsequently, digital measurement data of ambient space temperature, surface temperature, and ambient space relative humidity are input to central processing unit (CPU) 118 for analysis. CPU 118 , which retains a pre-programmed digital instruction set, accesses a set-point database 119 during computation to establish whether condensation preclusion or removal action is indicated. In such an event, CPU 118 initiates a signal-to-switching circuit 120 , thereby causing internal electronic or mechanical contactors to close. Thereafter, DC electrical power relative to ground 122 is directed from switching circuit 120 through conductor 121 thus energizing components downstream.
With reference to FIG. 11, conductor 121 at the output of switching circuit 120 branches into two conductors 123 and 124 . Conductor 123 is connected to a single-speed or multi-speed fan 125 located within duct 129 . When fan 125 is energized, it rotates or increases its speed in order to generate or increase the volume of airflow directed toward the surface, thereby raising the temperature of the surface and the ambient space surrounding it so as to preclude condensation, or alternately if condensation is present, vaporizing water droplets deposited thereon.
FIG. 11 illustrates a further option (Option 3 ), according to which electrical power is applied by conductor 124 to electric heating coil 127 . Both the fan and the heating coil are electrically grounded by grounds 126 and 128 respectively. Energization of heating coil 127 raises the temperature of the air flowing over the heating coil element and thereafter flowing to and onto the face of the surface, thereby raising its temperature and the ambient space surrounding it and precluding condensation, or alternatively if condensation is present, vaporizing water droplets deposited thereon.
According to a further option (Option 4 ), electrical power is supplied by conductor 124 to an electric motor or solenoid actuator 130 , which is electrically grounded by ground 131 . Electric motor or solenoid actuator 130 is connected by linkage arm 133 to damper 132 , which moves as indicated in FIG. 11 so as to divert the airstream to an adjacent but interconnecting and parallel duct 135 within which a heater core 134 is mounted. Heater core 134 raises the temperature of the airstream passing through parallel duct 135 . Thereafter, heated air is directed toward and onto the face of the surface, thereby raising the temperature of the surface and the ambient space surrounding it so as to preclude condensation, or alternately if condensation is present, vaporizing water droplets deposited thereon.
According to a further option (Option 5 ), electrical power is supplied by conductor 124 to TEC controller circuit 136 , which is electrically grounded by ground 128 . TEC controller circuit 136 subsequently energizes TEC 138 , through electrical conductors 139 and 140 . TEC 138 is positioned relative to duct 129 such that its cold side face directly contacts the exterior surface of, and is mechanically attached, bonded, or otherwise affixed to duct 129 . In the same location, heat sink 141 is mechanically attached, bonded or otherwise affixed to the inside surface of duct 129 . Heat sink 141 is comprised of a thermally conductive material, which may be constructed with fins, protrusions, or similar extensions, as illustrated. Duct 129 extends past TEC 138 and heat sink 141 , thereafter attaching to a 180-degree elbow 144 of the same cross-sectional area and dimensions as duct 129 , and positioned within the same plane. Thereafter, elbow 144 attaches to a further duct 143 , of the same cross-sectional area and dimensions as duct 129 , and is positioned within the same plane as the distal end of elbow 144 . Duct 143 extends parallel to duct 129 such that it extends past TEC 138 as illustrated. The hot side of TEC 138 directly contacts the exterior surface of, and is mechanically attached to, bonded to, or otherwise affixed to duct 143 . In the same location, heat sink 142 is mechanically attached to, bonded to, or otherwise affixed to the inside surface of duct 143 . Heat sink 142 is comprised of a thermally conductive material, which may be constructed with fins, protrusions, or similar extensions, as is illustrated.
In addition to energizing TEC controller 136 , switching circuit 120 also concurrently energizes a single-speed or multi-speed fan 125 through conductor 123 . Fan 125 is located within duct 129 and is electrically grounded by ground 126 . When fan 125 is energized, it rotates or increases its speed in order to generate or increase the volume of airflow directed through duct 129 , the airstream flowing past and through TEC cold side heat sink 141 , causing moisture in the airstream to be condensed into droplets 145 and to be removed and thereafter past and through TEC hot side heat sink 142 , so as to be re-heated and directed toward the surface, thus directing warmed and dehumidified air toward the surface so as to provide condensation suppression action. Water droplets 145 pass to the lower interior surface of elbow 144 in which an opening and drain trap 146 are affixed. Drain trap 146 is constructed with a loop seal so that air passing through duct 129 and elbow 144 are precluded from escaping through trap 146 by the coalesced condensate 147 collected therein. As further moisture droplets 145 are created that then pass to elbow 144 and into trap 146 , the increased volume of condensate 147 within trap 146 causes a hydraulic pressure imbalance, resulting in the ejection of condensate, as is illustrated.
A further illustrative embodiment of a condensation detection and suppression system is shown in FIG. 12 . Goggles 148 may be intended for underwater use such as by swimmers, but may also be of the type used by construction workers, carpenters, skiers, hazardous materials workers, the military, pilots, etc. Goggles 148 have a transparent faceplate 149 , whose inner surface is to be monitored for defogging purposes, and have a circular hole 150 cut out of upper horizontal seal 151 . A sensor circuit board 152 , positioned in an inverted fashion and containing a humidity sensor and a temperature sensor, is mounted to the underside of a main circuit board 154 . The humidity sensor and temperature sensor reside within a protective enclosure 153 , which may be fabricated in part out of a hydrophobic material, so as to permit the transference of gases across its boundary but be impermeable to liquid water. Sensor circuit board 152 and protective shroud 153 extend beneath and protrude below the bottom plane of hermetically sealed enclosure 155 such that, when enclosure 155 is affixed to goggles 148 thus mating with upper horizontal seal 151 , circuit board 152 and protective shroud 153 insert within hole 150 . In such a position, the humidity and temperature sensors (and protective shroud) are placed within the enclosed ambient space formed by the goggles' inner surfaces and the wearer's face.
Main circuit board 154 also contains CPU 156 , voltage regulators 157 , ADC's 158 , and integrated switching mechanism 159 . Batteries 160 and 161 , positioned within cylindrical recesses 162 and 163 , supply direct-current electrical power to main circuit board 154 and sensor circuit board 152 . Gasketed threaded end caps 164 and 165 provide hermetic sealing of battery enclosures 162 and 163 respectively.
FIG. 13 illustrates the juxtaposition of the device's ambient-space humidity and thermal sensor with respect to the hydrophobic protective enclosure. Shown rotated along a horizontal axis 180-degrees from that depicted in FIG. 12, humidity sensor 166 and thermal sensor 167 are mounted on common sensor circuit board 168 (corresponding to circuit board 152 of FIG. 12 ). Protective enclosure 169 (corresponding to protective enclosure 153 of FIG. 12 ), also shown rotated from its position as depicted in FIG. 12, is of a size and volume sufficient to completely envelop the circuit board 168 and its components. Hydrophobic cover 169 ensures that, should liquid water flood the ambient space (in this case, the space between the inner surface of the goggles and the wearer's face), the device will still work once the water is cleared off of the inner surface of the goggles. Liquid water can still remain in the bottom of the ambient space, but any that splashes or floods the top of the ambient space (where the sensors reside) is prevented by the protective hydrophobic cover from fouling the sensors.
With reference to FIG. 14, the ambient space temperature, ambient space relative humidity, and surface temperature levels held in the sample-and-hold buffers are supplied to the central processing unit for analysis according to either of two alternatives as shown. In the first alternative, the CPU computes or determines, through direct calculation (using the Clausius-Clapeyron Equation or any of its derivatives), by accessing an internal look-up table, or by sequentially accessing a look-up table and interpolating or extrapolating and calculation, the theoretical saturated steam pressure in the ambient space at the ambient space temperature. Thereafter, the CPU multiplies this ambient space saturated steam pressure value by the ambient space relative humidity level supplied to it, so as to determine the actual partial pressure of steam in the ambient space. Thereafter, the CPU computes or determines, through direct calculation (using the Clausius-Clapeyron Equation or any of its derivatives), by accessing an internal look-up table, or by sequentially accessing a look-up table and interpolating or extrapolating and calculation, the theoretical saturated steam pressure at the surface temperature previously provided to the CPU. Finally, the CPU compares, by division, the ambient space steam partial pressure to the saturated steam pressure at the surface temperature, to obtain a “pseudo RH” value. This computed value is then compared to the value limit or limits stored in a set-point database. For example, if the value is 1.0 or greater, then condensation either exists on the surface being monitored or is imminent, and defogging action is initiated. If the value is about 0.93 to 1.0, condensation is likely, and preclusive defogging action is initiated. If the value is less than about 0.93, condensation is not likely, and no action is required. Thus, in the event that the computed value is within the bounds or constraints of the database, no action is taken to preclude condensation conditions or remove condensation on the surface. The device then nulls input data values, returns and re-polls the sample and hold buffers and performs a further computational analysis as previously described. In the event that the computed value is outside the bounds or constraints of the database, action is taken to preclude condensation conditions and/or remove condensation on the surface. While this action continues, the device nulls input data values, returns and re-polls the sample and hold buffers, and performs a further computational analysis as described. Condensation preclusion and/or removal action continues until such time that the ratio of the computed ambient space steam partial pressure to the saturated steam at the surface temperature is within the bounds or constraints of the set-point data base.
In a second alternative, the CPU computes or determines, through direct calculation (using the Clausius-Clapeyron Equation or any of its derivatives), by accessing an internal look-up table or by sequentially accessing a look-up table and interpolating or extrapolating and calculation, the theoretical saturated steam pressure in the ambient space at the ambient space temperature provided to the CPU. Thereafter, the CPU multiplies this ambient space saturated steam pressure value by the ambient space relative humidity level supplied to it, so as to determine the actual partial pressure of steam in the ambient space. Thereafter, the CPU computes or determines, through direct calculation (using the Clausius-Clapeyron Equation or any of its derivatives), by accessing an internal look-up table or by sequentially accessing a look-up table and interpolating or extrapolating and calculation, the dew-point temperature of the ambient space steam partial pressure. This value is subtracted from the temperature of the surface, to result in a “pseudo dew point difference” value. Finally, if the CPU-computed value is within the bounds or constraints of the database, no action is taken to preclude condensation conditions or remove condensation on the surface. The device then nulls input data values, returns and re-polls the sample and hold buffers, and performs a further computational analysis as previously described. In the event that the value is outside the bounds or constraints of the database, action is taken to preclude condensation conditions and/or remove condensation on the surface. For example, if the value is greater than about seven, condensation is not likely, and no action is required. If the value is zero or less, then condensation either exists on the surface being monitored or is imminent, and defogging action is initiated. If the value is between zero and about seven, condensation is likely, and preclusive defogging action is initiated. While this action continues, the device nulls input data values, returns and re-polls the sample-and-hold buffers, and performs a further computational analysis as described. Condensation preclusion and/or removal action continues until such time that the difference between the ambient space dew-point temperature and surface temperature is within the bounds or constraints of the set-point database.
There have been described devices and methods for sensing condensation conditions, and for preventing and removing such condensation from surfaces. It will be apparent to those skilled in the art that numerous additions, subtractions, and modifications of the described devices and methods are possible without departing from the spirit and scope of the appended claims. For example, instead of the condensation preclusion and/or removal mechanisms being activated directly by the circuitry disclosed herein, the circuitry could provide a warning to a user of a vehicle that includes the windscreen, the goggles, the helmet that includes the visor, the computer monitor that includes the screen, the room or enclosure that includes the window, the electronic equipment that includes the enclosure, etc., thereby causing the condensation preclusion and/or removal mechanism to be activated by the user.
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A device and method is provided for sensing or predicting when condensation having a given physical state is present or imminent and for suppressing such condensation from a surface, such as a vehicle windscreen, eyewear, goggles, helmet visor, computer monitor screen, window, electronic equipment, etc, by preventing or removing it. A first thermal sensor is in thermally conductive contact with the surface. A second thermal sensor is in an environment separated from the surface. A humidity sensor is in the environment of the second thermal sensor. A circuit causes a condensation suppression mechanism to be activated for preventing or removing condensation having the given physical state from the surface when a temperature sensed by the first thermal sensor, a temperature sensed by the second thermal sensor, and a humidity sensed by the humidity sensor indicate that a condensation condition is either present or imminent and requires prevention or removal at the surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a National Phase Filing Under 35 U.S.C. 371, of International Application No. PCT/US04/27893, filed Aug. 27, 2004, which claims priority to U.S. Provisional Patent Application Ser. No. 60/498,742, filed Aug. 28, 2003, both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Technical Field
Generally, the present invention relates to inverse treatment planning. More specifically, the present invention relates to an artificial intelligence method for guiding inverse treatment planning.
2. Description of the Related Art
Modern day radiation therapy of tumors has two goals: eradication of the tumor and avoidance of damage to healthy tissue and organs present near the tumor. It is known that a vast majority of tumors can be eradicated completely if a sufficient radiation dose is delivered to the tumor; however, complications may result from use of the necessary effective radiation dose. Most complications are due to damage to healthy tissue that surrounds the tumor or to other healthy body organs located close to the tumor. The goal of conformal radiation therapy is to confine the delivered radiation dose to only the tumor volume defined by the outer surfaces of the tumor, while minimizing the dose of radiation applied to surrounding healthy tissue or adjacent healthy organs.
Conformal radiation therapy has been traditionally approached through a range of techniques and typically uses a linear accelerator (“LINAC”) as the source of the radiation beam used to treat the tumor. The linear accelerator typically has a radiation beam source that is rotated about the patient and directs the radiation beam toward the tumor to be treated. The beam intensity of the radiation beam has a predetermined, constant beam intensity. Multileaf collimators, which have multiple leaf or finger projections that can be moved individually into and out of the path of the radiation beam, can be programmed to follow the spatial contour of the tumor as seen by the radiation beam as it passes through the tumor, or the “beam's eye view” of the tumor during the rotation of the radiation beam source, which is mounted on a rotatable gantry of the linear accelerator. The multiple leaves of the multileaf collimator form an outline of the tumor shape, as presented by the tumor volume in the direction of the path of travel of the radiation beam, and thus block the transmission of radiation to tissue disposed outside the tumor's spatial outline as presented to the radiation beam, dependent upon the beam's particular radial orientation with respect to the tumor volume.
Another approach to conformal radiation therapy involves the use of independently controlled collimator jaws that can scan a slit field across a stationary patient at the same time that a separate set of collimator jaws follows the target volume as the gantry of the linear accelerator rotates. An additional approach has been the use of attachments for LINACs that allow a slit to be scanned across the patient, the intensity of the radiation beam in the entire slit being modified as the slit is being scanned.
A further approach for conformal radiation therapy treatment has been the use of a narrow pencil beam of high energy photons, with energy that can be varied, and the beam is scanned over the tumor target volume so as to deliver the best possible radiation dose distribution in each orientation of the gantry upon which the photon beam source is mounted.
A major problem associated with such prior art methods of conformal radiation therapy are that if the tumor volume has concave borders, or surfaces, varying the spatial configuration, or contour, of the radiation beam, the therapy is only successful part of the time. In particular, when the convolutions, or outer surfaces, of a tumor are re-entrant, or concave, in a plane parallel to the path of the radiation treatment beam, healthy tissue or organs may be disposed within the concavities formed by the outer tumor concave surfaces, as well as the fact that the thickness of the tumor varies along the path of the radiation beam.
In order to be able to treat tumors having concave borders, it is necessary to vary the intensity of the radiation beam across the surface of the tumor, as well as vary the outer configuration of the beam to conform to the shape of the tumor presented to the radiation beam. The beam intensity of each radiation beam segment should be able to be modulated to have a beam intensity related to the thickness of the portion of the tumor through which the radiation beam passes. For example, where the radiation beam is to pass through a thick section of a tumor, the beam intensity should be higher than when the radiation beam passes through a thin section of the tumor.
Dedicated scanning beam therapy machines have been developed wherein beam intensity modulation can be accomplished through the use of a scanning pencil beam of high-energy photons. The beam intensity of this device is modulated by increasing the power of its electron gun generating the beam. The power increase is directed under computer control as the gun is steered around the tumor by moving the gantry upon which it is mounted and the table upon which the patient lies. The effect is one of progressively “painting” the target with the thickness, or intensity, of the paint, or radiation beam intensity, being varied by the amount of paint on the brush, or how much power is applied to the electron gun, as the electron gun moves over the tumor. Such dedicated scanning beam therapy machines, which utilize direct beam energy modulation, are expensive and quite time consuming in their use and operation, and are believed to have associated with them a significant patient liability due to concerns over the computer control of the treatment beam itself.
Other methods and apparatus for conformal radiation therapy have been developed that spatially modulate the beam intensity of a radiation beam across a volume of tissue in accordance with the thickness of the tumor in the volume of tissue by utilizing a plurality of radiation beam segments. Such methods and apparatus utilize attenuating leaves, or shutters, in a rack positioned within the radiation beam before the beam enters the patient. The tumor is exposed to radiation in slices, each slice being selectively segmented by the shutters. However, a minor disadvantage of that method and apparatus results from the fact that only two slices of tissue volume may be treated with one rotation of the gantry of the linear accelerator. Although the slices may be of arbitrary thickness, greater resolution is accomplished by selecting slices for treatment that are as thin as possible. As the thickness of the treatment slices decreases, the time it takes to treat the patient increases because more treatment slices are required in order to treat the entire tumor volume.
The foregoing methods and apparatus are designed to minimize the portion of the structures being exposed to radiation. However, because exposure to surrounding structures cannot be completely prevented, treatment plans are desired that are optimized to eradicate the tumor volume while minimizing the amounts of radiation delivered to the surrounding structures. Existing methods and apparatus for optimizing treatment plans use a computer to rate possible plans based on score functions, which simulate a physician's assessment of a treatment plan. However, existing methods and apparatus have proven to be insufficient.
Existing methods and apparatus utilize a computational method of establishing optimized treatment plans based on an objective cost function that attributes costs of radiation of various portions of both the tumor and surrounding tissues, or structures. One such computational method is known in the art as simulated annealing. Existing simulated annealing methods utilize cost functions that consider the costs of under-exposure of tumor volumes relative to over-exposure of surrounding structures. However, the cost functions used in existing methods do not account for the structure volumes as a whole, relying merely on costs related to discrete points within the structure, and further do not account for the relative importance of varying surrounding structure types. For example, certain structure types are redundant in their function and substantial portions of the structure volume can be completely eradicated while retaining their function. Other structure types lose their function if any of the structure is completely eradicated. Therefore, the more sensitive structure volumes can receive a measured dose of radiation so long as no portion of the structure is subjected to a lethal dose.
Existing cost functions utilized in the optimization of treatment plans do not account for such varying costs associated with the different types of structures. After the treatment plan is optimized, the physician currently must evaluate each computed treatment plan for compliance with the desired treatment objective. If the computed treatment plan does not successfully meet the treatment objectives, the optimization process is repeated until a treatment plan can be computed that meets the physician's treatment objectives for both the tumor volume and the surrounding structures. Further, existing methods and apparatus do not allow the physician to utilize the familiar Cumulative Dose Volume Histogram (“CDVH”) curves in establishing the desired dose distributions.
Recent studies indicated that conformal dose distribution could be effectively achieved with the treatment technique called intensity-modulated radiation therapy (IMRT). Several promising delivery devices have also become available, such as static or dynamic MLC and tomotherapy to deliver conformal radiation dose. The basic concept of IMRT is that a dedicated delivery device with an intensity-variable modulates a uniform intensity in a traditional treatment field. However, it is still a very challenging issue in terms of how to generate an effective and optimal intensity spectrum and how to verify modulated radiation delivery. The first issue is also related to the problem of inverse treatment planning (or treatment planning optimization).
An inverse planning method describes a specific treatment planning procedure in which, differing from traditional approach, both dose and volume are given first. Then a set of modulated beams is generated through a computer-aided optimization process in order to satisfy the prescription. The process is extremely important if the shapes of the target and critical organs are complicated, especially when the target has concavity and a critical organ lies in the hollow of the concavity. Typically, inverse treatment planning for intensity modulated radiation therapy involves the selection of an objective function and method of optimization. For a given objective function, an optimal treatment plan usually requires the optimization of beam intensity elements, a prescription method, and beam number and orientation.
One of the most challenging problems in the optimization of treatment planning is how to construct a model by which the aim of radiation therapy can be fulfilled. The models that have been studied in the past can be classified as either physical or biological. There have been detailed discussions in recent literature concerning the merits and limitations of these two types of models. While biological models may be able to directly measure the clinical outcome, they still remain in the formative stages and suffer from controversy concerning the validity of the radiobiological response data used (such as, tumor control probability (TCP) and normal tissue complication probability (NTCP)). On the other hand, the physical dosimetric prescription has been well established as the clinical norm. In the traditional physical models, one optimizes an objective function that is the measure of closeness of the calculated dose distribution to the prescribed dose distribution. The crucial problem here is how to give the optimal dose value for the normal tissue so that the two objectives, delivering the desired dose to the target volume and minimizing the dose to normal tissues, can be achieved accordingly.
A quadratic model has typically being used in inverse treatment planning. The model is widely discussed and has two major limitations, no direct biological information and no minimal constraints to normal tissues. Linguistically, the purpose of radiotherapy may be stated as (a) delivering a desired tumor dose and zero dose outside the target volume; (b) delivering a high dose to the target volume and a low dose to the normal tissue. The statement (a) and (b) may be served as absolute linguistic prescription (ALP) and relative linguistic prescription (RLP), respectively. Although the ALP is ideal, it is clearly impossible to deliver due to the laws of nature. On the other hand, RLP clinically describes the strategy of radiation therapy. The words ‘high’ and ‘low’ used here are vague terms that are associated with the limitation of making precise definition. The complexity of treatment planning optimization is evident from the need to formulate some kinds of clinical goals to be optimized since there is no unique treatment plan which is clinically feasible and fulfills the two conflicting objectives: maximizing dose in the target volume while minimizing dose in normal tissues.
Recently, several researchers have paid attention to the analysis of uncertainties in radiation treatment planning optimization. The tolerance of normal tissues has been discussed. Spirou et al., developed an inverse planning algorithm with soft constraints. The method allows acceptable doses of maximum and minimum as well as dose-volume constraints to the tissues of interest.
The search for the optimal beams usually can be interpreted to be an optimization problem. Thus, the searching problem is converted to find the extremum of a given objective function. Several methods and algorithms have been investigated for inverse planning. Some examples are simulated annealing iterative approaches, as well as filtered back-projection and Fourier transformation. Although these methods are very promising, there are some aspects that can be further improved upon. The simulated annealing method may require long computation time due to the nature of random search. Most iterative approaches are parameter-dependent. The convergence and the quality of convergence may be affected by these parameters that are often determined by try-and-error. The filtered back-projection and direct Fourier transformation may have limitations on dose prescription and kernel selection. Inverse treatment planning is still at its early stage and many important aspects require be to further improved.
Additionally, Starkschall proposed an approach that removed the necessity of defining a “best” treatment plan, and incorporated the dose-volume constraints into a system to search for a feasible plan that could satisfy the constraints. If no calculated doses satisfy the treatment goal, the planner provides a guide about how the dose-volume constraints may be modified to achieve a feasible result. This approach is only applied to the conventional three-dimensional (3D) treatment planning. Wu and Mohan developed an optimization system, which employed both dose- and dose-volume-based objective functions. In the system, the optimal plan is selected by calculating the cost of the objective function, or “plan score” (the lower the score, the better the plan). Xing et al. presented a method that employed a second stage evaluation function to compute the differences between the calculated and the ideal dose volume histograms. Based on the results of the evaluation function, the weighting factors in the objective function are adjusted. The procedure minimizes both the objective and evaluation functions in a round-robin manner. Later, further improvement is achieved by using a statistical measure called preference function, which is constructed based on the empirical judgment. The problem of the selection of weighting factor still exists because it translated to the problem of how to specify the parameters in the evaluation or preference function. A similar method was also proposed by Wu et al. using a genetic algorithm to optimize the weighting factors and beam weights in the conventional 3D treatment planning. Li and Yin introduced fuzzy logic into the inverse planning system to adjust the weighting factors for normal tissue. The result was promising. However, optimizing the parameters for the target and critical organ were not included in the system. Also, the weighting factors initialized by the fuzzy functions still need to be modified by the trial-and-error approach.
It would therefore be useful to develop a method or apparatus for conformal radiation therapy, for use with a radiation beam having a predetermined, constant beam intensity for treatment of a tumor, which is simple and economical to use, has a high safety factor for patient safety, computes an optimal treatment plan to meet conflicting, pre-determined, treatment objectives of a physician, accounting for objectives in both the target tumor volume and multiple structure types, and provides the desired dose distributions for each target tumor volume and tissue and structure types.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a fuzzy inference system for use in modulating radiation treatment including a fuzzifier for inputting imaging data, an inference device operatively connected to the fuzzifier, the inference device being used for analyzing the imaging data and determining radiation treatment target from non-treatment target, and a defuzzifier for modulating radiation treatment pursuant to the analysis from inference device. Also provided is a method of modulating radiation treatment by inputting patient data into the fuzzy inference system disclosed above and modulating radiation treatment pursuant to data obtained from the fuzzy inference system. An apparatus for producing modulating radiation therapy in patients including an imaging device for creating and storing image data of relevant tissue and organ parts and a fuzzy inference system operatively connected to the imaging device for modulating radiation treatment is provided. A fuzzy inference system for use in modulating radiation treatment including a fuzzifier for inputting imaging data, an inference device operatively connected to the fuzzifier, the inference device being used for analyzing the imaging data and determining strength of radiation treatment, and a defuzzifier for modulating radiation treatment pursuant to the analysis from the inference device is also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention are readily appreciated as the same becomes better understood by reference to the following detailed description, when considered in connection with the accompanying drawings wherein:
FIG. 1 shows the schematic illustration of the fuzzy inference system (FIS) used for modification of the weighting factors;
FIGS. 2A-D are illustrations of membership functions used in FIS; FIG. 2A shows the membership functions “High” and “Low” defined for input variable C TV ; FIG. 2B shows the membership functions “High” and “Low” defined for input variable C CO ; FIG. 2C shows the membership functions “High” and “Low” defined for input variable C NT ; FIG. 2D shows the membership functions “Decrease”, “No change”, and “Increase” defined for the output variable ΔW TV ;
FIG. 3 shows the demonstration of the inference procedure including the following steps: Step 1: Inputs fuzzification; and Step 2: Degree of support; Step 3: Fuzzy inference (implication operation); Step 4: Aggregation operation; and Step 5: Output defuzzification;
FIG. 4 shows the flow chart of the fuzzy logic guided inverse treatment planning system;
FIGS. 5A and B show the central slices for ( FIG. 5A ) a simulated case and ( FIG. 5B ) a clinical case, wherein TV, CO and NT represent the target volume, the critical organ and the normal tissue, respectively and arrows pointed to the target volume indicate the beam directions;
FIGS. 6A and B show the variations of ( FIG. 6A ) characteristic doses and ( FIG. 6B ) weighting factors versus the iteration number in the simulated case for the dose prescription [100%, 30%, 50%], the initial weighting factors [1,1,1] were normalized to [0.58,0.58,0.58] using formula (4);
FIGS. 7A-C show the dose-volume histograms of the calculated doses in the simulated case for ( FIG. 7A ) the target volume, ( FIG. 7B ) the critical organ, and ( FIG. 7C ) the normal tissue for four sets of dose prescriptions;
FIGS. 8A-D show the dose distributions in the central slice of simulated case for four sets of dose prescriptions ( FIG. 8A ) [100%, 20%, 50%], ( FIG. 8B ) [100%, 30%, 50%], ( FIG. 8C ) [100%, 40%, 50%], ( FIG. 8D ) [100%, 50%, 50%];
FIGS. 9A and B show the variations of ( FIG. 9A ) characteristic doses and ( FIG. 9B ) weighting factors versus iteration number in the clinical case for the dose prescription [100%, 30%, 50%] and the initial weighting factors [1,1,1] were normalized to [0.58, 0.58, 0.58] using formula (4);
FIGS. 10A-E show the dose-volume histograms of calculated dose distributions for five involved organs: ( FIG. 10A ) the target volume, ( FIG. 10B ) the normal tissue, ( FIG. 10C ) the critical organ 1 , ( FIG. 10D ) the critical organ 2 , and ( FIG. 10E ) the critical organ 3 at iteration 5 , 10 , and 15 , respectively; and
FIGS. 11A-C show the dose distributions in the clinical case at ( FIG. 11A ) Iteration 5 , ( FIG. 11B ) Iteration 10 , and ( FIG. 11C ) Iteration 15 .
DESCRIPTION OF THE INVENTION
The present invention provides a method of using fuzzy logic to optimize treatments of patients. More specifically, the present invention uses a fuzzy inference system (FIS) that uses three modules: a Fuzzifier, an Inference engine that includes fuzzy rules, and a Defuzzifier. During the process of fuzzification, a single input value is compared to the membership functions as defined for that input variable. If the membership functions have a nonzero output, it will take effect in the final results of the FIS. The Fuzzifier calculates the response of rules for the input values and the inference engine modifies the consequent rules in response to input values. The Defuzzifier generates a final output based on the result of the inference engine.
The artificial intelligence (AI) method, fuzzy logic, is applied to optimize parameters in the inverse treatment planning for intensity-modulated radiation therapy (IMRT). With the capability of fuzzy inference, the parameter modification of the objective function is guided by physician's treatment intention and experience. For the different parameters involving inverse planning, the corresponding fuzzy inference systems (FISs) are developed in order to accomplish the treatment requirement. With the function of fuzzy inference, the efficiency and quality of inverse planning can be substantially improved.
The system operates in a specifically preferred manner on the basis of the so-called fuzzy-set theory approach: thus, the rules are subject to some uncertainty. The fuzzy-set theory is concerned with “fuzzy sets” whose elements belong to individual sets in different ways. While in the classical theory of sets a specific element does or does not belong to a set, the fuzzy-set theory pertains to elements that only belong to a set to a certain degree. The degree of belonging is indicated by a function for the individual elements of a set. With the approach, it is possible to make decisions based on incomplete knowledge and in the absence of exactly measured input values. Fuzzy systems are capable of operating in a stable manner even in the case of contradictory individual rules.
A fuzzy approach is developed to optimize the prescription of normal tissue. The presented method is based on the theory of fuzzy sets, and attempts to sufficiently use uncertain information under the tolerance. The method contains two types of optimizations: intensity-modulated beam optimization and normal tissue prescription optimization. The former employs the fast-monotonic descent (FMD) technique. In this technique, a new iteration method is being developed in which the update scheme is analytically determined to avoid defected convergence.
The present invention is beneficial because the heuristic and practical experience (from physician, physicist, planner) can be used to optimize the parameters of inverse planning in order to improve the dose distribution. Additionally, the conformity of target dose distribution can be improved and high target dose improves the quality of inverse planning. The time spent on trial-and-error testing can be significantly reduced and the planner can be free from this time-consuming task, thereby improving the efficiency of inverse planning.
Execution of an IMRT conformal plan using a dedicated delivery system requires accurate patient positioning. If patient is not correctly positioned, conformal radiation beams may be delivered to normal tissues rather than the planned target. Therefore, patient mis-positioning can limit the applicability of dose escalation that is the key for IMRT.
A conventional radiation field is documented by use of a portal film in a two-dimensional version. Information included in this image may not be sufficient for IMRT procedure, because the leaf position is not stationary during treatment for each field. Most quality assurance procedures for IMRT are performed in phantom. It is therefore important to find a way to verify both anatomically and dosimetrically for IMRT treatment. It has been noted that monitoring actual dose delivered in IMRT using megavoltage computed tomography (MVCT) and portal imaging taken together with transit dosimetric method grows in great importance. At present, a rapid and cost-effective method of verifying conformal IMRT radiotherapy based on limited number of fields is currently unavailable in clinical practice.
A combined method was developed to perform three-dimensional verification of patient setup and to document dose distribution treated using limited number of static IMRT fields. In this method, a megavoltage CT reconstruction technique was developed based on Multilevel Scheme Algebraic Reconstruction Technique (MLS-ART) using a megavoltage x-ray imaging device. By combining the transmitted treatment beams with the regular CT imaging projection beams, both patient geometry at treatment position and actual dose distribution can be reconstructed. The geometry and dose can be compared to the patient, setup position and prescribed dose, which are used to correct subsequent beam placement or dose delivery accordingly.
Portal CT and portal dose reconstruction is a novel verification technique in radiation therapy (especially in IMRT) with several advantages. It is online and allows direct verification of IMRT for both patient position and dose delivery. Moreover, mega-voltage CT-based technology can replace conventional patient simulation that uses kilo-voltage simulator or diagnostic x-ray CT and mega-voltage CT-based images can be used for treatment planning.
The optimization of intensity-modulated beams (IMBs) consists of two main tasks: modeling (selection of objective function) and optimization (method of minimizing objective function). In this context, modeling means that the construction of a model in which knowledge (physical, biological, and clinical) about the irradiated structure's response to radiation is expressed by an objective function. The task of optimization is to develop a method by which one can obtain the optimal solution of minimizing the objective function.
For multilateral optimization of radiation treatment planning, improving computation efficiency is an important topic. In the method of the present invention, an optimal step-length, the key parameter in the update scheme for iteration, and an optimal solution to the problem of negative intensity are analytically derived. Therefore, the convergence to global minimum is not only guaranteed, but also fast and monotonic descent. The method is called the fast-monotonic descent (FMD) method, which can provide an optimal solution to the intensity-modulated beams either when the intensity value is greater than zero or when a negative solution is encountered.
More specifically, the method functions as follows. Let x=(x 1 , x 2 , . . . , x N ) be an intensity vector; x n is the nth component of intensity vector x. For each dose point (i,j,k), let P ijk represent the prescribed dose, and D ijk denote the calculated dose
D
ijk
=
∑
n
=
1
N
A
n
,
ijk
x
n
,
(
1
)
where A n,ijk is a non-negative constant coefficient that can be directly calculated. The weight w ijk ≧0 is used to indicate the importance of matching prescription and calculation. A quadratic objective function is therefore defined by
f ( x ) = ∑ i ∑ j ∑ k w ijk ( P ijk - D ijk ) 2 . ( 2 )
In the case of an optimization problem having an objective function of Equation (2), the minimum cost problem is that of finding an admissible intensity vector such that objective function is minimized. This constrained optimization problem can be written as
minimize ( x ) { f ( x ) } ( 3 a ) subject to x n ≥ 0 ∀ n . ( 3 b )
Now consider an unsynchronous updating scheme used in iteration method. For an arbitrary evolution time l, when l→l+1,
x n ( l + 1 ) = { x n ( l ) + Δ x n if n = m x n ( l ) otherwise ( 4 )
and
f ( x ( l ))→ f ( x ( l+ 1)),
where m is one of (1, 2, . . . , n, . . . , N). The updating scheme (4) says that, for each evolution time l, only one variable is adjusted. If each of variables is adjusted one time, then it is called one cycle.
Based on the theory of classical minimum, the necessary and sufficient condition of descent for/is that the iterative rule satisfies: for each n
Δ x n = - λ n ∂ f ( x ( l ) ) ∂ x n , ( 5 )
where λ n , is a small positive number and called step-length. Note that the iteration sequence generated by Equations (4) and (5) is not guaranteed to converge to the minimum of f. This convergence is always dependent upon the choice of λ n . Adequate selection of this parameter is critical for the success of iteration method. Generally, the choice of λ n is a craft that is problem-specific. For a quadratic function, the parameter can be analytically derived and f will converge rapidly and monotonically to the minimum with the following condition:
∂ f ( x ( l + 1 ) ) ∂ x n = 0 ∀ n . ( 6 )
Parameter λ n can then be derived from the condition listed above.
λ m = 1 2 ∑ i ∑ j ∑ k w ijk A m , ijk 2 . ( 11 )
W/th these two conditions (Eqns (5) and (6)), f descends rapidly to the global minimum if for each m (l≦m≦N)
x m ( l + 1 ) = { x m ( l ) + ∑ n = 1 N B mn x n ( l ) + C m if x m ( l + 1 ) > 0 , 0 otherwise ; ( 7 )
where / denotes the l-th iteration,
B
mn
=
-
∑
i
∑
j
∑
k
w
ijk
A
m
,
ijk
A
n
,
ijk
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i
∑
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w
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m
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ijk
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,
and
C
m
=
∑
i
∑
j
∑
k
w
ijk
A
m
,
ijk
P
ijk
∑
i
∑
j
∑
k
w
ijk
A
m
,
ijk
2
.
The FMD algorithm can be summarized as follows:
1) Fix the maximum number of iterations L, weights {w ijk }, and termination criterion ε>0. 2) Initialize x(0)=(x 1 (0), x 2 (0), . . . , x N (0)), and x≧0 for each n. 3) For l=1, 2, . . . , L;
a. Update intensity vector using Equation (4). b. Compute
E
l
=
max
{
n
}
x
n
(
l
+
1
)
-
x
n
(
l
)
.
c. IF E l ≦ε stop; ELSE next l.
4) Compute dose distribution using Equation (1).
f is a constrained quadratic objective function. A set of values x 1 , x 2 , . . . , xN that satisfies the non-negative constraints expressed by Equation (3b) is called an admissible vector, and the admissible vector that minimizes the objective function is called the optimal admissible vector. An optimal admissible vector can fail to exist for two reasons. There are no admissible vectors (i.e., the given constrains are incompatible) or there is no minimum (i.e., there exists a direction in N space where one or more of the variables can be taken to negative infinity while still satisfying the constraints). Fortunately, neither of them is satisfied in the problem of intensity-modulated beam optimization. First, it is clear that, the sets in Equation (3b) are convex, and the intersection consists of many points. Therefore, the non-negative constraints in Equation (3b) are compatible. The second reason is also false, since the intensity variables are non-negative.
There is one important parameter {W ijk } in Equation (2) that has not been addressed above. Typically, the prescribed dose for the target volume and the upper limit for the sensitive organ is known. The prescription for the normal tissue is usually not given. Therefore, the optimization result varies with the prescription selected for the normal tissue. An intuitive strategy for finding the optimal normal tissue prescription would be to compare values of objective function calculated by using different prescribed doses and then to choose the minimum. In this way, w n , the weight for the normal tissue, is a function of p n , the prescribed dose for the normal tissue. Here, the subscript n represents a point (i, j, k) inside the normal tissue. The difficulty of using this strategy is how to formulate the relationship between weight w n and prescribed dose p n . Generally, all that is known is a plausible relationship between them: w n is the least when p n approaches to zero and w n is the greatest when p n approaches to the upper limit. A dynamic weight function is used to express this fuzzy relationship. An optimal prescription dose for normal tissue is then determined by a validity function.
A quadratic objective function, as shown in Equation 2, with fuzzy weight as
P ijk = { p t , if i , j , k ∈ Ω t p s , if i , j , k ∈ Ω s p n ; if i , j , k ∈ Ω n
and
w ijk = { w t , if i , j , k ∈ Ω t w s , if i , j , k ∈ Ω s w n . if i , j , k ∈ Ω n
p t , p s and p n denote the prescribed doses for the target volume, the sensitive organ and the normal tissue, respectively Ω t , Ω s and Ω n represent regions of these three corresponding structures. W ijk ε[0,1] is called fuzzy weight function that is used to emphasize the importance of matching the prescribed dose and the calculated dose for the point (i, j, k). Instead of fixing {P ijk } and {w ijk } in the hard inverse planning (HIP), p n is defined as a variable and w n is represented by a function of p n in fuzzy inverse planning (FIP). Also, it is assumed that
p t = P t , p s = P s , w t = w s = 1
and w n = { 1 , if p n > P n g ( p n ) , otherwise ( 9 )
where P t represents the prescribed dose in the target volume, P s is the tolerance dose in the sensitive organ, and P n , is the tolerance dose in the normal tissue. g(p n ) is a continuous function that increases with p n . g(p n )=1 when p n is equal to the tolerance dose P n . Here g(p n ) is called fuzzy weight function.
Regarding the function g(•), one has only some vague knowledge that can be stated by the following two fuzzy rules: 1) the closer p n is to P n , the closer w n is to one (w n =1 means the most important); 2) the closer p n is to zero, the closer w n is to zero (w n =0 means the least important). Fuzzy technology is used to express the vague knowledge and to achieve an optimal solution. The form of fuzzy weight function can be obtained from a planner's experience. As will be seen below, however, it is effective to use the following function:
g ( p n ) = ( p n P n ) K ,
0 ≤ p n ≤ P n ( 10 )
where K is a positive constant that controls the pattern of g(•). These functions are shown in FIG. 1 . Obviously, any function with a K value of equal to or greater than 1 can be selected to express the mathematical meaning of the following linguistic prescription. For the normal tissue, the closer the prescribed dose p n is to the tolerance dose, the greater the importance of the dose (i.e., the difference between the tolerance dose and the prescribed dose).
Fuzzy inverse planning allows many feasible solutions to occur for a specific clinic problem. Selection of a specific treatment plan is determined by evaluating planning validity. Note that Equation (8) cannot be served as a validity function since the objective of radiation therapy optimization for non-target volume cannot be expressed by a quadratic function. To measure the validity of radiation treatment, a validity function is introduced, v({P ijk };x), which is written as
v ( { P ijk } ; x ) = ∑ i , j , k ∈ Ω t P ijk - D ijk + ∑ i , j , k ∉ Ω t D ijk . ( 11 )
where, the first term represents the degree of dose uniformity for the target volume, and the second term represents the grade of protection of the non-target volume. For prescription validity, the ideal dose distribution can be achieved by minimizing v({P ijk };x) under the tolerance of normal tissues:
minimize{ v ({ P ijk };x )}. (12)
With the introduction of this validity function, the fuzzy inverse planning (FIP) algorithm can be summarized as follows. Fix the maximum number of trial dose prescriptions T for normal tissue, the maximum number of iterations L, and the termination criterion s>0. Choose fuzzy weight function g(•). Initialize x(0)=x 1 (0), x 2 (0), . . . , x N (0)), and x n ≧0 for each n. Then, for t=1, 2, . . . , T, given p n (usually p n increases with t on the interval (0, P n ), calculate w n using Equation (9), for l=1, 2, . . . , L and update intensity vector using Equation (7), compute
E l = max { n } x n ( l + 1 ) - x n ( l ) .
if E/≦ε, calculate v using Equation (11), otherwise next l. IF v t+1 >v t stop, otherwise next t. The dose distribution can then be computed using Equation (1).
Preferably, a computer is utilized to automatically calculate this in response to the input of data, however, a human can also calculate the same using the formula.
The invention is further described in detail by reference to the following experimental examples. These examples are provided for the purpose of illustration only, and are not intended to be limiting unless otherwise specified. Thus, the invention should in no way be construed as being limited to the following examples, but rather, should be construed to encompass any and all variations which become evident as a result of the teaching provided herein. The FIP is evaluated by two artificial examples. Dose-volume histograms (DVH) of the target volume (TV) and the sensitive organs (SO) are used as a primary tool for presenting and comparing dose distributions.
EXAMPLES
Example 1
This is a simulated cylindroid object and its central slice is illustrated in FIG. 2 . The geometry of this slice is similar to a CT head axial cut with two sensitive organs (analog to eyes) that are very close to the target volume. The prescription was given as follows: 100 dose units to the target volume, 20 dose units to the sensitive organs, and upper limit of 60 dose units to the normal tissue. Seven fan beams as shown in FIG. 2 were uniformly arranged between 0-2 π. Based on the primary-only model, the dose at depth is estimated by means of the percent depth dose data that were measured from a field size of 4×4 cm with 6 MV photon beams. However, beam divergence was included.
In order to show the convergence and fastness of FMD method, the FMD algorithm was run using three different values of the step-length: λ n =0.01, λ n =λ opt and λ n =0.001 (n=1, 2, . . . , N). Here λ opt is the optimal step-length. FIG. 3 shows the differences of convergence behavior between λ n =λ opt and λ n =0.001, and between λ n =λ opt and λ n =0.01 (n=1, 2, . . . , N). The result indicates that the effectiveness of iteration methods is dependent upon the choice of step-length. The optimal step-length λ opt derived here, however, provides an optimal performance in both the speed of convergence and the quality of convergence. FIG. 4 shows that FMD can provide a satisfactory result after 10 cycles.
Effect of Normal Tissue Dose
In the study, a validity function is introduced to judge the optimal normal tissue prescription. Variation of validity function v versus prescribed normal tissue dose is plotted in FIG. 5 . The data in FIG. 5 indicated that p n =25 dose units appear to be the optimal prescription for normal tissue. Table 1 shows the fuzzy inverse planning (FIP) performance as a function of the normal tissue prescription dose with K=5 and L=100. Here p n =0 means no normal tissue is considered in the FMD optimization algorithm, i.e., w n =0 and w s =w t =1. Although statistic indices for the target volume in the case of p n =0 are better than others, the average dose of 52.6 dose units and the standard deviation of 33.8 dose units for the normal tissue far exceed the upper limit of 60 dose units. The data listed in Table 1 show that the optimal balance between objectives of high target dose and low normal tissue dose is achieved when p n =25 dose units. FIG. 6 shows corresponding dose-volume histograms for the target volume ( FIG. 6( a )), the sensitive organs ( FIG. 6( b )) and the normal tissue ( FIG. 6( c )). The improvement of performance is evident with the optimization of normal tissue dose prescription.
Comparison of FIP and HIP Methods
The case described above, with a normal tissue dose prescription of 25 units, can be considered an optimal result for the FIP algorithm: In this section the result obtained by the FIP method is compared to that obtained by the hard inverse planning (HIP) method. HIP means that only the FMD algorithm is applied. For the HIP method, two extreme prescriptions are selected: (a) no normal tissue is considered in the optimization algorithm, i.e., w n =0 and w s =w t =1; (b) the prescribed normal tissue dose is fixed, i.e., p n =P n =60 and w n =w s =w t =1.
Dose-volume histograms are calculated and illustrated in FIG. 7( a ) for the target volume obtained using FIP, HIP(a), and HIP(b), respectively. Corresponding dose-volume histograms for the sensitive organs and the normal tissue are illustrated in FIG. 7( b ) and FIG. 7( c ). Table 2 provides the relevant statistical parameters. It has been shown that the overall results obtained by optimizing prescription of normal tissue dose (FIP method) are better than those obtained by HIP(a) and HIP(b).
Effect of Parameter K
As discussed in Section III, validity function g(•) is considered to be adequate if K=1. The effect of the parameter K in Equation (10) on the performance of FIP method is evaluated by using values of K=1, 2, . . . , 5. Dose-volume histograms obtained using different K values for the target volume ( FIG. 8( a )), the sensitive organs ( FIG. 8( b )), and the normal tissue ( FIG. 8( c )) are calculated and compared. Results indicated that the uniformity of dose for the target volume is improved as K increases. At the same time, the control of dose for the sensitive organ is stronger as K increases. However, the control of dose for the normal tissue is weaker as K increases. Therefore, the result of K=5 is more desirable than those of others are. If K is greater than 5, the performance of normal tissue would be less desirable despite of dose improvement in other structures.
Example 2
The central slice of the phantom geometry in Example 2 is illustrated in FIG. 9 . Similar to Example 1, seven fan beams are arranged at 0, 2 π/7, 4 π/7, 6 π/7, 8 π/7, 10 π/7, and 12 π/7, respectively. The prescribed doses were set: 100 dose units for the target volume, 20 dose units for the sensitive organs and the upper limit dose of 60 dose units for the normal tissue. The other parameters were L=100 and K=5.
FIG. 10 shows dose-volume histograms obtained by using FIIP, HIP(a) and HIP(b) methods for the example 2. FIG. 10( a ) corresponds to the target volume, FIG. 10( b ) to the sensitive organs, and FIG. 10( c ) to the normal tissue. Table 3 indicates the relevant statistical parameters: means, standard deviations for the three structures in Example 2. The performance patterns of the FIP algorithm in Example 2 is consistent with the results obtained in Example 1. However, the optimal normal tissue value p n here is equal to 30. Note that in this example one can also obtain a desirable result without considering normal tissue, i.e., FIP has similar result as HIP(a).
Megavoltage CT Image Using Limited Number of Projections
The use of a fluorescent/CCD-based EPID, coupled with a novel Multilevel Scheme Algebraic Reconstruction Technique (MLS-ART), was analyzed for a feasibility study of portal CT reconstruction (Ying 1990, Wong 1990, Yin 1994, Zhu 1995). An EPID set it to work at the linear dynamic range and collimated 6 MV photons from a linear accelerator to a slit beam of 1 cm wide and 25 cm long was used. Scans were performed under a total of 200 MUs for several phantoms in which the number of projections and the MUs per projection were varied. The reconstructed images demonstrated that using the new MLS-ART technique, megavoltage portal CT with a total of 200 MIUs can achieve a contrast detectability of 2.5% for an object of size 5 mm×5 mm and a spatial resolution of 2.5 cm.
Using a Csl(T1) transparent scintillator x-ray detector together with the multi-level scheme algebraic reconstruction technique (MLS-ART) for megavoltage computed tomography (CT) reconstructions. The reconstructed CT images can be useful for positional verification in radiotherapy. The Csl(T1) imaging system consists of a scintillator screen coupled to a liquid-nitrogen-cooled slow-scan CCD-TV camera. The system provides better contrast resolution than the standard electronic portal imaging system (EPID), which is especially useful given the low number of projections used. The geometry of the imaging system has also been optimized to achieve high spatial resolution (1 lp/mm) in spite of the thickness of the screen. The reconstructed images were presented using a pediatric head phantom using a total of 99 projections, and a combined phantom using 50 projections. Image reconstruction was carried out using the MLS-ART technique. The CT images obtained using the back projection technique for comparison purposes were also presented.
In addition, the use of the kinestatic charge detector (KCD) combined with the multi-level scheme algebraic reconstruction technique (MLS-ART) for x-ray computer tomography (CT) reconstruction was also investigated. The KCD offers excellent detective quantum efficiency and contrast resolution. These characteristics are especially helpful for applications in which a limited number of projections are used. In addition, the MLS-ART algorithm offers better contrast resolution than does the conventional convolution backprojection (CBP) technique when the number of projections is limited. Here the images of a Rando head phantom that was reconstructed by using the KCD and MLS-ART were presented. Also presented, for comparison, the images reconstructed by using the CBP technique. The combination of MLS-ART and the KCD yielded satisfactory images after just one or two iterations.
The advantages of MLS-ART applied to conformal radiotherapy are following:
a. The MLS-ART outperforms the conventional CBP technique for low contrast detection given a limited number of projections and it is especially useful for megavoltage CT reconstruction since in radiotherapy one cannot rotate the linear accelerator gantry to acquire a large number of projections in a reasonably short of time. Contrast detectability is strongly dose-dependent, and for some situations in x-ray imaging, high contrast resolution is not as important as the ability to provide excellent image contrast (Yaffe and Rowlands 1997). Such is the case with megavoltage CT imaging for radiation treatment verification. The high-energy x-ray photons experience inherently low attenuation in tissues. In addition, attenuation of radiation by tissues in the energy range is mainly due to Compton scattering that depends on electron density but not the atomic number. The two factors combined resulted in poor differentiation between various tissues (Johns and Cunningham 1983). Further, the detective quantum efficiency (DQE) of current megavoltage imaging devices is at least one order lower than those of detector for diagnostic x-ray CT. Therefore, megavoltage portal CT requires an efficient reconstruction technique like the MLS-ART, especially the one that is optimal for situations of low-contrast detectability. Better contrast detectability also helps for more accurate dose reconstruction since spatial resolution imposed on dose is even more relaxed.
b. MLS-ART can be used for CT reconstruction using the radiation treatment beams in addition to the regular CT projection beams. Such a 2-step reconstruction produces much better reconstruction accuracy than simply using the treatment beams themselves because the latter is a case of incomplete data (although even for this case, MLS-ART itself works better than CBP.) In this way, the patient position can be directly and continuously monitored and even corrected during the treatment.
c. Doing conformal radiotherapy using intensity modulated beams and portal CT is complicated by the tumor irregularity. Depending on the target shapes and sparing of critical organs, select treatment beam orientations to be orthogonal or close to orthogonal are important. The orientations must yield small geometrical correlations (less dose overlap) and most complementary dose distribution information. One can select the beam orientations following the MLS ordering, or in combination with methods known to those of skill in the art, such as the methods used by Gokhale, Soderstrom, Bortfeld.
d. MLS-AIRT can be used for dose reconstruction. It is more accurate than the analytical method given a limited number of beams because for any analytical dose integration method, there is an implicit assumption that an infinite number of projections were used. But the integration method fails if the angles between beams are large unless special techniques like arc therapy for tomotherapy are used.
Reconstruction of IMRT Beams for Dose Distribution
Methods:
Inverse Treatment Planning Algorithm for IMRT:
Research Method:
First, it should been pointed out that the definition of fuzzy weight function as shown in Equation (10) is not a unique form. Different functions can be used to achieve different goals. The Gaussian function was tested instead of Equation (10) and it was found that the result obtained using Equation (10) is better than that obtained using a Gaussian function. Second, in the present study two loss functions are introduced. One is the objective function as shown in Equation (8) and the other is the validity function as shown in Equation (11). The former is used to optimize beam intensity. The latter is employed to evaluate the prescription of normal tissue. The objective function as shown in Equation (8) cannot replace the validity function as shown in Equation (11). For example, it is equal important in terms of loss value when the calculated dose in normal tissue is either 10 below or 10 above the prescribed dose. Therefore, Equation (8) does not completely express the objectives of radiotherapy, and a validity function as shown in Equation (11) is necessary. In addition, it is clear that Equation (11) is an unbiased measure function since the loss for the non-target volume is calculated from zero.
In the present study there is described a fuzzy inverse planning (FTP) method for solving the problem of uncertain prescription optimization in radiation therapy. The study is concerned only with the optimization of normal tissue prescription. The dose prescription in the sensitive organs is fixed. Typically, the upper limit dose for the sensitive organ is less than that for the normal tissue. It is difficult to control the calculated dose less than the upper limit for the sensitive organ (except for those cases in which the sensitive organs are far from the target volume). Typically, the mean dose in the sensitive organs is greater than the upper limit dose. The importance of matching the calculated dose and the prescribed dose for the target volume is equal to that for the sensitive organ, i.e., w t =w s =1. Clinically, it means that the importance of protecting the sensitive organ is the same as that of controlling the tumor. However, different weighting factors can be chosen by radiation oncologists for a specific clinical case to fulfill a special objective.
A fuzzy inverse treatment-planning algorithm has been developed. The method provides an alternative to soft optimization for treatment planning. The main advantages have two folds. (a) The developed FMD has the fastest convergence speed in the stage of optimizing the beam intensity and the algorithm is simple to use in which no parameter is problem-specific. And (b) the FIP technique can use uncertain information in inverse treatment planning to achieve the optimal balance between the objectives of matching the calculated dose and the prescribed dose for the target volume and minimizing the dose in normal tissue. The presented technique optimizes not only beam intensity distribution but also normal tissue prescription. The performance of the new algorithm has been compared to that of the hard, inverse planning methods for two treatment geometries. The calculation time is less than 2 minutes on PC machine (333 mHz, 64 MB RAM) for 10 slices with a matrix size of 256×256. At the present, it is difficult to compare between different approaches due to difference in test cases, dose calculation and other factors.
Inverse planning method involves two key components: objective function to define the goal for the optimization, and optimization method to find the optimal solution for a given objective function. The optimization algorithm developed here may be also applicable to resolve objective functions based on biological model.
f
(
x
)
=
∑
i
∑
j
∑
k
w
ijk
(
P
ijk
-
D
ijk
)
2
The physical meaning of W ijk , P ijk , and D ijk are as described above.
Optimization Method
Compared to some existing iteration techniques, there are several unique characteristics of FMD technique. (1) The key parameter, step-length, used in update scheme is analytically calculated so that no trial-and-error is involved. Choice of update scheme is critical for fast convergence and optimal results. Inappropriate selection of the step-length may lead to poor convergence or even non-convergence. (2) Fast and monotonically convergence guarantees the global minimum of the optimization algorithm. (3) The problem of negative beam intensities is effectively eliminated. (4) The algorithm is simple to understand and implement for clinical applications.
Fuzzy Representation of Vague Prescription
The concept for a logistic plan is to deliver full dose to the target region while keeping the dose below the maximum tolerance for normal tissues. The quadratic model in the above section is not sufficient to address the upper limits for normal tissue prescription. A fuzzy function was introduced to represent vague normal tissue prescription.
The theory of fuzzy set is a mathematical tool used to represent uncertain or partial knowledge. In inverse treatment planning, one only knows the upper limits for normal structures but is not certain what is the optimal prescription, especially the prescription for normal tissue and critical organs. Therefore, the category of problem can be represented by the theory of fuzzy set.
The objective function can be divided into three terms. The first term relates to the target volume that is expected to receive uniform prescription dose. The second term relates to the critical organs that are sensitive to radiation damage and a tolerance dose will be set. The third term relates to the normal tissues except critical organs in which dose is expected to be as low as possible. To achieve these goals, the weight factors in the objective function can be redefined as follows:
W ijk in target volume wt=tt, where tt is a constant and is used to indicate the importance of matching target dose. Typically, tt=1.
W ijk in critical organs w c =cc*h(p c ,P c ), where cc is a constant and is used to indicate the importance of matching prescription for each critical organ.
W ijk in critical organs w n =nn*g(p n ,P n ), where nn is a constant and is used to indicate the importance of matching prescription for normal tissues.
Here both g and h are two fuzzy functions. The fundamental of constructing a fuzzy function is to find proper weighting factors in the objective functions. Linguistically, the closer the prescribed dose is to the tolerance dose, the greater the importance of the dose (i.e., the difference between the tolerance dose and the prescribed dose). Mathematically, it can be described by a following function:
g ( p n ) = ( p n P n ) K , 0 ≤ p n ≤ P n ( 10 ) h ( p c ) = ( p c P c ) K , 0 ≤ p c ≤ P c ( 10 )
where K is a positive constant that controls the patterns of g(•) and h(•) These functions are shown in FIG. 1 . Obviously, any function with a K value of equal to or greater than 1 can be selected to express the mathematical meaning of the following linguistic prescription.
Penalty of Optimization Method
Fuzzy inverse planning allows many feasible solutions to occur for a specific clinic problem. Selection of a specific treatment plan is determined by evaluating planning validity. Note that Equation (8) cannot be served as a validity function since the objective of radiation therapy optimization for non-target volume cannot be expressed by a quadratic function. For example, when the calculated dose is greater than (but closer to) the prescribed dose, the objective function will not able to penalize such a situation. To measure the validity of radiation treatment, a validity function is introduces, say v({P ijk };x), which is written as
∑ v ( { P ijk } ; x ) = tt ∑ i , j , k ∈ Ω t P ijk - D ijk + nn ∑ i , j , k ∉ Ω t D ijk + cc ∑ i , j , k ∉ Ω t D ijk ( 11 )
The importance of requiring the quadratic function is that it is proved that the global minimum does exist and is unique. Here tt, nn, and cc are used to indicate the importance of matching each term. The parameters can be determined by the planner based on the clinical needs for each individual patient. When an equal importance is reached, tt, nn, and cc are equal to 1. If DVH is used to judge the results, tt, nn, and cc can be used changed to reach final plan.
Evaluation of Inverse Planning Method:
Phantom Test
The developed inverse planning method was tested with three cylindrical, phantoms: brain, head and neck, and pelvis. Each geometry has both complicated target volume and critical organs around it. The primary beam was acquired from TMR data for 4×4 cm field size of 6 MV photon beam.
Patient Case Test
IMRT Experiment
Clinical implementation was based on step-and-shot approach including the following:
a. patient CT image;
b. input to Pinnacle 3-D planning system;
c. contour target and critical structure and external edges;
d. export contours and CT images to inverse planning algorithm;
e. generate IMRT intensities for each beam;
f. segment each beam for step-and-shot;
g. import segmented field to Pinnacle 3-D system; and
h. calculate MIUs for each segment.
Three-Dimensional Reconstruction of Dose Distribution
With the patient at the treatment position, the same projection data for the geometry reconstruction was used to estimate the true dose delivered to the patient. A scheme for 3-D dose verification was developed, which requires overlaying the reconstructed patient geometry at treatment with the distribution of the delivered dose. This serves as a verification tool to the initial treatment planning.
In the current megavoltage CT imaging, a uniform beam was used for both the calibration runs and the projection measurements. For the EMIRT, the x-ray beam from each projection was modulated in intensity, i.e., non-uniform. Therefore, the IMRT beams were measured before the patient is placed in the treatment room to get the entrance intensity distribution. An alternative way was to download the distribution from the IMRT delivery files; however, this option is less direct than measurement. Without these entrance beam intensity, one would be unable to decide whether any exit intensity change is due to the entrance intensity change or different attenuation within the patient geometry. Image reconstructions using the intensity-modulated beam can be tested initially using simply compensator or wedge.
Different patient dose calculation methods can be used based on the measured transmission x-rays (most of the detected x-rays are primary components for that there is a 50 cm air gap between the patient exit surface and the detector. The scatter fraction for a 20×20 field size, 17 cm thick water and 30 cm air-gap is 10% [Jaffray et al., 1994]). The first two methods are based on the primary photon fluences at the point of dose calculation. These are called the convolution-superposition and the superposition-convolution method. In the first method, the x-ray fluence at the detector surface is ray-traced back to inside the patient's geometry. The fluence can be convoled inside the patient with an appropriate energy deposition kernel (dose spread array) to obtain the dose distribution. By superimposing all the distributions over the reconstructed patient geometry, one can obtain the total dose distribution. In the second method, first, the x-ray fluences of all the beams at the detector surface are ray traced back and superimposed together to get the total primary x-ray fluence distribution inside the patient. Then one can convolve the total fluence distribution with a rotation dose spread kernel to get the total dose distribution. In both methods, normalization (calibration) is needed. The third method is based on the primary photon distribution attenuated inside the patient. The overall primary attenuation distribution in the patient, which is different from the total primary fluence ray traced back from the detected x-rays, can also be reconstructed, using the similar methods for the emission tomographic reconstructions such as PET and SPECT. (For each beam the attenuation profile was obtained by subtracting the penetrated primary from the entrance beam.) Then, the overall attenuation distribution was convolved with a special rotation dose kernel (which is calculated based on the photon numbers rather than the photon fluence) to get the dose distribution. MLS-ART can be applied for such a photon attenuation reconstruction (with some modification) based on the experiences of Herman [1993], but not the conventional CBP technique due to the limited beam numbers. Further, the homogeneity corrections can be directly calculated based on the geometric reconstructions. Compared to the first two methods, the third method is more direct, accurate and convenient. It is also easier for the intensity-modulated beams. With faster and growing computation technology including hardware specifically designed for MLS-ART and FFT, one can achieve faster and more accurate on-line verification.
To be more accurate, one needs to calculate the primary fluence on the detector's surface by deconvolving the projection data (measured during treatment session, therefore no additional dose to the patient) using the “EPIID kernel” (the point spread function of EPD).
One can also use some portal dosimetry methods to model the exit dose distribution and to compare it to the calculation results. It can also be used to model the absorbed dose inside the treatment volume (actually the dose along the beam path) based on the treatment geometry as reconstructed using the MLS-ART. The results were compared to some other dose modeling and verification methods such as the portal dose imaging (PDI) technique [Wong et al., 1990], the superposition/convolution method [McNutt et al., 1996a & b], and the inverse filtered (convolution) back-projection method of Holmes and Mackie [1994].
The other advantage of using the C51(T1) detector for dose modeling and verification throughout the treatment volume is that compared to commercial EPID which overrespond to low energy x-rays for dosimetry studies, the detector is more tissue equivalent. If a-Si detector is used, a more active way to reduce over-response is to use organic scintillators (low-Z plastic materials) on the detector so that detector response will be more tissue equivalent. One way is to use a low-Z screen with a buildup phantom such as the solid water. Then the photons undergo interactions in the buildup material. The secondary electrons are mainly absorbed in the organic screen, and the visible photons are emitted toward the a-Si photodiode sensor. The merit of using such an organic screen is that the dose deposition by electrons inside the tissue can be exactly modeled by using the tissue-equivalent organic material. The screen needs to be fabricated by a medical imaging company because the currently available screen has poor surface smoothness.
For clinical application of megavoltage portal CT, improving the accuracy of reconstruction rests on more efficient detectors and optimized reconstruction algorithms to most effectively use the available dose. In the study, three interrelated specific goals can be analyzed.
(1) Adapt an efficient x-ray detector to carry out the study. There are 3 options: a) use Varian Portal Vision Electronic Portal Imaging Device (EPD), which tested to be the best commercial EPID system; b) use the amorphous silicon system; and c) use a C5I(T1) CCD system which was specifically designed for megavoltage imaging. The Csl(T1) system is one of the best megavoltage imaging systems, providing both good contrast and spatial resolution.
(2) Image reconstruction. The MLS-ART technique can be used for this specific application, in which a limited number of cone beam projections (dosage close to that in diagnostic CT) are used to get megavoltage CT reconstruction for patient geometry. Then the treatment beams can be used to further modify the reconstruction. The two-step reconstruction has three important purposes: 1. the second stage locally improves the CT image quality inside the tumor; 2. the second stage also determines the placement of treatment beams inside the patient geometry obtained by the first step; and 3. the treatment (dose covered) area can be visualized from the final CT images. MLS-ART can easily perform the reconstruction. However, it is impossible for the conventional convolution backprojection (CBP) technique.
(3) Dose reconstruction and verification. From the portal image taken at the treatment portal, one can obtain the portal (transit) dosimetry and convert the portal dose information to photon fluence. The fluence can be traced back to the patient and one can determine the fluence inside the target. The convolution-superposition or superposition-convolution or other methods can then be used to calculate the dose inside the patient use the fluence. Such a 3D dose distribution can be overlaid onto the patient geometry to verify the treatment plan. Any major discrepancy between the prescribed and actual dose can be corrected by modification of the treatment setup.
Example 3
Materials and Methods
For a given dose prescription, conventional inverse treatment planning consists of two steps: (1) finding the suitable weighting factors for involved organs and (2) optimizing the intensity spectrum based on the given weighting factors. As there are a large number of choices for weighting factors, finding the desired ones for a given objective function is difficult. The involved organs in this system are categorized as the target volume (TV), the critical organs (CO), and the normal tissue (NT).
The Principle of the Fuzzy Inference System
The flow chart of FIS is illustrated in FIG. 1 . It consists of three main modules: the Fuzzifier, the Inference Engine (consisting of fuzzy rules) and the Defuzzifier. For each variable input to the fuzzy inference system, a number of fuzzy sets are defined with appropriate membership functions. These membership functions are labeled with linguistic tags frequently used by humans (such as “High” dose). During the process of fuzzification (corresponding to the module of Fuzzifier), the single input value is compared to the membership functions defined for that input variable. If the membership functions have a non-zero output, it will take effect on the final result of the FIS. Generally, the fuzzifier calculates the response of rules for the input values, and the inference engine modifies the consequent of rules in response to the input values and the defuzzifier generates the final output based on the result of the inference engine.
The inputs to this system are defined as the characteristic doses [C TV , C CO , C NT ] which consist of the mean dose (Mean i , i=TV, CO, NT) and its standard deviation (STD i ,il=TV, CO, NT). For the target volume, C TV =Mean TV −STD TV . For the critical organs and normal tissue, CCO=Mean CO +STD CO and C NT =Mean NT +STD NT . The outputs of FIS [ΔW TV , ΔW CO , ΔW NT ] are defined as the adjustment of the weighting factors for each involved organs. For each input variable, two fuzzy sets, “High (H)” and “Low (L)”, are defined with membership functions [f i H (x), f i L (x), i=TV, CO, NT], as shown in FIGS. 2 a - 2 c . For each output variable, three fuzzy sets, “Increase (I)”, “No change (N)”, and “Decrease (D)”, are defined with membership functions [g i I (x), g i N (x), g i D (x), i=TV, CO, NT]. For the target volume, these three membership functions are shown in FIG. 2 d . Similar membership functions are defined for critical organ and normal tissues for the same adjustment strategy.
Based on the input and output variables defined above, fuzzy rules are established for the fuzzy inference engine. Eight rules are employed in the system. In each rule, the “if” part of rule is called antecedent and the “then” part of rule is called consequent. Two of them (Rule 5 and Rule 8 ) are used to demonstrate the procedure of fuzzy inference as shown in FIG. 3 . Note that the input (output) variables are labeled using the bold fonts and their corresponding linguistic tags are labeled using the italic fonts in each rule. According to the linguistic tags, the corresponding membership functions for the input fuzzification are specified as shown in Step 1 of FIG. 3 . Such as the input variable C TV , the membership function f H TV is specified in Rule 5 by the linguistic tag “High”. For each rule, the outputs of the fuzzification are [D 5 TV , D 5 CO , D 5 NT ] and [D 8 TV , D 8 CO , D 8 NT ], respectively. Based on these outputs of fuzzification, the degree of support (D SUPPORT ) for each rule is achieved by a logic operator “Min”, such as D 5 support =Min (D 5 TV , D 5 CO , D 5 NT ) and D 8 support =Min (D 8 TV , D 8 CO , D 8 NT ), as shown in Step 2 of FIG. 3 . The degree of support represents the applicability of the rule's antecedent for given inputs. Based on the degree of supports, the fuzzy inference is performed by a standard implication method, which is accomplished by a logic operator “Min”. For example in Step 3, the membership function g N TV (x) in Rule 5 is modified as g N,D5 TV (x)=Min (D 5 support , g N TV (x)). The modified membership functions became [g N,D5 TV (x), g N,D5 CO (x), g N,D5 NT (x)] and [g N,D8 TV (x), g N,D8 CO (x), g N,D8 NT (x)] for Rule 5 and Rule 8 , respectively. As there are two sets of modified membership functions obtained, it is necessary to combine them to produce a single one. In Step 4, the functions were aggregated into one set by a logic operator “Max”, i.e.,
[ g TV ( x ), g CO ( x ), g NT ( x )]=[Max( g TV N,D 5 ( x ), g TV N,D 8 ( x )], Max( g CO N,D 5 ( x ), g CO N,D 8 ( x )), Max( g NT N,D 5 ( x ), g NT N,D 8 ( x ))].
The aggregated functions represent the combined consequent from all the rules. Finally, the aggregated functions are defuzzified to a single value by the centroid method in Step 5. The x-coordinate of the centroid (represented by sign “⊕”) for each aggregated function was the final output, the adjustment amount of weighting factors.
The Fuzzy Logic Guided Inverse Planning Algorithm
The flow chart of the FLGIP system is schematically illustrated in FIG. 4 . First, the dose prescription and weighting factors are set to their initial values. Then, an iterative gradient algorithm is used to calculate the intensity spectrum x. In the study, the objective function is defined as follows:
f ( x ) = ∑ i ∑ j ∑ k w ijk ( p ijk - d ijk ) 2 ,
Where
d ijk = ∑ n = 1 N A n , ijk x n ( 1 )
is the calculated dose for each voxel, A n,ijk is the relative dose coefficient, or dose per unit intensity of pencil beam. P ijk is the dose prescription and w ijk is the weighting factor defined as follows:
p ijk = { P TV , if ( i , j , k ) ∈ Ω TV P CO , if ( i , j , k ) ∈ Ω CO P NT , if ( i , j , k ) ∈ Ω NT ,
w ijk = { W TV , if ( i , j , k ) ∈ Ω TV W CO , if ( i , j , k ) ∈ Ω CO W NT , if ( i , j , k ) ∈ Ω NT .
Ωw TV , Ωw CO and Ωw NT denote the target volume, the critical organ volume, and the normal tissue volume, respectively. The minimization of the objective function under the constraint of x n ≧0 can be written as a problem of
min x { f ( x ) }
subject to x n ≥ 0 , ∀ n . ( 2 )
Equation 2 can be solved by the fast-monotonic-descent (FMD) method developed by Li and Yin, which is an optimized iterative gradient technique for the quadratic function. Based on the optimized intensity spectrum, the characteristic doses are calculated and then input to the FIS. Using fuzzy inference, the adjustment amounts of weighting factors [ΔW TV , ΔW CO , ΔW NT ] are obtained. Then, the weighing factors for the next iteration are modified as follows:
W i ( n +1)= W i ( n )[1 +ΔW]iε{TV,CO,NT}, ΔWε[− 1,1]. (3)
As the weighting factors affect the output of inverse planning by their relative values rather than the absolute values, they are re-normalized to [0, 1] by the following formula:
W i * ( n + 1 ) = W i ( n + 1 ) W TV ( n + 1 ) 2 + W CO ( n + 1 ) 2 + W NT ( n + 1 ) 2
i ∈ { TV , CO , NT } . ( 4 )
This updating procedure repeats until the following convergence criterion (5) is satisfied:
[ C TV ( n + 1 ) - C TV ( n ) ] 2 + [ C CO ( n + 1 ) - C CO ( n ) ] 2 + [ C NT ( n + 1 ) - C NT ( n ) ] 2 C TV ( n ) 2 + C CO ( n ) 2 + C NT ( n ) 2 < T . ( 5 )
where T is a small threshold number, such as 0.01.
Results
The performance of FLGIP system was examined using two cases (one simulated and one clinical). Dose-volume histograms (DVHs), plus the variation of characteristic doses and weighting factors versus the iteration number, are used as the primary tools to evaluate the performance of this system. Pencil beams of 6 MV were used. For simplicity, the primary-only dose at depth is used in the calculation. The initial weighting factors [W TV , W CO , W NT ] are set to [1,1,1] (after re-normalization using formula (4), they became [0.58, 0.58, 0.58]) and the convergence constant T was set to 0.01.
The Simulated Case
The central slice of this case is illustrated in FIG. 5 a . The layout on this slice simulates the spinal cord with a target volume surrounding it. Seven treatment beams are uniformly arranged between 360 degrees. The configuration is typical in spinal radiosurgery using IMRT.
The FLGIP system was tested using four sets of different dose prescriptions: [100%, 20%, 50%], [100%, 30%, 50%], [100%, 40%, 50%], [100%, 50%, 50%]. FIG. 6 shows the variation of (a) characteristic doses and (b) weighting factors versus the iteration number for dose prescription [100%, 30%, 50%]. The results indicate that for the target volume and critical organ, the characteristic doses monotonieally converge to the prescribed doses (the normal tissue dose also converges, but at a much less rate due to its large volume.) The results shown in Table 1 demonstrate that the high target dose and low critical organ dose are achieved simultaneously and both meet the prescribed doses. The corresponding DVHs for (a) the target volume, (b) the critical organ, and (c) the normal tissue are shown in FIG. 7 . The final results also depend on the provided dose prescriptions. For each set of dose prescriptions, the corresponding isodose distributions are shown in FIG. 8 .
The effect of initial weighting factors on the final characteristic doses was examined by using eight sets of initial values with the same dose prescriptions [100%, 30%, 50%]. The characteristic doses for each set converged within 50 iterations. The final results and the standard deviations are shown in Table 2. The results indicate that the achieved characteristic doses by different sets of initial weighting factors are comparable. The final eight sets of weighting factors were averaged. The mean weighting factors and their standard deviations are 0.139±0.113 for the target volume, 0.985±0.025 for the critical organ, and 0.004±0.003 for the normal tissue.
The Clinical Case
The central slice for the present study is illustrated in FIG. 5 b . Eleven beams are arranged at 0°, 33°, 66°, 90°, 120°, 150°, 210°, 240°, 270°, 300°, 330°. The configuration represents a complicated IMRT case. The dose prescription is set to [100%, 30%, 50%]. The variations of the characteristic doses and weighting factors versus the iteration number are shown in FIG. 9 a and FIG. 9 b , respectively. The characteristic dose C TV monotonically converges to its prescribed dose 100% while the characteristic doses C CO and C NT monotonically converges to the doses below their prescribed values, 30% and 50% respectively. The DVHs of the calculated doses for different organs at three iterations 5 , 10 , 15 are shown in FIG. 10 . The results indicate that the gap between the DVHs of target volume ( FIG. 10 a ) and critical organs ( FIG. 10 c ) increases with increased iteration number. The substantial improvements of isodose distributions around the critical organ CO 1 , (the one closet to target volume) in different iterations can be easily identified from FIG. 11 .
Discussion
A fuzzy inference system was developed to automatically modify the weighting factors in inverse treatment planning in order to achieve the dose distributions best matching the treatment requirements. The fundamental inference mechanism is demonstrated by a mini system consisted of rules as shown in FIG. 3 . Among the eight rules, Rule 5 plays the primary role to drive the system toward the convergence while Rule 8 (plus the other six rules) drives the inputs toward its prescribed ones. For example, when the inputs for critical organ and normal tissue are much higher than their prescribed doses, the output of FIS can mainly be determined by the adjustment of Rule 8 . Once the inputs approach their prescribed ones to better match the antecedent of Rule 5 (usually after several iterations), the consequent of Rule 5 takes more effect on the output of FIS and drives the system towards convergence. The other six rules are used to process different scenarios of mismatching between characteristic doses and prescribed doses of different organs.
The details of the adjustment process are shown in FIG. 6 and FIG. 9 . At the first several iterations, the weighting factor for the target volume decreases and the weighting factor for the critical organs increases quickly. After a few iterations, as the characteristic doses approach the prescribed ones, the adjustments of weighting factors gradually reduce. The characteristic doses for the target and critical organs in the last iteration satisfy their dose prescriptions. For the normal tissue, however, the final characteristic dose is appreciably lower than its prescribed dose due to its large volume. Although some rules seemingly take less effect on or are seldom used in these two cases, these rules are necessary for the more complicated cases. In addition, the results shown in FIG. 7 indicate that using different dose prescriptions can result in different dose distributions. Potentially, the fuzzy inference technique can also be used to optimize other parameters in inverse planning such as the beam orientation, the dose prescription, etc.
As the configuration of FIS is flexible, it provides a wide space to customize the configuration for different applications. In the system, the input characteristic doses are chosen as the mean dose combined with its standard deviation. For target, the lower than mean input dose helps the FIS to drive the target dose to be higher toward the prescribed one in the next iteration. Similarly, for critical organ and normal tissue, the higher than mean input dose drives critical and normal tissue doses to be lower toward the prescribed ones in the next iteration. In this way, both high target dose and lower critical organ (and normal tissue) doses can be easier to achieve. For output variables, they are simply defined as the relative adjustment of the weighting factors, which are between −1 and 1. For the selection of inference rules, it is primarily determined by the clinical experience. The general treatment intention can be described as: If the target dose is low, its weighting factor should be increased. If the critical organ and normal tissue doses are high, their weighting factors should be increased. In the system of the present invention, such treatment intention is expressed by eight rules, which is a complete combination of linguistic tags for three kinds of involved organs. The option can avoid any unpredicted input values. As for the selection of membership functions, the Gaussian function is adopted due to its simplicity and popularity for most of the engineering applications. In some circumstances, part of the Gaussian function is used, such as those shown in FIG. 2 a - 2 c.
CONCLUSION
A fuzzy logic guided inverse planning system has been developed. The system provides an effective and efficient approach to optimize the parameters used in inverse planning. The main advantage of using FIS is that it can perform the sophisticated inference formerly done by trial-and-error approach. Relying on the planner's experience and knowledge on how to compromise parameters among different organs involved, the optimization of weighting factors can be easily accomplished by encoded rules. As demonstrated by the result of two cases, the fuzzy inference system can undertake the very complex task of parameter optimization in inverse planning.
Throughout the application, author and year and patents by number reference various publications, including United States patents. Full citations for the publications are listed below. The disclosures of these publications and patents in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this invention pertains.
The invention has been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention can be practiced otherwise than as specifically described.
TABLE I
Comparison of results by using different sets of dose prescriptions.
Calculated dose (%)
Dose prescription (%)
Target
Critical
Normal
Target
Critical
Normal
volume
organ
tissue
volume
organ
tissue
Mean
STD
Mean
STD
Mean
STD
100
20
50
102.1
6.3
20.5
2.4
26.2
18.9
100
30
50
102.3
5.3
31.1
2.1
26.6
19.1
100
40
50
102.3
4.6
40.2
1.8
26.9
18.7
100
50
50
102.4
4.1
50.3
2.0
27.2
18.6
TABLE II
Comparison of results by using different sets of initial
weighting factors.
Calculated dose (%)
Weighting factor
Target
Critical
Normal
Target
Critical
Normal
volume
organ
tissue
volume
organ
tissue
Mean
STD
Mean
STD
Mean
STD
0.1
0.1
0.1
100.8
5.6
30.2
0.8
25.8
18.8
0.1
0.1
1.0
101.0
5.9
30.0
0.2
25.7
19.1
0.1
1.0
0.1
101.1
6.0
30.0
0.2
25.7
19.1
1.0
0.1
0.1
100.3
4.5
30.8
3.0
25.3
18.5
1.0
1.0
1.0
100.8
5.6
30.2
0.8
25.8
18.8
1.0
1.0
0.1
100.5
5.1
30.4
1.5
25.5
18.6
1.0
0.1
1.0
100.4
5.2
30.3
1.3
25.3
18.7
0.1
1.0
1.0
100.7
6.0
30.0
0.1
26.6
22.5
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A fuzzy inference system for use in modulating radiation treatment includes a fuzzifer for inputting imaging data, and inference device operatively to the fuzzifer for analyzing the imaging data and determining radiation treatment target from non-treatment target, and a defuzzifier for modulating radiation treatment pursuant to the analysis from the inference device.
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The present invention relates to a method and apparatus to receive radio waves, and more particularly frequency-modulated radio waves with a plurality of antennas, especially adapted for use with automotive vehicles, in which a plurality of antennas are installed in or on the vehicle.
BACKGROUND OF THE INVENTION
Quality of reception and especially frequency-modulated (FM) radio reception in vehicles is impaired by two major sources of disturbances: (1) multi-path reception; (2) ignition noise due to neighboring vehicles, and other ambient radio noise.
The reception conditions in movable vehicles change continuously. Thus, use of directional antennae, suitable with stationary installation and there substantially improving reception quality, is not generally possible. Rather, antennas for vehicles are designed to be essentially independent of direction, that is, to have reception sensitivity which is location-independent. It has previously been proposed to use receivers with a plurality of antennas in order to improve reception. The selection of which one of the antennas to be coupled to the receiver is usually based on field strength, that is, level of the signal appearing at any one of the antennas. This selection does not necessarily, however, connect the antennas with maximum signal-to-noise level to the receiver. Optimization of signal-to-noise level in the receiver thus is not ensured.
SUMMARY OF THE INVENTION
It is an object to improve reception of radio waves, and more particularly FM reception in a vehicle, in which interference and noise signals are minimized.
Briefly, a local carrier is generated and the signals received from each of the antennae are mixed with a local carrier to provide a plurality of intermediate frequency (IF) signals. Weighting coefficients are then generated for each of the IF signals, which are based on a composite signal. The IF signals are then weighted by the weighting coefficient, for example by mixing the signals with a weighting coefficient signal, and the thus weighted IF signals are summed or added to form a sum signal. This sum signal is used twofold (1) to generate the weighting coefficient, which are obtained by minimizing the temporal variation of amplitude of the summed signal; and (2) the added, or summed signal is demodulated and applied to an audio output stage.
In accordance with a preferred feature of the invention, the mixed IF signals are connected, as such, after weighting to an adder, to carry out the adding, or summing step; additionally, the IF signals are split and rotated 90° in phase, the 90°-phase rotated signals have their own weighting coefficients applied thereto and, after weighting, they are also added in the adder to form the sum signal.
The method, and system, apparatus or circuit has the advantage that the optimizing criterion for selection is minimizing of an interference, disturbance or noise signal. The temporal amplitude variation of a disturbed, or noisy FM sum signal is minimized, so that the IF signal which would be demodulated will have a temporally constant amplitude, that is, an amplitude which is effectively constant with respect to time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a system in accordance with the invention, in carrying out the method;
FIG. 2 is a block circuit diagram of a control circuit used to generate the coefficients and forming part of the circuit of FIG. 1;
FIG. 2A is a fragmentary diagram illustrating the variation of the circuit of FIG. 2;
FIG. 3 is a detailed block diagram illustrating a portion of the system of FIG. 1;
FIG. 4 is a schematic representation of a vehicle with four antennae located thereon;
FIG. 5 is a schematic representation of an example of reception conditions;
FIG. 6 is a time diagram of an IF signal without using the present invention;
FIG. 7 is a time diagram of a demodulated signal without use of the present invention;
FIG. 8 is a time diagram similar to FIG. 6, and applying the present invention;
FIG. 9 is a time diagram of a demodulated signal, similar to FIG. 7, and using the present invention;
FIG. 10 illustrates four directional diagrams at selected time intervals during a single adaptation cycle, and
FIG. 11 is a table of mathematical relationships.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The circuit of FIG. 1 illustrates, schematically, a plurality of antennae 1.1 to 1n. Only antenna 1.1 and antenna 1n are shown; the value of n may be any integer larger than one and, in a practical embodiment in connection with a passenger vehicle shown in FIG. 4, may be four.
Each one of he antennae is connected to a pre-amplifier 2.1 to 2n. The output signal from the preamplifier 2.1 . . . 2n is connected to a respective mixing stage 3.1 . . . 3n. A tunable local oscillator 71 generates a local signal which is connected to a second input of the respective mixer 3.1 . . . 3n. The resulting mixed intermediate frequency (IF) signals u 1 . . . u n are branched. One branch, each, connects to a 90° phase shifter 5.1 . . . 5n, from which phase-shifted signals u 1' . . . u n' are derived. Additionally, the signals from the mixer 3.1 . . . 3n are connected to one input of respective multipliers 4.1 . . . 4n. The outputs from the phase shifter 5.1 . . . 5n are connected to further multipliers 6.1 . . . 6n. The outputs from all the multipliers 4.1 . . . 4n and 6.1 . . . 6n are connected to a summing or adding circuit 70.
The sum signal u 0 at the output of the summing circuit 70 is coupled, as well known, to an IF amplifier stage which includes a filter 72 and a limiter 73, as well as amplification circuitry, as well known, and not further shown since it is conventional. The output from the limiter 73 is connected to a demodulator 74, the output 75 of which has low-frequency or audio signals available for further audio amplification.
In accordance with a feature of the invention, the multipliers 4.1 . . . 4n, 6.1 . . . 6n receive respective weighting coefficients, with which the IF signals u 1 . . . u n , as well as the 90° phase-shifted IF signals u 1' . . . u n' are weighted. The coefficients applied to multipliers 4.1 . . . 4n, in a mathematical sense, are real components of a complex coefficient w i ; the coefficients applied to the multipliers 6.1 . . . 6n are the imaginary components of the complex coefficient w i .
The subscript i denotes association with any one of the decimal--denoted signals or components 0.1 to n.
The voltages u i (+) and the voltage u a (+) can be considered complex values. They are represented by relationships (1) and (1a) of the attached table of mathematical relationships, see FIG. 11.
The sum voltage is obtained from relationships (1) and (1a) and shown in relationship (2).
The disturbance or noise to be minimized can be considered the square deviation F of the envelope u 0 (t) of constant level C and defined as shown in relationship (3).
When the optimum is reached, the equation (4) must be satisfied. The relationship of equation 4 is valid for deterministically defined noise or errors, as well as for the expected value of superimposed, or modulated variations which are similar to noise. If the gradient method is selected as the basis for deriving of the coefficient w i (t), then, from equations (1) to (4), the equation (5) is obtained.
The adaptation constant γ determines the stability and the dynamic behavior of the adaption algorithm.
When the adjustment cycle is terminated, the relationship of equation (6) will pertain.
Let us know look at equation (7) which includes the factor
1/ |u.sub.i (τ)|
This factor modifies the adaptation constant γ in equation (5), then, with respect to equation (5), only dynamic behavior changes, not, however, the stationary end value.
This modification has the advantage that the simple possibility arises to carry out the adaption selectively, that is, with respect to only the transmitter being considered, without requiring a high degree of filtering, and substantial filter components. The requirements in relationship (7) of
u.sub.0 (t)/|u.sub.0 (t)| or, respectively, u.sub.i (t)/|u.sub.i (t)|
can be instrumented by means of limiters and amplifiers, or limiting amplifiers. The product of the first and the conjugated complex value of the second corresponds to the lower sideband of the frequency spectrum occurring upon mixing. This product depends only on the phase angle between u 0 (t) and u i (t). The function w i (t) represented by equation (7) can easily be obtained in a control circuit and coefficient generator 76 (FIG. 1), supplying the second inputs to the respective multipliers 4.1 . . . 4n and 6.1 . . . 6n. The detailed circuit of the coefficient generator 76 is shown in FIG. 2, to which reference will now be made.
The input terminal 81 receives the respective IF signal u i ; it is connected through a band-pass 82 and an amplitude limiter 83 to a first multiplier 84. A second input 85 receives the output signal u 0 from the summing circuit 70 (FIG. 1). The input terminal 85 is connected through a second band-pass filter 86 and a second amplitude limiter 87 to the second input of the first multiplier 84.
The output signal of the multiplier 84 is multiplied with the envelope curve derived by amplitude demodulating the signal u 0 , derived from terminal 85 in a demodulator 88. It is multiplied in a second multiplier 90, and connected to a subtraction circuit 91. The difference with respect to an applied constant value C is formed in a subtraction circuit 91, which, in turn, is connected to an integrator 89. The output terminal 92 of the integrator 89 then will have the respective weighting coefficient w i available.
The influence on the formation of the product of the useful frequency signal portions are small if the frequency characteristics of the IF filter 82,86 are identical, even if the pass curves of the filters are less than ideal. Undesired frequency components are separated by the filters from the limiters 83,87 so that, upon mixing of their output signals, no disturbing combination frequencies may occur. Such combination frequencies are contained in the output signals of the amplitude demodulator 88 which has a wide band signal applied thereto derived from the sum signal. They do not, however, contribute to control information at the input of the integrator 89, since only the equal frequency signal portions applied to the inputs of the second multiplier 90 lead to a basic band signal.
The control circuit and coefficient generator 76 (FIG. 1) includes a plurality of circuits shown in FIG. 2, one each for the real portion of the coefficient w i , for each one of the antenna channels, and a further one for the imaginary component of the coefficient w i' . Consequently, for n antennae, 2n control circuits are needed.
In accordance with a modification, shown in FIG. 2A, a common amplitude demodulator 88 and band pass 86, as well as limiter circuit 87, can be used for a plurality of circuits, by merely repositioning the respective multipliers 84,90.
FIG. 3 shows a portion of the circuit of FIG. 1, in which the controlling coefficient generator circuit 76 is shown in detail, represented by four circuits 93,94,95,96, each one, for example, being constructed as shown in FIG. 2 or FIG. 2A. A suitable placement for four antennae 101,102,103,104 on a passenger car 100 is illustrated in FIG. 4. The antennas are located, respectively, on the windshield, the rear window, and the two side windows; the spacing of the respective antennas should not be substantially less than a half wavelength of the radio band to be received; in the FM range, this corresponds to a spacing of about 1.5 m, which can easily be obtained in usual commercial passenger cars.
The effectiveness and operation of the circuit and method in accordance with the present invention will be explained in connection with FIGS. 5 to 10, in which the results were obtained by simulation.
The following data are assumed:
basic carrier frequency 100 MHz
modulation frequency: 2 kHz
frequency excursion ± 75 kHz.
The antenna system is constructed of four single antennas, located similar to the arrangement shown in FIG. 4, the spacing between two respectively opposite positioned single antennas being 1.5 m.
FIG. 5 illustrates the resulting antenna direction diagram before a control or adaption cycle has been started, with fixed, randomly selected adjustment coefficients of the initial values. The straight line vectors characterize the amplitude as well as the reception direction of the direct wave and, respectively, of the echoes which are received, delayed by the delay periods Δt 1 to Δt 3 , as well as the delay time value in microseconds.
FIG. 6 shows the amplitude of the sum signal, that is, the IF amplitude with fixed coefficients, with respect to time, without use of control, derived from the controlling coefficient generating circuit 76. The corresponding audio signal at the output 75 of the demodulator 74 (FIG. 1) is shown, with respect to time, in FIG. 7.
FIG. 8 shows the course of the IF amplitude after start of control by applying the weighting coefficients as described, and FIG. 9 shows the resulting audio signal and output terminal 75.
Comparison of FIGS. 6 and 8 and 7 and 9 clearly shows that the disturbances have been attenuated after less than 1 millisecond to a minor and effectively negligible rest value. This short swing-in period of the method of the present application thus makes it readily adaptable for reception in a mobile receiver, typically in an automobile receiver.
The resulting direction diagrams of the antenna system at selected intervals during an adaptation cycle are shown in FIG. 10. These diagrams are all drawn to the same scale and, except for the time difference, represent the same system. Diagram a of FIG. 10, as can be seen, is similar to FIG. 5; at diagram d, adaption is terminated and, as can be seen, the disturbance signals formed by the echoes 1,2 and 3 (see FIG. 5) have been essentially eliminated from the signal which is applied to the audio output, and forms the sum signal. The initial, or continuing echo signals are shown in the diagrams for comparison purposes although, as can be clearly shown by the associated lobes, their influence has become practically negligible. Diagram a, thus, shows the condition before an adaption cycle has started, whereas the diagram (d) shows the result with adaption terminated.
Various changes and modifications may be made, and features described in connection with any embodiment may be used with any other, within the scope of the inventive concept.
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For diversity reception from a plurality of antennas, particularly in an automotive vehicle (FIG. 4), the respectively received signals are mixed with a local oscillator signal to form a plurality of IF signals (u 1 . . . u n ). The respective IF signals are weighted with a weighting coefficient which is derived from a sum circuit of all the IF signals, and the respective IF signal, which weighting circuit includes an integrator to minimize temporal variations in the amplitude of the sum signal. The sum signal forms the actual IF signal, for further processing, and demodulating to derive an audio signal. Preferably, the signals from the antennas are branched, and the branch signals phase-shifted 90°, which, again, are weighted by similarly generated weighting coefficients, and the weighted, phase-shifted signals are combined in the adding or summing circuit (70) to form said eventual IF signal for demodulation.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit under 35 USC §119(e) of U.S. Provisional Patent Application Ser. No. 61/101,049 filed 29 Sep. 2008, which application is hereby incorporated fully by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to fabric systems, and more specifically to bed coverings constructed of high gauge circular knitted fabrics that accommodate and maintain optimum thermal conditions for sleep, which in turn can lead to faster sleep initiation and deeper, more restorative sleep.
[0004] 2. Description of Related Art
[0005] Sleep problems in the United States are remarkably widespread, affecting roughly three out of four American adults, according to research by the National Sleep Foundation (NSF). Consequently, a great deal of attention has been paid to the circumstances surrounding poor sleep, along with strategies for how to improve it.
[0006] The implications are not merely academic. Sleep—not only the right amount of it but also the right quality—impacts not just day-to-day performance, but also “the overall quality of our lives,” according to the NSF. Addressing the causes of poor quality sleep, therefore, has ramifications for millions.
[0007] Though many factors contribute to sleep quality, the sleep environment itself plays a critical role, and sleep researchers routinely highlight temperature as one of the most important components in creating an environment for optimal sleep. As advised by the University of Maryland Medical Center, “a cool (not cold) bedroom is often the most conducive to sleep.” The National Sleep Foundation further notes that “temperatures above 75 degrees Fahrenheit and below 54 degrees will disrupt sleep,” with 65 degrees being the ideal sleep temperature for most individuals, according to the NSF.
[0008] A lower environmental temperature is not the only thermal factor associated with improved sleep. Researchers have noted a nightly drop in body temperature among healthy, normal adults during sleep. This natural cycle, when inhibited or not functioning properly, can disrupt sleep and delay sleep onset, according to medical researchers at Cornell University. Conversely, the researchers noted, a rapid decline in body temperature not only accelerates sleep onset but also “may facilitate an entry into the deeper stages of sleep.”
[0009] Therefore, maintaining an appropriately cool sleep environment and accommodating the body's natural tendency to cool itself at night should be a top priority for individuals interested in optimizing their sleep quality. Performance fabrics crafted into bedding applications would be uniquely capable of promoting cool, comfortable—and therefore better—sleep, as these advanced fabrics maximize breathability and heat transfer. Performance fabrics are made for a variety of end-use applications, and can provide multiple functional qualities, such as moisture management, UV protection, anti-microbial, thermo-regulation, and wind/water resistance.
[0010] There has been a long felt need in several industries to provide improved bedding to help individuals get better sleep. Such improved bedding would include beneficial wicking among other properties. For example, in marine, boating and recreational vehicle applications, bedding should resist moisture, fit odd-shaped mattresses and beds, and reduce mildew. Particularly with watercraft, there is a need to protect bedding, and specifically sheets, from moisture and mildew accumulation.
[0011] An additional problem with bedding, not just with marine and recreational vehicles, is the sticky, wet feeling that can occur when the bedding sheets are wet due to body sweat, environmental moisture, or other bodily fluids. In particular, when bedding is used during hot weather, or is continuously used for a long time by a person suffering from an illness, problems can arise in that the conventional bed sheet of cotton fiber or the like cannot sufficiently absorb the moisture. All of these issues lead to poor sleep.
[0012] To date, performance fabric bedding products are not known. There are width limitations in the manufacturing of high gauge circular knit fabrics, because the finished width of bedding fabrics are dictated by the machine used in its construction. At present, performance fabrics are manufactured with a maximum width of under 90 inches wide, given present manufacturing and technical limitations, along with the inability of alternate manufacturing processes to produce a fabric with identical performance attributes. Yet, normal bed sheet panels can be 102 by 91 inches or larger. Thus, performance fabrics cannot yet be used for bed sheets.
[0013] Some conventional solutions for the above issues that hinder a good night's sleep include U.S. Pat. No. 4,648,186, which discloses an absorbent wood pulp cellulose fiber that is provided in a variety of sizes and is placed under a mattress. The wood pulp is water absorbent and acts to capture moisture to prevent such moisture from being retained by the bedding or the bedding sheets. However, this proposed solution does not interact with the bedding or the bedding sheets, but merely acts as a sponge for moisture that is in proximity to the target bedding.
[0014] U.S. Pat. No. 5,092,088 discloses a sheet-like mat comprised of a mat cover, the inside of which is divided into a plurality of bag-like spaces, and a drying agent packed into a bag and contained in the bag-like spaces in such a manner that the drying agent cannot fall out of the bag-like spaces. A magnesium sulfate, a high polymer absorbent, a silica gel or the like can be used as the drying agent. As can be seen, this proposed solution to moisture in bedding is cumbersome and chemically-based.
[0015] In the athletic apparel industry, moisture wicking fabric has been used to construct athletic apparel. For example, U.S. Pat. No. 5,636,380 discloses a base fabric of CoolmaxQ high moisture evaporation fabric having one or more insulating panels of ThermaxB or ThermastatQ hollow core fiber fabric having moisture wicking capability and applied to the inner side of the garment for skin contact at selected areas of the body where muscle protection is desired. However, this application cannot be applied to bedding sheets due to the limitations of the size of the performance fabrics manufactured. Further, performance fabric such as this type cannot be easily stitched together as the denier is so fine that stitching this fabric results in the stitching simply falling apart.
[0016] Circular knitting is typically used for athletic apparel. The process includes circularly knitting yarns into fabrics. Circular knitting is a form of weft knitting where the knitting needles are organized into a circular knitting bed. A cylinder rotates and interacts with a cam to move the needles reciprocally for knitting action. The yarns to be knitted are fed from packages to a carrier plate that directs the yarn strands to the needles. The circular fabric emerges from the knitting needles in a tubular form through the center of the cylinder. This process is described in U.S. Pat. No. 7,117,695. However, the machinery presently available for this method of manufacture can only produce a fabric with a maximum width of approximately 90 inches. Therefore, this process has not been known to manufacture sheets, since sheets can have dimensions of 91 inches by 102 inches or greater.
[0017] Further, the machinery that is used for bedding is very different than for athletic wear. For example, bedding manufacturing equipment is not equipped to sew flatlock stitching or to provide circular knitting. Bed sheets typically are knit using a process known as warp knitting, a process capable of producing finished fabrics in the widths required for bedding. This method, however, cannot be employed to produce high-quality performance fabrics. Warp knitting is not capable of reproducing these fabrics' fine tactile qualities nor their omni-direction stretch properties, for example.
[0018] Circular knitting must be employed to produce a performance fabric that retains these fabric's full range of benefits and advantages. However, in order to produce a fabric of the proper width for bedding applications, a circular knit machine of at least 48 inches in diameter would be necessary. Manufacturing limitations therefore preclude the construction of performance fabrics at proper widths for bedding. The industry is unsure if it could actually knit and then finish performance fabrics at these large sizes, even if the machinery were readily available.
[0019] Further, athletic sewing factories are typically not equipped to sew and handle large pieces of fabrics so that equipment limitations do not allow for the manufacture of bedding sheets.
[0020] What is needed, therefore, is a bedding system that utilizes performance fabrics and their beneficial properties, the design of which acknowledges and addresses limitations in the manufacture of these fabrics. It is to such a system that the present invention is primarily directed.
BRIEF SUMMARY OF THE INVENTION
[0021] Briefly described, in preferred form, the present invention is a high gauge circular knit fabric for use in bedding, and a method for manufacturing such bedding. The bedding fabric has superior performance properties, while allowing for manufacture by machinery presently available and in use. In order to achieve a finished width of the size needed to create sheet-sized performance fabric, a high gauge circular knit machine of at least 48 inches in diameter is necessary. And while warp knitting machines are available that can produce wider fabrics, this method will not provide a fabric with the tactile qualities required, nor provide a fabric with omni-directional stretch.
[0022] In an exemplary embodiment, the present invention is a method of making a finished fabric comprising at least two discrete performance fabric portions, and joining at least two discrete performance fabric portions to form the finished fabric. Forming the at least two discrete performance fabric portions can comprise knitting at least two discrete performance fabric portions, and more preferably, circular knitting at least two discrete performance fabric portions. Joining the at least two discrete performance fabric portions to form the finished fabric can comprise stitching at least two discrete performance fabric portions together to form the finished fabric.
[0023] The at least two discrete performance fabric portions can have different fabric characteristics. Fabric characteristics as used herein include, among other things, moisture management, UV protection, anti-microbial, thermo-regulation, wind resistance and water resistance.
[0024] The finished fabric can be used in, among other applications, residential settings, or in marine, boating and recreational vehicle environments.
[0025] The present sheets offer enhanced drape and comfort compared to traditional cotton bedding, and are as fine as silk, yet provide the benefits of high elasticity and recovery along with superior breathability, body-heat transport, and moisture management as compared to traditional cotton bedding.
[0026] Conventional fitted sheets can bunch and slide on standard mattress sizes. Furthermore, if the fitted bed sheets do not fit properly, they do not provide a smooth surface to lie on. The present invention overcomes these issues.
[0027] The present high gauge circular knit fabrics stretch to fit and offer superior recovery on the mattress allowing the fabric to conform to fit the mattress without popping off the corners of the mattress or billowing. The performance fabric can include spandex, offers a better fit than conventional bedding products, can accommodate larger or smaller mattress sizes with a single size sheet, and can conform to mattresses with various odd dimensions.
[0028] Spandex—or elastane—is a synthetic fiber known for its exceptional elasticity. It is stronger and more durable than rubber, its major non-synthetic competitor. It is a polyurethane-polyurea copolymer that was invented by DuPont. “Spandex” is a generic name, and an anagram of the word “expands.” “Spandex” is the preferred name in North America; elsewhere it is referred to as “elastane.” The most famous brand name associated with spandex is Lycra, a trademark of Invista.
[0029] The present high gauge circular knit fabric offers durability in reduced pilling and pulling when compared to other knit technologies, and offer reduced wrinkles and enhanced color steadfastness
[0030] In a preferred embodiment, the present performance fabric can allow for a one-size fitted sheet that can actually fit two different size mattresses. For example, the full fitted sheet of the present invention can fit on both the full and queen size bed. The twin fitted sheet of the present invention will also fit an XL twin. In a boating application, the present invention can be produced to fit almost every custom boat mattress.
[0031] Testing of the present invention conducted at the North Carolina State University (NCSU) Center for Research on Textile Protection and Comfort confirms that the present performance fabrics provide a cooler sleeping environment than cotton. Performance bedding was tested side-by-side with commercially available cotton bed sheets in a series of procedures designed to measure each product's heat- and moisture-transport properties, as well as warm/cool-to-touch thermal transport capabilities.
[0032] Across all tests, the present performance fabrics in bedding outperformed cotton, demonstrating the performance fabric's superiority in establishing and maintaining thermal comfort during sleep. This advantage is evident to users from the very onset, as NCSU testing indicates that, on average, performance bedding of the present invention offers improved heat transfer upon initial contact with the skin, resulting in a cooler-to-the-touch feeling.
[0033] During sleep, high gauge circular knit performance bedding of the present invention helps to maintain thermal comfort by trapping less body heat and breathing better than cotton. Testing has demonstrated that performance bedding made out of performance fabrics transfers heat away from the body up to two times more effectively than cotton. This is critically important not only for sustained comfort during sleep, but also in terms of enabling the body to cool itself as rapidly as possible to facilitate sleep onset. In addition to trapping less heat, performance bedding breathes better than cotton—up to 50% better, giving performance bedding a strong advantage in terms of ventilation and heat and moisture transfer.
[0034] The performance advantage over cotton holds true for simulated dry and wet skin conditions, confirming that certain performance fabrics in bedding are better suited than cotton at managing moisture (e.g., sweat) to maintain thermal comfort. In addition to wicking moisture away from the skin through capillary action, the performance fabric's advanced breathability further enables heat and moisture transfer through evaporative cooling. As a result, the user is kept cooler, drier and more comfortable than with cotton.
[0035] The present performance bedding holds a distinct advantage over cotton in enabling, accommodating and maintaining optimum thermal conditions for sleep, which in turn can lead to faster sleep initiation and deeper, more restorative sleep.
[0036] These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0037] FIG. 1 illustrates a preferred embodiment of the present invention.
[0038] FIG. 2 illustrates another preferred embodiment of the present invention.
[0039] FIG. 3 illustrates a further preferred embodiment of the present invention.
[0040] FIG. 4 illustrates another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0041] Although preferred embodiments of the invention are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the preferred embodiments, specific terminology will be resorted to for the sake of clarity.
[0042] It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. For example, reference to a sheet or portion is intended also to include the manufacturing of a plurality of sheets or portions. References to a sheet containing “a” constituent is intended to include other constituents in addition to the one named.
[0043] Also, in describing the preferred embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
[0044] Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value.
[0045] By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.
[0046] It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a fabric or system does not preclude the presence of additional components or intervening components between those components expressly identified.
[0047] Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, the present invention of FIGS. 1 and 4 provides a sheet 10 shown having dimensions of 102 inches in length and 91 inches in width. The material is manufactured from performance fabric, which can include, for example, varying amounts of one or more of Lycra, Coolmax, Thermax and Thermastat. In a preferred embodiment, the fabric is treated so that the fabric has antimicrobial properties. By using circular-knit performance fabric, the fabric is able to provide elasticity in all four directions. This property allows for the sheet to fit extraordinary mattress, cushion and bedding shapes, as well as providing better fits for traditional rectangular sheets. By using performance fabrics, the sheet has elastic properties that allow stretching in the directions shown as 30 . In addition, by using circular-knit performance fabric, the resulting bedding retains an exceptionally fine tactile quality critical for providing maximum levels of enhanced comfort.
[0048] An alternative to circular knitting is non-circular knitting—for example, warp knitting. This method can achieve widths greater than circular knitting. Industrial warp knit machines, for example, can produce tricote warp knit fabrics up to 130-140 inches in width. Circular knitting, however, is less expensive, as it requires less set-up time. Circular knitting also provides greater multidirectional stretch.
[0049] In order to provide a sheet that exceeds the maximum dimensions of fabric that can be produced by available circular knitting machines, flat lock stitching 12 is used to join a plurality of portions resulting in a sheet that is 91 inches wide (as shown). In an exemplary embodiment, piping 11 can be included in close proximity to the stitching. The stitching can be the same color as the fabric of the sheet portions, or different color(s). The piping can be ¾ inch straight piping without a cord or other filler. In one preferred embodiment, the stitching is 16 stitches per inch. Piping 11 can be included at one end of the sheet and can be the same or a different color as the sheet fabric.
[0050] For a fitted sheet, the sheet can include an elastic portion surrounding the edge of the fitted sheet to better keep the fitted sheet in place when placed on a mattress or other sleeping surface. A cord can be sewn into the edge of the fitted sheet and cinched around the mattress or other sleeping surface to better hold the fitted sheet in place.
[0051] Referring to FIG. 2 , a sheet is shown having dimensions of 91 inches wide and 102 inches in length. In this embodiment, stitching 14 is shown 34 inches from an interior edge 18 of a main portion 16 and another stitch 14 at edge 20 of the sewn-on portion. Flat lock stitching can be used for the stitching. Piping can be applied at or in proximity to the stitching.
[0052] Referring to FIG. 3 , a non-rectangular shaped sheet is shown. In this exemplary embodiment, elastic can be included around the edge of the fitted sheet to better maintain the fitted sheet in position when placed on a sleeping surface. In one embodiment, pull ties 24 can be installed at various locations around the edge of the fitted sheet in order to assist in maintaining the fitted sheet secured to the sleeping surface. The pull tie can be cinched to increase tension around the edge of the fitted sheet as shown by 26 .
[0053] Stitching used for securing the portions of the sheet together can include that shown as 28 a . In another embodiment, the stitching used for securing the portion of fabric together is shown as 28 b.
[0054] Referring to FIG. 4 , yet another preferred embodiment of the invention is shown. In this embodiment, the sheet can be assembled through stitching of differing fabrics for generating performance zones in the sheet. For example, zone 32 can have higher wicking properties than the other zones since this area is where the majority of the individual body rests. Areas 34 a through 34 d can have higher spandex or other elastic fabric properties so that the fit around a sleeping surface is improved. Area 36 may have thermal properties such as increased cooling since this area is generally where the individual's head lies. In an exemplary embodiment, the pillow covers of pillows used by the individual also have differing properties from the remainder of the sheet, e.g., thermal properties.
[0055] The present invention encompasses the construction of bedding materials that have superior performance properties while allowing for manufacture by machinery presently available and in use. More specifically, the invention is related to a new method for fabricating a covering and or sheets in bedding. When using the circular knitting machine, the high gauge performance fabrics can only be made to a maximum size of 72.5 inches without losing the integrity of the spandex in the fabric. Yet, normal sheet panels are 102×91 inches. This presents problems when manufacturing sheets from performance fabrics.
[0056] Additionally, special stitching techniques must be used given the thread density of the fabric. Using this special stitching, panels are sewn together to produce bedding or a sheet that is the proper size for standard bed sheets. Because discrete portions/panels are used in the manufacture of the present fabrics, panels can be selected that provide different properties for different areas of the bedding ( FIG. 4 ). Stitching or seams on the sheet can also allow for the ease of making the bed. Because the bedding is made from performance fabric with spandex, it stretches to permit multiple and custom sizing for applications in cribs, recreational vehicles and boats.
[0057] Circular knitting machines used for high gauge performance bedding fabrics are called high-gauge circular knitting machines, because of dense knitting with thin yarn. High gauge generally denotes 17 gauges or more. Seventeen gauges indicate that 17 or more cylinder needles are contained in one inch. Circular knitting machines of less than 17 gauges are referred to as low-gauge circular knitting machines. The low-gauge circular knitting machines are often used to knit outerwear.
[0058] “Yarn count” indicates the linear density (yarn diameter or fineness) to which that particular yarn has been spun. The choice of yarn count is restricted by the type of knitting machine employed and the knitting construction. The yarn count, in turn, influences the cost, weight, opacity, hand and drape of the resulting knitted structure. In general, staple spun yarns tend to be comparatively more expensive the finer their count, because finer fibers and a more exacting spinning process are necessary in order to prevent the yarn from showing an irregular appearance.
[0059] A top width in the 90-inch range is currently possible using a circular knit fabric formed on a 36-38-inch diameter machine, although higher levels of spandex in the performance fabric tend to pull the width in. In just one example, on a 30-inch diameter machine, the spandex can reduce an otherwise 94-inch circumference fabric tube to one with a 60-65 inch finished width.
[0060] A major limitation in finished width is not strictly a knitting concern but also concerns finishing. With performance fabric, it tends to sag in the middle—increasingly so with greater widths—making finishing difficult to impossible above a certain threshold. A possible 90-inch finished width is contingent upon having a good finishing set-up capable of handling the present performance fabric. This potential for difficulties would only become compounded at the larger widths required for bed sheets.
[0061] In a preferred process, the present fabric undergoes a heat setting finishing process. Applying a moisture-wicking finish to another fabric—like cotton—that can be produced at larger widths appears unlikely to match the moisture-control properties of the present fabric, as polyester itself is naturally moisture-resistant and there are physical actions (e.g. capillary action) at play. Further, the use of cotton comes at the expense of breathability and heat-transfer capabilities (as confirmed by laboratory testing) and stretchability.
[0062] Numerous characteristics and advantages have been set forth in the foregoing description, together with details of structure and function. While the invention has been disclosed in several forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions, especially in matters of shape, size, and arrangement of parts, can be made therein without departing from the spirit and scope of the invention and its equivalents as set forth in the following claims. Therefore, other modifications or embodiments as may be suggested by the teachings herein are particularly reserved as they fall within the breadth and scope of the claims here appended.
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Bedding material including a first fabric section manufactured from performance fabric and having a first and second side; and, a second fabric section attached to the first side of the first fabric section. Additionally, a third fabric section can be attached to the second side of the first fabric section. The first fabric section can be attached to the second fabric section through a flatlock stitch. The first fabric section can include a first zone and a second zone wherein the first zone contains different performance properties from the second zone and the first zone can have thermal or moisture wicking properties.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an array antenna system and in particular to a technique of calculating antenna weights for null direction control.
[0003] 2. Description of the Prior Art
[0004] In base stations of a mobile communications system, signals received by respective antenna elements of an array antenna are subjected to adaptive signal processing to form nulls in incoming directions of interference waves, which allows the interference to be suppressed. In addition, the null pattern obtained from the received signals is also used for signal transmission.
[0005] In the case of asymmetric communication such as Web access using ADSL (asymmetric digital subscriber line) service, however, the null pattern obtained from the received signals is not always best suited for transmission, In this case, it is necessary to determine null directions in some way and form nulls in the determined directions.
[0006] Antenna weights forming nulls in desired directions can be obtained by using a Poweils-Applebaum adaptive array control algorithm in a model which is formed when the antenna weights are calculated and receives a signal wave and interference waves at designated directions. Details of the Howells-Applebaum adaptive array control algorithm are discussed in, for example, Chapter 4 titled MSN adaptive array, pp. 67-86, “Adaptive Signal Processing by Array Antenna” by Nobuo Kikuma, SciTech Press.
[0007] FIG 1 is a flow chart showing a conventional null direction control method using the Howells-Applebaum adaptive array control algorithm. When null and beam forming directions, θ beam, θnull(l) . . . , θnull(M), are designated, steering vectors, Abeam, Anull_ 1 , . . . , Anull_M, in the null and bean forming directions are generated and then are combined to produce Asum. The combined steering vectors Asum is used to calbulate a covariance matrix R aa . An inverse matrix of R aa is used to calculate the optimum weights, Wbeam, of the array antenna.
[0008] However, the optimum weight computation according to the above prior art needs the inverse matrix calculation. This causes processing time and amount of calculation to be increased, resulting in lowered processing speed and increased amount of hardware
SUMMARY OF THE INVENTION
[0009] An object of the present invention is to provide a null direction control method which can obtain optimum antenna weights forming designated null beam directions without calculating an inverse matrix.
[0010] In an N-element array antenna, a designated null beam antenna pattern is obtained by processing a 2-element antenna weight vector forming a null in a sequentially selected one of M designated null directions and a (N−M) -element antenna weight vector forming a beam in a designated beam direction to produce an antenna weight vector for the N-element array antenna. The final antenna weight vector is calculated by incrementing the number of elements of a work antenna weight vector each time a null is formed in a sequentially selected one of the M designated null directions.
[0011] According to an aspect of the present invention, a method for producing an antenna weight vector for an N-element array antenna to form a designated antenna pattern having a single beam direction θbeam and M null directions θnull( 1 )-θnull (M) (1=<M=<N−2), includes the steps of: a) producing a work antenna weight vector for a (N−M) -element array antenna to form a beam in the single beam direction; b) sequentially selecting one of the M null directions; c) producing a 2-element antenna weight vector for a 2-element array antenna to form a null in the selected null direction; d) multiplying the work antenna weight vector by a first weight and a second weight of the 2-element antenna weight vector to produce a first work weight vector and a second work antenna weight vector; e) appending 0 to a trail end of the first work weight vector and to a head of the second work weight vector to produce a first expanded weight vector and a second expanded weight vector, and adding the first expanded weight vector and the second expanded weight vector to produce a work antenna weight vector; and f) repeating the steps (c)-(e) until antenna weight vector as the antenna weight vector for an N-element array antenna.
[0012] The step (a) may include the step of calculating the work antenna weight vector W pattern =[W beam(1) , . . . , W beam(N−M) ] using the following expressions:
δ w beam =exp{− j·k·d ·sin(θbeam)},
w beam(l) =1, and
w beam(i) =w beam(i−l) ·δw beam ( i= 2, 3, . . . , N−M ),
[0013] where d is a distance between antenna elements of the N-element array antenna, k is propagation constant of free space (k=2π/λ) λ is wavelength in free space.
[0014] The step (c) may include the step of calculating the 2-element antenna weight vector W null(m) =[w null — 1(m) , w null — 2(m) ] using the following expressions:
δ w null(m) =−exp{− j·k·d ·sin(θnull( m ) 0 },
w null — 1(m) =l, and
[0015] [0015] w null_ 2 ( m ) = w null_ 1 ( m ) · δw null ( m ) = - exp { - j · k · d · sin ( θ null ( m ) ) } ,
[0016] where m=1, 2, . . . , M.
[0017] The step (d) may include the step of calculating the first work weight vector W beam1 and the second work antenna weight vector W beam2 using the following expressions:
W beam1 =w null — 1(m) ·W pattern =1· W pattern ,
[0018] and
w beam2 = w null_ 2 ( m ) · w pattern = exp { - j · k · d · cos ( θ null ( m ) ) } · w pattern .
[0019] The step (e) may include the steps of: appending 0 to the trail end of the first work weight vector W beam1 and to the head of the second work weight vector W beam2 to produce the first expanded weight vector [W beam1 , 0] and the second expanded weight vector [0, W beam2 ]; and adding the first expanded weight vector and the second expanded weight vector to produce the work antenna weight vector W pattern =[W beam1 , 0]+[0, W beam2 ].
[0020] According to anther aspect of the present invention, a method for producing an antenna weight vector for an N-element array antenna to form a designated antenna pattern having M null. directions θnull( 1 )-θnull(M) (1=<M=<N−1), includes the steps of: a) arbitrarily preparing a work antenna weight vector for a (N−M)-element array antenna; b) sequentially selecting one of the M null directions; c) producing a 2-element antenna weight vector for a 2-element array antenna to form a null in the selected null direction; d) multiplying the work antenna weight vector by a first weight and a second weight of the 2-element antenna weight vector to produce a first work weight vector and a second work antenna weight vector; e) appending 0 to a trail end of the first work weight vector and to a head of the second work weight vector to produce a first expanded weight vector and a second expanded weight vector, and adding the first expanded weight vector and the second expanded weight vector to produce a work antenna weight vector; and f) repeating the steps (c)-(e) until the M null directions have been selected, to produce a fluid work antenna weight vector as the antenna weight vector for an N-element array antenna.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a flow chart showing a conventional null direction control method using the Howells-Applebaum adaptive array control algorithm;
[0022] [0022]FIG. 2 is a block diagram showing a transmission digital beam forming apparatus employing a null direction control method according to the present invention;
[0023] [0023]FIG. 3 is a flow chart showing a null direction control method according to a first embodiment of the present invention;
[0024] [0024]FIG. 4 is a schematic diagram showing a flow of generating a single beam and three nulls in the case where the null direction control method according to the first embodiment is applied to a 6-element array antenna;
[0025] [0025]FIG. 5A is a graph showing an antenna pattern in the stage of 3-element array antenna as shown in FIG. 4( a );
[0026] [0026]FIG. 5B is a graph showing an antenna pattern in the stage of 4-element array antenna as shown in FIG. 4( b );
[0027] [0027]FIG. 5C is a graph showing an antenna pattern in the stage of 5-element array antenna as shown in FIG. 4( c );
[0028] [0028]FIG. 5D is a graph showing an antenna pattern in the stage of 6-element array antenna as shown in FIG. 4( d );
[0029] [0029]FIG. 6 is a flow chart showing a null direction control method according to a second embodiment of the present invention; and
[0030] [0030]FIG. 7 is a block diagram showing a reception digital beam forming apparatus employing a null direction control method according to the present invention;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Hereinafter, embodiments of the present invention will be described in detail by referring to the drawings.
[0032] Referring to FIG. 2, an array antenna is composed of N antenna elements 1 . 1 - 1 .N, which are spaced uniformly and aligned in a line. The respective antenna elements 1 . 1 - 1 .N are connected to N transmitters 2 . 1 - 2 .N, which are in turn connected to a signal processor 4 through N digital-to-analog (D/A) converters 3 . 1 - 3 .N.
[0033] The signal processor 4 includes N multipliers 9 . 1 - 9 .N and an antenna weight calculator 5 . The multipliers 9 . 1 - 9 .N are connected to the D/A converters 3 . 1 - 3 .N and assign antenna weights W beam(1) -W beam(N) to transmission data, respectively. The antenna weights W beam(1) -W beam(N) are calculated from designated beam direction θbeam and null directions θnull( 1 ), . . . , null(M) by the antenna weight calculator 5 .
[0034] The signal processor 4 including the multipliers 9 . 1 - 9 .N and the antenna weight calculator 5 is implemented by a digital signal processor on which an antenna weight calculation program is running, which will be described later.
[0035] In the above circuit, when the transmission data enters the signal processor 4 , the multipliers 9 . 1 - 9 .N multiply the transmission data by respective ones of the antenna weights W beam(1) -W beam(N) generated by the antenna weight calculator 5 . In this way, N weighted streams of transmission data are converted from digital to analog by the D/A converters 3 . 1 - 3 .N, respectively. The respective analog transmission signals are transmitted by the transmitters 2 . 1 - 2 .N through the antenna elements 1 . 1 - 1 .N.
[0036] Antenna weight calculation (1)
[0037] Referring to FIG. 3, a beam forming direction θbeam and null forming directions θnull( 1 ),. .., θnull (M) are inputted to the antenna weight calculator 5 (step S 101 ). Here, M is the number of nulls whose directions are designated and M is restricted to N−2 or less.
[0038] When inputting these directions, the antenna weight calculator 5 calculates an antenna weight vector W beam to be assigned to a (N−M)-element array antenna having the beam forming direction θbeam using the following expressions (1)-(4):
W beam =[w beam(1) , . . . , w beam(N−M) ] (1),
δ w beam =exp{− j·k·d ·sin(θbeam)} (2),
w beam(1) =1 (3),
[0039] and
w beam(i) =w beam(i−1) ·δw beam : i= 2, 3, . . . , N−M (4),
[0040] where d is a distance between antenna elements, k is propagation constant of free space (k=2π/λ), λ is wavelength in free space (step S 102 ). Thereafter,
W pattern =W beam (5)
[0041] and m=1 (steps S 103 , S 104 ) and the following steps S 105 -S 109 are repeatedly performed until m=M, where m=1, 2, . . . , M.
[0042] Step S 105 .
[0043] An antenna weight W null(m) for a 2-element array antenna forming null in the direction θnull(m) is calculated by the following expressions (6)-(9):
W null(m) =[w null — 1(m) , w null — 2(m)] (6),
δ w null(m) =−exp{− j·k·d ·sin(θnull( m ))} (7),
w null — 1(m) =l (8),
[0044] and
w null_ 2 ( m ) = w null_ 1 ( m ) · δw null ( m ) = - exp { - j · k · d · sin ( θ null ( m ) ) } . ( 9 )
[0045] Step S 106 :
[0046] Using W pattern and W null(m) , two antenna weight vectors W beam1 and W beam2 for a (N−M)-element array antenna are calculated by the following expressions (10) and (11):
W beam1 =w null — 1(m) ·W pattern =1· W pattern (10);
[0047] and
w beam2 = w null_ 2 ( m ) · w pattern = exp { - j · k · d · cos ( θ null ( m ) ) } · w pattern . ( 11 )
[0048] Step S 107 :
[0049] Appending 0 to the trail end of W beam1 and to the head of W beam2 , antenna weight vectors for the (N−M+1)-element array antenna are calculated and added to produce W pattern using the following expression:
W pattern ={W beam1 , 0]+[0, W beam2 (12 )
[0050] Thereafter, m is incremented (step S 108 ) and it is determined whether m=M (step S 109 ). If m does not reach M (NO in step S 109 ), control goes back to the step S 105 and the steps S 105 -S 108 are repeated until m=M.
[0051] In this manner, a final antenna weight vector W pattern =[W beam(1) , . . . , W beam(n) ] is obtained and these antenna weights are output to respective ones of the multipliers 9 . 1 - 9 .N. In other words, each of the beam and null directions is designated by a single complex weight and these complex weights are only multiplied and added to produce a final antenna pattern having the designated beam direction θbeam and null directions θnull( 1 ), . . . , θnull (M), resulting in decreased amount of computation.
EXAMPLE
[0052] As an example, the case of N=6 and M=3 will be described below. In this example, a single beam directionθ beam and three null directions θnull( 1 ), θnull( 2 ) and θnull( 3 ) are designated in a 6-element array antenna system.
[0053] Since N−M=3, as shown in FIG. 4( a ), an antenna weight vector W beam0 , of a 3-element array antenna having the beam direction θbeam is first calculated by the expressions (1)-(4).
[0054] Subsequently, the expressions (6)-(9) are first used to calculate an antenna weight vector W null(1) of a 2-element array antenna forming null in the direction θnull( 1 ). Using this W null(1) and the above W beam0 , two antenna weight vectors W beam3(1) and W beam2(1) for the 3-element array antenna are calculated according to the expressions (10) and (11). By appending 0 to the trail end of W beam(1) and to the head of W beam2(1) , two antenna weight vectors for a 4-element array antenna are calculated and added to produce W pattern(1) using the expression (12) as shown in FIG. 4( b ).
[0055] Similarly, the expressions (6)-(9) are used to calculate an antenna weight vector W null(2) of a 2-element array antenna forming null in the direction θnull( 2 ). rising this W null(2) and the above W pattern(1) , two antenna weight vectors W beam1(2) and W beam2(2) for the 4-element array antenna are calculated according to the expressions (10) and (11). By appending 0 to the trail end of W beam1(2) and to the head of W beam2(2) , two antenna weight vectors for a 5-element array antenna are calculated and added to produce W pattern(2) using the expression (12) as shown in FIG. 4( c ).
[0056] Since m does not reach M=3, the expressions (6)-(9) are similarly used to calculate an antenna weight vector W null(3) of a 2-element array antenna forming null in the direction θnull ( 3 ). Using this W null(3) and the above W pattern(2) , two antenna weight vectors W beam(3) and W beam(3) for the 5-element array antenna are calculated according to the expressions (10) and (11) By appending 0 to the trail end of W beam(3) and to the head of W beam2(3) , two antenna weight vectors for a 6-element array antenna are calculated and added to produce W pattern(3) using the expression (12) as shown in FIG. 4( d ).
[0057] In this manner, the final antenna weight vector W pattern(3) =[W beam(1) , . . . , W beam(6) ] is obtained and these antenna weights W beam(1) , . . . , W beam(6) are output to respective ones of the multipliers 9 . 1 - 9 . 6 and thereby amplitude and phase of transmission data are controlled Accordingly, a single beam having the designated beam direction θbeam and three nulls having the directions θnull( 1 ), θnull( 2 ) and θnull( 3 ) can be obtained without inverse-matrix calculation. In this example, three complex weights W null(1) , W null(2) , W null(3) are used to designate the respective null directions.
[0058] FIGS. 5 A- 5 D show antenna patterns corresponding to the respective stages of 3-element, 4-element, 5-element, and 6-element array antennas as shown in FIG. 4( a ), 4 ( b ), 4 ( c ), and 4 ( d ). In FIGS. 5 A- 5 D, dashed lines denote an antenna pattern corresponding to the expression (6) and solid lines denote an antenna pattern corresponding to the expressions (5) and (12).
[0059] In this manner, a final complex antenna weight W pattern =[W bean(1) , . . . , W beam(6) ] is obtained and these antenna weights are output to respective ones of the multipliers 9 . 1 - 9 . 6 . In other words, each of the beam and null directions is designated by a single complex weight and these complex weights are only multiplied and added to produce a final antenna pattern having the designated beam direction 6 beam and null directions θnull( 1 ), θnull( 2 ) and θnull( 3 ). Accordingly, there is no need of inverse-matrix computation, resulting in decreased amount of calculation.
[0060] Antenna weight calculation (2)
[0061] A second embodiment of the present invention will he described with reference to FIG. 6. In the second embodiment, only null directions θnull( 1 ), . . . , θnull(M) are designated to produce antenna weights forming a designated null direction.
[0062] Referring to FIG. 6, the null forming directions θnull( 1 ), . . . , θnull(M) are inputted to the antenna weight calculator 5 (step S 201 ). Here, M is the number of nulls whose directions are designated and M is restricted to N−1 or less.
[0063] Thereafter, an arbitrary antenna weight vector W beam to be assigned to a (N−M)-element array antenna as represented by the following expression (13):
W beam =[W beam(1) , . . . , W beam(N−M) ] (13)
[0064] (step S 202 ). Thereafter, W pattern =W beam and m=1 (steps S 203 , S 204 ) and the following steps S 205 -S 209 are repeatedly performed until m=M, where m=1, 2, . . . , M.
[0065] Step S 205 :
[0066] An antenna weight W null(m) for a 2-element array antenna forming null in the direction θnull(m) is calculated by the following expressions (14)-(17):
W null(m) =[w null —1(m), w null — 2(m) ] (14),
δ w null(m) =exp{− j·k·d ·cos(θnull(m))} (15)
w null 13 1(m) =1 (16),
[0067] and
W null_ 2 ( m ) = W null_ 1 ( m ) ′ δW null ( m ) = exp { - j · k · d · cos ( θ null ( m ) ) } . ( 17 )
[0068] Step S 206 :
[0069] Using W pattern and W null(m) , two antenna weight vectors W beam1 and W beam2 for a (N−M)-element array antenna are calculated by the following expressions (18) and (19):
W beam1 =w null — 1(m) ·W pattern =l·W pattern (18);
[0070] and
W beam2 = W null_ 2 ( m ) · W pattern = exp { - j · k · d · cos ( θ null ( m ) ) } · W pattern . ( 19 )
[0071] Step S 207 :
[0072] Appending 0 to the trail end of W beam1 to the head of W beam2 , antenna weight vectors for the (N−M+1)-element array antenna are calculated and added to produce W pattern using the following expression:
W pattern =[W beam1 , 0]+[0, W beam2 ] (20)
[0073] Thereafter, m is incremented (step S 208 ) and it is determined whether m=M (step S 209 ). If m does not reach M (NO in step S 209 ), control goes back to the step S 205 and the steps S 205 -S 208 are repeated until m=M.
[0074] In this manner, a final antenna weight vector W pattern =[W bean(1) , . . . , W beam(N) ] is obtained and these antenna weights are output to respective ones of the multipliers 9 . 1 - 9 N. In other words, each of the beam and null directions is designated by a single complex weight and these complex weights are only multiplied and added to produce a final antenna pattern having the designated null directions θnull( 1 ), . . . , θnull(M), resulting in decreased amount of computation.
[0075] Referring to FIG. 7, an array antenna is composed of N antenna elements 1 . 1 - 1 .N, which are spaced uniformly and aligned in a line. The respective antenna elements 1 . 1 - 1 .N are connected to N receivers 6 . 1 - 6 .N, which are in turn connected to a signal processor 8 through N analog-to-digital (A/D) converters 7 . 1 - 7 .N.
[0076] The signal processor 8 includes N multipliers 9 . 1 - 9 .N, an antenna weight calculator 5 , and a combiner 10 . The multipliers 9 . 1 - 9 .N connects the A/D converters 7 . 1 - 7 .N and the combiner 10 and assign antenna weights W beam(1) -W beam(N) to respective ones of received data streams, respectively. The antenna weights W beam(1) -W beam(N) are calculated from designated beam direction θbeam and null directions θnull( 1 ), . . . , θnull (M) by the antenna weight calculator 5 . The antenna weight calculation method is the same as that of the first embodiment and therefore the details are omitted.
[0077] The signal processor 8 including the multipliers 9 . 1 - 9 .N and the antenna weight calculator 5 is implemented by a digital signal processor on which the antenna weight calculation program is running.
[0078] In the above circuit, N received signals by the N receivers 6 . 1 - 6 .N through the N antenna elements 1 . 1 - 1 .N are converted from analog to digital by the N A/D converters 7 . 1 - 7 .N, respectively. The respective received data streams are weighed by the multipliers 9 . 1 - 9 .N according to the antenna weights W bean(1) -W beam(N) . The weighted received data streams are combined by the combiner 10 to produce received data.
[0079] As described above, according to the present invention, antenna weights forming a designated beam null direction pattern can be obtained without the need of calculating an inverse matrix, resulting in dramatically reduced amount of computation.
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A null direction control method allows optimum antenna weights forming designated null beam directions without calculating an inverse matrix. In an N-element array antenna, a designated null beam antenna pattern is obtained by processing a 2-element antenna weight vector forming a null in a sequentially selected one of M designated null directions and a (N−M) -element antenna weight vector forming a beam in a designated beam direction to produce an antenna weight vector for the N-element array antenna. The final antenna weight vector is calculated by incrementing the number of elements of a work antenna weight vector each time a null is formed in a sequentially selected one of the M designated null directions.
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This application is the U.S. national phase of International Application No. PCT/EP2012/055641, filed 29 Mar. 2012, which designated the U.S. and claims priority to Europe Application No. 11160492.2, filed 30 Mar. 2011, the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a downhole tool extending in a longitudinal direction, comprising a tool housing; an arm assembly movable between a retracted position and a projecting position in relation to the tool housing; and an arm activation assembly for moving the arm assembly between the retracted position and the projecting position. Furthermore, the invention relates to a downhole system.
BACKGROUND ART
Downhole tools are used for operations inside boreholes of oil and gas wells. Downhole tools operate in a very harsh environment and must be able to withstand inter alia corroding fluids, high temperatures and high pressure.
To avoid unnecessary and expensive disturbances in the production of oil and gas, the tools deployed downhole have to be reliable and easy to remove from the well in case of a breakdown. Tools are often deployed at great depths several kilometers down the well, and removing jammed tools are therefore a costly and time-consuming operation.
Well tools are often part of a larger tool string containing tools with different functionalities. A tool string may comprise both transportation tools for transporting the tool string in the well and operational tools for performing various operations downhole, e.g. centralising tools for centralising the tool or tool string in the borehole, driving units for moving the tool or tool string in the borehole and anchoring tools for anchoring the tool or tool string in the borehole.
The use of tools and/or units with extracting members for engaging the borehole wall has potential risk of jamming in the borehole in case of a breakdown. Extreme conditions such as very high pressures, high temperatures and an acidic environment therefore place high demands on mechanical mechanisms in downhole tools.
The above often results in a minimum use of such tools downhole to avoid unwanted breaks in production times. Therefore, a need exists for downhole tools that are relatively fail-safe and thus extractable from the borehole, also in case of a breakdown.
SUMMARY OF THE INVENTION
It is an object of the present invention to wholly or partly overcome the above disadvantages and drawbacks of the prior art. More specifically, it is an object to provide an improved downhole tool wherein a spring member ensures a fail-safe retraction of extracting members of the downhole tool.
The above objects, together with numerous other objects, advantages, and features, which will become evident from the below description, are accomplished by a solution in accordance with the present invention by a downhole tool extending in a longitudinal direction, comprising:
a tool housing, an arm assembly movable between a retracted position and a projecting position in relation to the tool housing, and an arm activation assembly for moving the arm assembly between the retracted position and the projecting position,
wherein the arm activation assembly comprises:
a piston housing comprising a piston chamber, said piston chamber extending in the longitudinal direction of the downhole tool, a piston member arranged inside the piston chamber and engaged with the arm assembly to move the arm assembly between the retracted position and the projecting position, the piston member being movable in the longitudinal direction of the downhole tool and having a first piston face and a second piston face, the piston member being able to apply a projecting force on the arm assembly by applying a hydraulic pressure on the first piston face moving the piston in a first direction, and a spring member applying a spring force to move the piston in a second direction opposite the first direction.
In one embodiment, the arm activation assembly may comprise a fluid channel and the hydraulic pressure may be applied to the first piston face with a pressurised hydraulic fluid such as oil through the fluid channel.
In another embodiment, the spring member may be arranged in a spring chamber and the piston may be arranged in a piston chamber.
Said piston housing may comprise a recess for receiving part of the shaft when the piston moves.
Moreover, the shaft may extend in the piston chamber and into the spring chamber.
Further, the piston member may divide the piston housing into a first and a second section, the first section being filled with fluid for moving the piston member.
The downhole tool according to the invention may further comprise a pump for pressurising the pressurised hydraulic fluid for moving the piston in the first direction.
Additionally, the downhole tool according to the invention may comprise an electrical motor for driving the pump.
In one embodiment, the downhole tool may be connected with a wireline and the electrical motor may be powered through the wireline.
Also, the downhole tool may comprise several arm assemblies and arm activation assemblies and each of the arm assemblies may be moved by one of the arm activation assemblies.
Additionally, the piston chamber and spring chamber may be arranged substantially end-to-end in the longitudinal direction of the tool.
The piston chamber and the spring chamber may be arranged substantially side-by-side in the longitudinal direction of the tool.
In one embodiment, the downhole tool according to the invention may further comprise a control member arranged inside a coil of the spring.
In another embodiment, the piston may comprise a distal part with a reduced diameter engageable with the spring member.
Said spring member may be is a coil spring, a helical spring, a bellows, a volute spring, a leaf spring, a gas spring or a disc spring.
The downhole tool according to the invention may further comprise electrical sensors for monitoring a pressure on the first piston face for producing a feedback signal to a control system.
Moreover, the downhole tool according to the invention may comprise electrical sensors for monitoring a position of the piston member for producing a feedback signal to a control system.
The above-mentioned spring member may be preloaded before being compressed by the piston during application of the hydraulic pressure on the first piston face moving the piston in a first direction.
Also, the piston member may be connected with the arm assembly using a worm shaft, a crank arm or a rack or a pivot joint or a recess in the piston member.
The present invention also relates to a downhole system, comprising:
a wireline, a mating tool such as a driving unit and/or an operational tool, and a downhole tool as described above.
Further, the arm activation assembly of the downhole tool as described above may comprise a crank arm, meaning that when the piston member is moved back and forth in the longitudinal direction of the piston chamber, the piston member will move the crank arm, and when the crank arm is moved, a crank shaft is rotated around a rotation axis, and hence the arm assembly being connected to the crank shaft is moved between a retracted position and a projecting position, and wherein a force arm distance between the rotation axis of the crank arm and a point of contact between the crank arm and the piston member may be longer in the retracted position than in the projecting position, meaning that a resulting projecting force applied to the arm assembly by the arm activation assembly is decreasing from a high resulting projection force in the retracted position towards a lower resulting projection force in the projecting position.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which
FIG. 1 shows a cross-sectional view of an arm activation assembly,
FIG. 2 shows a cross-sectional view of an arm activation assembly in a projecting position,
FIG. 3 shows a cross-sectional view of an arm activation assembly in a retracted position,
FIG. 4 shows a cross-sectional view of another embodiment of the arm activation assembly,
FIG. 5 shows a cross-sectional view of another embodiment of the arm activation assembly,
FIG. 6 shows, for illustrative purposes, a top view of part of a downhole tool with one arm assembly in a projecting position and another arm assembly in a retracted position,
FIG. 7 shows, for illustrative purposes, a top view of part of a downhole tool with one arm assembly in a projecting position and another arm assembly in a retracted position, wherein the arm assemblies comprise a wheel,
FIG. 8 shows a downhole system comprising an arm activation assembly for moving an arm assembly in a driving section,
FIG. 9 shows a tool string comprising an arm activation assembly for moving an arm assembly in a driving section.
FIG. 10 shows a cross-sectional view of an arm activation assembly,
FIG. 11 shows a cross-sectional view of an arm activation assembly,
FIG. 12 shows a cross-sectional view of an arm activation assembly,
FIG. 13 a shows a cross-sectional view of an arm activation assembly in a retracted position,
FIG. 13 b shows a cross-sectional view of an arm activation assembly in a projecting position,
FIG. 14 a shows a perspective view of an arm activation assembly and an arm assembly in a retracted position, and
FIG. 14 b shows a perspective view of an arm activation assembly and an arm assembly in a projecting position.
All the figures are highly schematic and not necessarily to scale, and they show only those parts which are necessary in order to elucidate the invention, other parts being omitted or merely suggested.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an arm activation assembly 40 for moving an arm assembly 60 which is shown in FIG. 6 between a retracted position and a projecting position. The arm activation assembly 40 is arranged in a tool housing 54 of a downhole tool being part of a tool string 10 . An example of such tool string is shown in FIG. 8 . The arm activation assembly 40 comprises a piston housing 41 , a piston chamber 42 extending in a longitudinal direction of the downhole tool. A piston member 47 is arranged inside the piston chamber and the piston member is engaged with the arm assembly. When the piston member 47 is moved back and forth in the longitudinal direction of the piston chamber, the piston member will move a crank arm 72 of an engaging crank 70 . When moving the crank arm 72 , a crank shaft 71 is rotated around a rotation axis 32 , and hence the arm assembly is moved between a retracted position and a projecting position. The crank 70 connects the piston member 47 with the arm assembly converting a transverse motion of the piston member to a rotation force acting on the arm assembly. In an arm activation assembly of the downhole tool, the arm assembly may be directly connected with a piston member 47 . As shown in the drawings, the crank arm is connected with the piston member by the crank arm being arranged in a recess in the piston member and engaging the piston member by engaging means 83 . The crank arm may, however, be connected to the piston member in any suitable way known to the person skilled, such as by using a rack also known as a toothed rack or gear-rack, or a worm shaft or a sliding pivot joint.
The piston member is dividing the piston chamber into a first section 42 a and a second section 42 b , the first section being in fluid communication with an activation fluid channel 80 . A hydraulic fluid such as oil may be injected through the fluid channel 80 into the first section 42 a of the chamber 42 , thereby applying a hydraulic pressure on a first piston face 48 of the piston member 47 . A spring member 44 is arranged in the second section 42 b of the chamber between a second piston face 49 of the piston member and a distal end face 42 d of the piston chamber. The spring member 44 applies a spring force to the second piston face 49 . The hydraulic fluid moves the piston in a first direction, and the spring member 44 moves the piston in a second direction opposite the first direction.
As shown, the arm activation assembly in FIG. 1 has the piston member 47 which may comprise a piston part 47 a and a piston shaft part 47 b . As shown, the spring member may then circumscribe the piston shaft part in such a way that the travel of the spring member 44 during compression and decompression is well controlled. Furthermore, the piston shaft part may engage a recess 82 in the piston housing 41 to further improve control of the travel of the piston member within the piston chamber. The control of the travel of the piston member is improved since a distal end of the piston shaft part abuts the walls of the recess during travel of the piston. The piston comprises a distal part 81 with a reduced diameter engageable with the spring member. Furthermore, the piston member may be connected with the arm assembly using a worm shaft, a rack or a pivot joint or a recess 471 in the piston member.
FIG. 2 shows the arm activation assembly in a projecting position. When the arm assembly needs to be projecting during downhole operations, a hydraulic pressure is applied to the first piston face 48 of the piston member 47 by pressurising a hydraulic fluid in the first section 42 a of the piston chamber 42 . When the hydraulic pressure is applied to the first piston face, the piston member moves towards the distal end face 42 d of the piston chamber, thereby compressing the spring member 44 . In order for the hydraulic pressure to move the piston member and thereby the arm activation assembly to the projecting position, the hydraulic pressure must exceed a spring force applied by the spring member 44 on the second piston face 49 and additional frictional forces stemming from the travel of the piston member in the piston chamber. Furthermore, the movement of the piston member results in a movement of the crank arm 72 since the piston member engages the crank arm. When the crank arm is moved in the longitudinal direction of the piston chamber towards the distal end face 42 d , the crank shaft 71 will rotate around the rotation axis 32 of the crank 70 .
FIG. 3 shows the arm activation assembly in a retracted position. When the arm assembly needs to be retracted during downhole operations, the hydraulic pressure, which during projection was applied to a first piston face 48 of the piston member 47 by pressurising a hydraulic fluid in the first section, is then removed. When the hydraulic pressure is removed from the first section, the hydraulic pressure will no longer exceed the spring force applied by the spring member on the second piston face, and the piston member will therefore begin to move towards the distal end face 42 c of the piston chamber forced by the spring member, thereby decompressing the spring member. In case of unintentional drops of hydraulic pressure in the first section of the chamber, the spring member acts as a fail-safe so that the tool can always be retracted from the well.
When working with downhole operations, jamming of downhole tools in a borehole is one of the most aggravating problems, which may cause downtime in the production, and even worse it may shut down a borehole if the jammed downhole tool cannot subsequently be removed. If the hydraulic pressure in the first section is lost, the arm activation assembly 40 will always move to a retracted position due to the spring member 44 . Being unable to project the arm assembly with the arm activation assembly is of course inexpedient but it is not critical to the downhole operation since the tool string is merely retracted to the surface by a wireline 9 via a top connector 13 or a coiled tubing 9 connecting the tool string to the surface (shown in FIG. 8 ). Furthermore, a downhole tool may comprise several arm assemblies and if one does not project, others will.
In FIG. 3 , the arm activation assembly 40 further comprises preloading means 85 for preloading the spring member 44 . The preloading means allows assembly of the arm activation assembly with an uncompressed spring member 44 , where the spring member then, subsequent to the assembly of the arm activation assembly, can be preloaded using the preloading means. The preloading means may comprise a screw 85 a or a plurality of screws 85 a and a washer 85 b . Apart from making the assembly of the arm activation assembly more convenient, the preloading means may furthermore allow the user to preload, i.e. compress, the spring member to a certain degree to accommodate for certain requirements to the retraction mechanism of the arm activation assembly. An example of a situation demanding a high retraction force may be if the arm assembly has been used to anchor the tool string in a production casing or the borehole and therefore is sticking to the surface of the production casing or wall of the borehole. On the other hand, a lower retraction force may be needed if for example the arm assembly is used for wheels 62 in a driving section 11 (see FIG. 7 ). The retracting force in this situation may not necessarily have to be very high, and a low retraction force exerted by the spring member 44 may be more appropriate for providing a slower retraction of the wheels.
In the arm activation assembly shown in FIG. 4 , the spring member is arranged in a spring chamber 42 a and the piston is arranged in a piston chamber 42 . The mounting of springs during production and/or maintenance of separable equipment including springs present a potential risk to the user. Therefore, enclosure of the spring member in a separate chamber may be advantageous to the handling and maintenance of such equipment, especially in a case where a very high preloading force of the spring is required.
When the spring member is arranged in a separate chamber such as shown in FIG. 4 and FIG. 5 , the spring force from the spring member still has to be capable of engaging the piston member in the piston chamber. In one embodiment, the piston shaft part may enter the spring chamber 42 a through a connection hole between the piston chamber and the spring chamber such as shown in FIG. 4 . Alternatively, the engagement of the piston member and the spring member may be facilitated by an intermediate piston member 86 sealing off the spring chamber as shown in FIG. 5 .
FIG. 6 is an illustration of a part of the downhole tool with one arm assembly in a projecting position and another arm assembly in a retracted position. During downhole operations the arm assemblies of the downhole tool would typically all be in a projecting or a retracted position. The arm assembly may be used for several purposes during downhole operations such as tool centralising in the borehole 4 in a formation 2 or inside a production casing 6 . Furthermore, an arm assembly may be used for anchoring, e.g. to ensure weight on bit during horizontal drilling, during downhole stroking or during operations perforating the production casing when setting up production zones.
The crank shaft may be connected to the arm member 61 by means such as a toothed crank shaft pattern mating with a similar pattern (not shown) in a bore in the arm member. The crank shaft and the arm member hereby interlock whereby the rotation force is transferred from the crank shaft to arm member.
FIG. 7 is another illustration of a part of the downhole tool with one arm assembly in the projecting position and another arm assembly in a retracted position. The arm assembly comprises an arm member and furthermore a wheel 62 for driving the tool string during downhole operations. An arm member 61 of the arm assembly 60 is seen in the left side of FIG. 7 in the projecting position and in this situation engaging an inner wall of a production casing 6 . Furthermore, it is shown in FIG. 7 that an elongate axis of the arm member 61 has a projection angle A 1 of less than ninety degrees with respect to the longitudinal axis of the tool string. In this way, the retraction of the arm assembly will not have a barbing function when pulling the wireline 9 or coiled tubing 9 . Pulling the wireline or coiled tubing will therefore contribute to the retraction of the arm assembly if the projection angle is less than ninety degrees. As shown in FIG. 7 , the crank shaft 71 is arranged away from a centre axis of the arm assembly. The intention is to be able to reach as far as possible away from the tool string, thereby being able to operate with larger casings.
The number of driving units 11 and/or the number of wheels 62 in a tool string may be varied depending on the required pulling force, e.g. high pulling force is required when operating a heavy tool string. Therefore, a number of arm activation assemblies and arm assemblies may be arranged in a driving unit and/or more than one driving unit may be arranged in the tool string.
The downhole tool string 10 shown in FIG. 8 comprises an electrical motor 17 for moving a hydraulic pump 18 . The hydraulic pump 18 may be used to generate a pressurised hydraulic fluid. The driving unit 11 is connected with a compensating device 20 for compensating the pressure within the driving unit so that a high pressure difference between the fluid surrounding the tool string 10 and the inside of the tool string 10 , e.g. the inside of the driving unit, does not result in the driving unit housing bulging outwards or collapsing inwards. The driving unit 11 may furthermore be connected with an operational tool 12 through a connector 14 . The pressurised fluid may be injected through the fluid channel 80 and into the first section of the chamber to project the arm assembly by means of the arm activation assembly. The electric motor 17 may be powered from the surface by a wireline 9 , or alternatively the electric motor may be powered by batteries (not shown) arranged in the tool string. During coiled tubing operations well-known to any person skilled in the art, the hydraulic pump may be replaced by a hydraulic pump at the surface generating a pressurised fluid at the surface which is pumped through a coiled tubing 9 to the downhole tool string. Coiled tubing operations are typically limited to smaller depths of boreholes due to the weight of the coiled tubing. At very large depths and in horizontal parts of the well, wireline operations are therefore more appropriate than coiled tubing operations.
The shown tool string comprises a downhole tool in the form of a driving unit 11 for moving the tool string forward downhole. The downhole tool extends in a longitudinal direction and comprises a tool housing, arm assemblies and arm activation assemblies. The tool string shown in FIG. 9 is moved forward by several wheels projecting towards the casing or side walls of the well. The wheels are mounted on the arm member 61 in such a way that they can be moved between a retracted position and a projecting position. When the wheels turn, the tool string is moved forward deeper into the hole, and typically the wireline or the coiled tubing is used to retract the tool string back towards the surface, since it is faster than using downhole propagation means such as the driving unit.
FIGS. 10-12 show cross-sectional views of the arm activation assembly 40 in a retracted position (see FIG. 10 ), in an intermediate position (see FIG. 11 ) and in a projecting position (see FIG. 12 ). As shown in FIGS. 10-12 , the spring member may be arranged in a different chamber than the piston member 47 . In order to minimise the use of space in the downhole tool in the longitudinal direction, the spring member may be arranged substantially side-by-side the piston member 47 (see FIGS. 13 a and 13 b ) instead of substantially end-to-end (see FIGS. 1-5 ). If the spring member and piston member 47 are arranged side-by-side, the spring member may apply a retracting force to the crank arm 72 by an intermediate member 45 . Alternatively, the spring member may apply a retracting force directly to the arm assembly (not shown).
As shown in FIGS. 10-12 , the distance D 1 , D 2 , D 3 between the rotation axis 32 and a point of contact between the crank arm 72 and the piston member 47 is preferably longer in the retracted position than in the projecting position, meaning that a resulting projecting force applied to the arm assembly by the arm activation assembly 40 is decreasing from a high resulting projection force in the retracted position towards a lower resulting projection force in the projecting position. This decreasing resulting projecting force ensures that the tool string is well centralised in the production casing during projection of the arm assembly, i.e. the further out the arm assembly is projecting, the smaller the resulting projecting force is. This means that the resulting force will always be highest on the parts of the arm assembly which are less projecting, thereby always ensuring that the tool string will automatically be well centralised in the production casing or well bore.
FIG. 13 a shows a cross-sectional view of an arm activation assembly 40 in a retracted position, where the piston member 47 and spring member 44 are arranged substantially side-by-side in the longitudinal direction of the tool string. As seen, this may save space in the longitudinal direction. In embodiments where the spring member 44 is not arranged in direct contact with the piston member 47 , an intermediate member 45 , such as the one shown in FIGS. 13 a , 13 b , 14 a and 14 b , may be arranged between the piston member 47 and spring member 44 . Thereby the spring member 44 is still allowed to apply the spring force opposite the projection force of the piston member to provide fail-safe retraction of the arm assembly 60 . FIG. 13 b shows a cross-sectional view of the arm activation assembly 40 of FIG. 13 a in a projecting position. FIGS. 14 a and 14 b show perspective views of the downhole tool shown in FIGS. 13 a and 13 b , also in a retracted and projecting position, respectively. As shown in FIGS. 14 a and 14 b , the spring member 44 is not required to be arranged in a confined chamber as long as the spring force acts opposite the projecting force so that the arm assembly 60 is retracted if hydraulic pressure on the piston member 47 is lost, ensuring a fail-safe retraction mechanism independent of hydraulic pressure in the tool.
The fluid transferred into the first section of the chamber may be branched out through other fluid channels to reach an adjacent arm activation assembly (not shown) in a driving unit. The arm activation assembly may thus comprise an integrated fluid circuit in the form of fluid channels provided in the walls of the piston housing. Several activation assemblies may then be combined to provide a larger fluid circuit without the need of external piping connecting the individual activation assemblies. Fluid channels of subsequent piston houses are joined by connectors (not shown) creating tight fluid joints.
The spring member 44 may be any type member exerting a spring force on the second piston face 49 such as a coil spring, helical spring, bellow, volute spring, leaf spring, gas spring or disc spring. The spring type may be used for designing an appropriate spring force exerted on the piston member such as a constant spring force or a spring force that increases during projection of the arm assembly, so that the highest spring force is obtained at the outermost position of the arm assembly.
By introducing intelligent sensors 84 (shown in FIG. 1 ) such as pressure gauges, switches for determining position of the piston member 47 and/or crank arm 72 , feedback signals may be fed back to the user and/or to controlling electronics 15 , 16 in the tool string (shown in FIG. 8 ).
Although the invention has been described in the above in connection with preferred embodiments of the invention, it will be evident for a person skilled in the art that several modifications are conceivable without departing from the invention as defined by the following claims.
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The present invention relates to a downhole tool extending in a longitudinal direction, comprising a tool housing; an arm assembly movable between a retracted position and a projecting position in relation to the tool housing; an arm activation assembly for moving the arm assembly between the retracted position and the projecting position; wherein the arm activation assembly comprises: a piston housing comprising a piston chamber, said piston chamber extending in the longitudinal direction of the downhole tool, a piston member arranged inside the piston chamber and engaged with the arm assembly to move the arm assembly between the retracted position and the projecting position, the piston member being movable in the longitudinal direction of the downhole tool and having a first piston face and a second piston face, the piston member being able to apply a projecting force on the arm assembly by applying a hydraulic pressure on the first piston face moving the piston in a first direction, and a spring member applying a spring force to move the piston in a second direction opposite the first direction. Furthermore, the invention relates to a downhole system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to locks and more specifically to locks finding particular but not exclusive utility for bicycles. More particularly, the present invention pertains to an improved cable lock and bracket for securing a cable lock to a bicycle both for storage and to secure the bicycle to a fixed object.
2. Discussion of the Prior Art
Bicycle locks include two primary types of locks. The first is a solid U-shaped padlock-type lock such as is manufactured by Kryptonite, under the name Kryptonite Locks. The U-shaped portion or shackle is typically made of hardened steel. The lock is carried on the bicycle in a holder or bracket.
A second common type of bicycle lock is a cable lock. The cable is usually composed of twisted strands of steel wire encased in a plastic or rubber cover. The cable is normally coiled for convenience of storage. One end of the cable is permanently fixed to a lock body or casing. The second end of the cable includes a locking pin, or bolt or tip, which may be attached into and removed from the lock body when the locking mechanism is activated or deactivated. The locking mechanism typically includes a key operated lock, although some cable lock devices utilize a combination lock.
Various brackets exist in the bicycle market for both types of locks. These brackets are conventionally attached to the bicycle frame by a bolt. In such devices, securing the lock to the bracket does not secure the lock to the bicycle frame. For this reason, the lock must be removed from the bracket and the shackle or cable threaded through the bicycle frame to secure the lock to the frame and, in turn, to secure the bicycle frame to a permanent object. Furthermore, since the lock body is not retained by the bracket when the lock is disengaged, the bicycle rider normally holds the lock body while threading the cable through the frame and around the permanent object. Accordingly, the object of this invention is to provide an improved and convenient apparatus and method for securing bicycles with cable locks.
SUMMARY OF THE INVENTION
The present invention is embodied in an improved cable lock bracket which may be secured to a support such as a frame tube of a bicycle or to an external tubular support. The bracket, when secured to both the bicycle and the cable lock, prevents the cable lock and bracket from being removed from the bicycle. The bracket comprises an elongated metal strap having first and second ends wherein the strap is folded into a loop which can be passed around the bicycle frame tube so that the first and second ends of the strap overlap in juxtaposed relation. The first and second ends of the strap have formed therein first and second apertures, respectively, which are substantially aligned so that the cable may be inserted therethrough and into the lock body, thereby securing the lock to the bracket and hence to the bicycle frame.
Another aspect of the present invention allows the cable lock to be used to secure the bicycle frame to a stationary object by placing the cable around or through the stationary object and reinserting the cable, through the bracket, into the cable lock body.
Another aspect of the present invention involves fitting a lock casing of a cable lock within the encircled strap between the bicycle frame tube and the strap. A receptacle on the lock casing is held in substantial alignment with the aligned openings of the strap to allow a bolt or tip on the end of the lock cable to be inserted through the openings and into the receptacle of the lock casing thus securing the two ends of the strap together and thereby securing the strap and lock to the bicycle.
Other aspects, features and details of the present invention can be more completely understood by reference to the following detailed description of the preferred embodiment, taken in conjunction with the drawings, and from the appended claims.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a bicycle having a cable lock and a lock bracket embodying the present invention mounted thereon.
FIG. 2 is an enlarged partial view of a bicycle frame with the cable lock and lock bracket of the present invention mounted thereon.
FIG. 3 is an enlarged partial view of the present invention installed on a bicycle frame tube with a cable lock retained therein.
FIG. 4 is a sectional view of the present invention taken substantially in the plane of line 4--4 on FIG. 3.
FIG. 5 is an enlarged sectional view of the present invention taken substantially in the plane of line 5--5 on FIG. 3.
FIG. 6 is an exploded view of the bracket embodying the present invention and a partial view of the cable lock associated therewith.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The bicycle lock and bracket assembly 10 embodying the present invention is shown in FIG. 1 in its preferred location on a bicycle 20. The bicycle 20 conventionally includes a frame 22, a front wheel 24, a rear wheel 26, a seat 28, a handle bar 30, a pedal and crank assembly 31, and a chain 32. The lock and bracket assembly 10 utilizes a standard cable lock 33 mounted on a unique bracket 34 and the assembly attached to a bicycle or support for either convenient storage or securing the bicycle to a stationary object 35 (FIG. 2). The stationary object 35 may be a tree, a light pole, a fence or any type of bike rack.
Bike racks for securing parked bikes come in all shapes and sizes and although they are often movable, they are heavy and awkward to move. For the purpose of securing a bicycle these bike racks are sufficiently immovable. Of course, any other heavy, fixed object may also be sufficient to secure a bicycle if the object will permit the standard cable lock 33 to pass around or through it. The previously mentioned bike racks may contain a series of metal bars or other sections which permit the cable lock 33 to pass through the rack and secure the lock thereto.
The cable lock 33 includes a lock casing or body 36 and a cable 38 (FIGS. 2-6). The cable has a first end 40 which is fixed to the lock body 36 and a second end with a bolt or tip 42 which is removably attachable to the lock body by a locking mechanism 44 (FIG. 5). Typically located on the lock body is a key receptacle 46 into which a key (not shown) may be placed to deactivate the locking mechanism to open the lock. The key and key receptacle 38 can be referred to as a deactivation means.
As is shown in FIG. 6, the bicycle lock bracket 34 for securing the lock 33 to the bicycle 20 comprises an elongated, folded strap 48 having a first end 50 and a second end 52. The strap is preferably formed of hardened metal so that it substantially retains its shape once folded. The elongated strap 48 is folded in a loop so that the first end 50 overlaps and is juxtaposed with the second end 52. When the loop is viewed in cross section (FIGS. 4 and 5), the loop is v-shaped with the tips or ends of each leg of the "v" folded over to overlap with each other. Further, the vertex of the "v" is rounded to mate with a tubular support.
An overlapping section 53 of the loop comprises the overlapping first end 50 and second end 52. Connected to this overlapping section 53 at each end thereof are first and second perpendicular sections 54 and 56. Each of the perpendicular sections are substantially perpendicular to the overlapping section 53 and substantially parallel to each other. The perpendicular sections 54 and 56 are connected together by a v-shaped section 58 to complete the loop. As stated above, the v-shaped section has a rounded vertex 59 to mate with a tubular support.
At the first end 50 of the elongated strap 48 is formed a first elongated aperture or opening 60 in the strap 48. The opening 60 is formed from an exterior surface 62 of the looped strap to an interior surface 64 of the looped strap (FIG. 6) Similarly, a second elongated aperture or opening 66 is formed at the second end 52 of the strap. The openings 60 and 66 of the looped strap 48 are formed at such positions on the folded strap so that they are substantially aligned with each other. Preferably, the first and second openings 60 and 66 are oval-shaped so that the openings need not be perfectly aligned to allow a portion of the lock to pass therethrough. Thus, the tip 37 of the cable lock 33 can be readily inserted through the two openings 60 and 66 to thereby secure the ends 50 and 52 of the strap 48 together. With the cable lock inserted through the openings thusly, the elongated strap 48 will be held together in this substantially aligned position.
As mentioned previously, the stiffness of the strap helps to maintain the shape of the strap. However, to hold the lock body securely in place within the folded strap 48 even when the cable lock 33 is not locked, the bracket has a rubber spacer 70 and an attaching means for removably attaching the first end 50 of the strap 48 to the second end 52. This attaching means is in addition to the above-described arrangement of aligned openings with a portion of the lock passing therethrough. This attaching means preferably comprises a pair of facing flanges 72 and 74 and a fastening means for fastening the two facing flanges together. The first facing flange 72 is formed to protrude outward from the first perpendicular section 54 near the first end 50 of the strap 48 adjacent to the first opening 60. The second facing flange 74 is formed at the second end 5 of the strap 48 adjacent to the second opening 66.
In the preferred embodiment, each facing flange 72 and 74 has a pair of holes 76 formed therein to allow a pair of bolts 78 to pass therethrough (FIG. 6). A pair of nuts 80 are placed on the bolts 78 to fasten the first and second facing flanges 72, 74 together. Of course, this fastening means, including the holes 76, bolts 78, and nuts 80, is but one example of the many possible means to fasten the two flanges together. Similarly, the two flanges 72 and 74 together with the fastening means are only one of many possible means for attaching the first and second ends 50 and 52 of the strap 48 together.
As can be seen in FIG. 6, the lock body 36 of the cable lock 33 is placed within the lock bracket 34 and sandwiched between the bicycle frame and the strap 48 so that a tip receptacle 84 on the lock body 36 is substantially aligned with the substantially aligned first and second openings 60 and 66. With the tip receptacle 84 in this position, the tip 42 of the cable 38 can be inserted through the two openings 60 and 66 and into the lock body 36 to engage the locking mechanism 44.
To prevent scratching of the bicycle, the rubber space 70 is inserted between the lock body 36 and the bicycle frame and formed so that it rests squarely against a flat back surface 86 of the lock body 36. Further, the rubber spacer 70 is formed to fit snugly against a tube 90 of the bicycle frame 22 or some other support. Alternatively, the portion of the bicycle frame to which the bracket 34 is attached may be the seat tube 92 or the handlebar 30. Either of these latter two possibilities would provide reduced security since the bracket could be removed by disconnecting the seat 28 or handlebar 30, or by sliding the bracket 30 off of the end of the handlebar 30. Security can be increased by placing the bracket 34 on one of the previously discussed frame tubes 90. Since frame tubes 90 are not uniform in diameter due to different styles and models of bicycles, the rubber spacer 70 may be provided in a variety of sizes.
The operation and use of the bicycle lock bracket 34 of the present invention is as follows. A commercially-available standard cable lock 33 is placed within the bracket 34 which is located on the vertical frame tube 90 of the bicycle 20. The cable lock 33 is oriented so that the key receptacle 46 which deactivates the locking mechanism is accessible from above for the convenience of the bicycle rider. The fixed end 40 of the cable 38 which is permanently attached to the lock body 36 protrudes from the bottom of the lock body and thus is oriented downward. Most standard cable locks 33 provide the cable 38 with a natural coil for ease of storage (FIG. 3).
The lock body 36 is tightly held in place within the bracket 34 by the bolts 78 and the nuts 80. Thus, when locking and unlocking the lock 33, the lock body 36 remains fixed on the bike within the bracket 34 and need not be held or handled. This relieves the rider of the need to hold the lock body 36 during these operations, making the present invention easier for the operator to use.
When riding the bicycle, or at any other time when it is desired to secure the bicycle, the cable 38 is inserted through the substantially aligned openings 60 and 66 of the bracket 34. The tip 42 of the cable 38 is engaged by the locking mechanism 44 automatically when placed into the tip receptacle 84 which is itself substantially aligned with the openings 60 and 66 of the bracket 34. The remainder of the cable 38 remains coiled and does not interfere with the operation of the bicycle.
When it is desired to secure the bicycle to a stationary object 35, the locking mechanism is deactivated by placing and turning a key (not shown) in the key receptacle 46. The tip 42 of the cable 38 is released from the lock body 36 and may be removed from the substantially aligned openings 60 and 66. The cable 38 may then be threaded through or placed around an adjacent stationary object 35. The stationary object 35 may be divided into sections to allow the cable 38 to be placed around one or several of the sections. The cable 38 is then re-inserted through the substantially aligned openings 60 and 66 and into the tip receptacle 84 of the cable lock 33. The bicycle 20 is now secured to the stationary object 35. It is not necessary to thread the cable lock through or around the frame 22 of the bicycle 20 as was the case with the prior art devices. This is because the lock is itself already secured to the frame by the inherent nature of the present invention. Because the cable lock has been placed through the substantially aligned openings 60 and 66 of the bracket 34, the lock cannot be removed from the bicycle without cutting through the metal strap, cutting through the cable or deactivating the locking mechanism. Thus, the ability to secure a bicycle without threading a cable through the frame is one of the major advantages of the present invention.
A presently preferred embodiment of the present invention has been described above with a degree of specificity. It should be understood, however, that this degree of specificity is directed toward the preferred embodiment. For example, the present invention could be used to secure a bracket and lock to other devices than a bicycle. Accordingly, the invention itself is defined by the scope of the appended claims.
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A bicycle lock bracket is formed by an elongated metal strap having an aperture in each end and folded in a loop with its opposite ends overlapped and juxtaposed with the apertures aligned. The strap is adapted to encircle a bicycle frame tube or other tube, rod or post, so that a cable lock body is held securely in place between the strap and the frame tube. The juxtaposed ends of the strap are attached together by bolts or other fasteners so that the cable lock body is tightly retained within the bracket when the lock is open. Inserting the cable through the aligned apertures into the lock body secures the strap, lock body and cable to the mounting tube.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 U.S.C. §119(e) from U.S. Provisional Patent Application No. 60/619,060 entitled “METHOD OF ASSIGNING OPCODES IN AN ISA OF A MICROPROCESSOR FOR REDUCING POWER CONSUMPTION” filed Oct. 15, 2004, the entire disclosure of which is incorporated herein by reference for all purposes.
BACKGROUND
This invention relates to reducing the power consumption of a microprocessor.
Microprocessors used in computers and other types of computing devices are typically power-sensitive components. That is, due to the large number of operations that a microprocessor performs, it is desirable to keep its power consumption per operation as low as possible, in order to reduce the energy usage of the device incorporating the microprocessor. In a computer, operation codes (opcodes) operate on registers, values in memory, values stored on the stack, the I/O ports, the bus, and so on. The opcodes are used to perform arithmetic operations and to move and change values. The opcodes operate on operands. Microprocessors convert the opcodes into sets of binary bits and perform operations using these sets of bits. Each bit in a set can have an on-state (typically represented as ‘1’) or an off-state (typically represented as ‘0’). Eight bits are usually referred to as a byte on most conventional processors, and two bytes are usually referred to as a word.
The basic set of commands, or instructions, that a microprocessor understands is termed a command set, or an instruction set. Various types of microprocessors can have differently sized instruction sets, and this difference often constitutes one of the main differences between the microprocessors. For example, RISC (Reduced Instruction Set Computer) microprocessors have relatively small instruction sets, whereas CISC (Complex Instruction Set Computers) processors have relatively large instruction sets.
When designing an Instruction Set Architecture (ISA) for a microprocessor, little thought is typically given to how the respective instructions in the opcode that is used in the microprocessor are assigned to bit sets. The number of bits in an opcode instruction typically depends on the total number of instructions that can be carried out by the microprocessor, and which bits are assigned ‘0’s and ‘1’s, respectively, is usually arbitrarily determined. In most microprocessors, 6-8 bits correspond to an opcode instruction. There is always a one to one correspondence between a particular opcode instruction and a set of bits forming a corresponding machine code instruction.
One of the most common operations of a microprocessor is to fetch instructions from a memory external to the microprocessor for execution by the microprocessor. This is a power intensive operation, as the number of signal transitions is high. Thus, in order to reduce the power consumption of the microprocessor, it would be desirable to construct the ISA in such a way that the number of signal transitions in its most common operations is as low as possible.
SUMMARY
In general, in one aspect, the invention provides methods and apparatus, including computer program products, implementing and using techniques for reducing the power consumption of a microprocessor. One or more signal transitions in an instruction set of a microprocessor are profiled. A probability of occurrence is assigned to each instruction in the instruction set. A binary operation code is assigned to each instruction, based on the probability of occurrence for the instruction. The instructions having the highest probability of occurrence are assigned operation codes that require fewer signal transitions. As a result, the power consumption of the microprocessor is reduced.
Advantageous implementations can include one or more of the following features. The profiling step can include compiling a set of microprocessor instructions into an assembly file, and executing the assembly file through a pattern matching software tool which calculates the occurrences of the instructions. A histogram showing the signal transitions occurring during operation of the microprocessor can be generated. The instruction with the highest probability of occurring can be assigned a binary operation code consisting of only zeros.
In general, in another aspect, the invention provides a microprocessor. The microprocessor includes a set of registers, an arithmetic logic unit, and a control unit. The set of registers stores temporarily data during operation of the microprocessor. The arithmetic logic unit executes arithmetic and logical operations of the microprocessor. The control unit interprets instructions contained in a program that is executed by the microprocessor. The instructions form a subset of the microprocessor's instruction set architecture, and each instruction in the microprocessor's instruction set architecture has a binary operation code that is assigned to the instruction, based on the probability of occurrence for the instruction during operation of the microprocessor.
The invention can be implemented to include one or more of the following advantages. By assigning opcodes in the ISA of the microprocessor such that the most common opcodes have the lowest number of signal transitions, the power usage of the microprocessor can be significantly reduced at an architectural level.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 shows a schematic diagram of a computer incorporating a microprocessor in accordance with the invention.
FIG. 2 shows a schematic diagram of a process for assigning opcodes to instructions in a microprocessor at design time.
FIG. 3A shows an exemplary histogram illustrating the number of occurrences of various opcode instructions in a microprocessor.
FIG. 3B shows an exemplary table illustrating the likelihood of occurrences of various opcode instructions in a microprocessor, corresponding to the histogram in FIG. 3A .
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
Reference will now be made in detail to a particular embodiment of the invention an example of which is illustrated in the accompanying drawings. While the invention will be described in conjunction with the particular embodiment, it will be understood that it is not intended to limit the invention to the described embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
FIG. 1 shows a schematic block diagram of the functional units of a computer ( 100 ). As can be seen in FIG. 1 , the computer ( 100 ) includes three main components: a microprocessor ( 104 ), a memory ( 102 ), and an input/output (I/O) system ( 112 ). The microprocessor ( 104 ) includes three main parts: the arithmetic logic unit (ALU) ( 108 ) where all arithmetic and logical operations take place, the registers ( 106 ) where data is temporarily stored, and the control unit ( 110 ), which interprets the instructions contained in the program that is being executed by the microprocessor ( 104 ). The memory ( 102 ) contains the program (i.e., a sequence of instructions) and the data to be processed by the microprocessor ( 104 ). The content in the memory ( 102 ) can be read as well as modified by the microprocessor ( 104 ). The I/O units ( 112 ) are used by the computer ( 100 ) to communicate with the outside world, as is well known by those of ordinary skill in the art.
As was described above, the microprocessor ( 104 ) performs operations using binary bits, and there is a one-to-one correspondence between a particular bit combination and a specific opcode instruction. That is, whenever a particular instruction is to be performed, the microprocessor ( 104 ) typically must change the states of one or more of the 6-8 bits to select the proper combination of zeroes and ones that form the opcode instruction. This switching of bits consumes power. Furthermore, in most conventional microprocessors, about 20% of the available instructions in the opcode set are performed about 80% of the time. Thus, by assigning specific bit combinations to the most common instructions, which require as few switches of bits as possible, the power consumption of the microprocessor ( 104 ) can be significantly reduced. A process ( 200 ) for reducing the power consumption of a microprocessor will now be described with reference to FIG. 2 . In the implementation shown in FIG. 2 , the process ( 200 ) is conducted at design time of the microprocessor.
As shown in FIG. 2 , the process ( 200 ) starts by profiling the number of signal transitions for the various operations in an ISA (step 202 ). In an implementation for an existing microprocessor, the profiling can be done by taking a sample set of instructions that the microprocessor would execute when executing a program. This code is compiled into an assembly file, which is executed through a pattern matching software tool. If no compiler is available for the processor architecture, profiles are generated for other, similar, architectures. A histogram is then generated of the instruction usage of the microprocessor (step 204 ), for example, using the pattern matching software tool recited above, which calculates the occurrences of the instructions and plots the histogram. An exemplary histogram can be seen in FIG. 3A , where the number of occurrences for each opcode instruction in the microprocessor's instruction set has been plotted. It should be noted that the number of opcode instructions and the number of occurrences illustrated in FIG. 3A have been significantly reduced, in order to more clearly illustrate the principles of the invention. As can be seen in FIG. 3A , the most common opcode instructions are “BCC”, “CLR”, and “MOV.”
Returning now to FIG. 2 , based on the histogram, a probability of occurrence is assigned to each instruction (step 206 ). FIG. 3B shows a table corresponding to the histogram in FIG. 3A , and where the probability has been calculated in the right hand column. As can be seen in FIG. 3B , the probabilities for the three most common instructions are 46.91% for the “MOV” instruction, 28.14% for the “CLR” instruction, and 13.33% for the “BCC” instruction. Again, it should be noted that this is merely a hypothetical example illustrating the principles of the invention. In a situation where no compiler is available, the histogram is generated based on the selected similar processor architectures and a first guess for opcode assignments is made as described below. Subsequently this guess can be refined when a compiler becomes available on the new architecture.
Again returning to FIG. 2 , in the last step of the process ( 200 ) an opcode is assigned to each instruction set, based on the probability for the instruction occurring (step 208 ), which completes the process. For example, if the profiling in step ( 202 ) shows that the ‘MOV’ instruction has the highest likelihood of occurring, then the assigning step ( 206 ) will assign bits ‘000000’ or ‘111111’ to the ‘MOV’ instruction, assuming that the opcode range is 6 bits, since neither of these assignments involve any signal transitions. The second most likely instruction can be encoded using the bit assignment that was not used by the most likely instruction, that is, ‘000000’ or ‘111111,’ respectively. The third most likely instruction can be encoded such that only a single signal transitions occurs, and so on.
As the person skilled in the art realizes, this architectural solution may allow the power consumption of the microprocessor to be significantly reduced and can be implemented at design time of the microprocessor. In another implementation, existing processors can be made compatible with the invention by adding extra circuitry that converts the existing bit assignments for the various instructions in the opcode set into bit assignments in accordance with the present invention.
The invention can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention can be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention can be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program can be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language can be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory. Generally, a computer will include one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits).
To provide for interaction with a user, the invention can be implemented on a computer system having a display device such as a monitor or LCD screen for displaying information to the user. The user can provide input to the computer system through various input devices such as a keyboard and a pointing device, such as a mouse, a trackball, a microphone, a touch-sensitive display, a transducer card reader, a magnetic or paper tape reader, a tablet, a stylus, a voice or handwriting recognizer, or any other well-known input device such as, of course, other computers. The computer system can be programmed to provide a graphical user interface through which computer programs interact with users.
Finally, the processor optionally can be coupled to a computer or telecommunications network, for example, an Internet network, or an intranet network, using a network connection, through which the processor can receive information from the network, or might output information to the network in the course of performing the above-described method steps. Such information, which is often represented as a sequence of instructions to be executed using the processor, may be received from and outputted to the network, for example, in the form of a computer data signal embodied in a carrier wave. The above-described devices and materials will be familiar to those of skill in the computer hardware and software arts.
A number of implementations of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, a similar concept can be applied to data and not only to instructions. For example, if data represented by 16 bits, the frequency of use for all possible bit combinations (i.e., 2^16 combinations) can be studied in a similar fashion and be used to create various power-saving data retrieval schemes. Furthermore, the invention has been described by way of example with respect to a microprocessor and a memory, but it should be realized that the inventive concept can be extended to any two semiconductor devices that exchange a limited instruction set, for which a frequency of use can be determined. Accordingly, other embodiments are within the scope of the following claims.
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Methods and apparatus, including computer program products, implementing and using techniques for reducing the power consumption of a microprocessor. One or more signal transitions in an instruction set of a microprocessor are profiled. A probability of occurrence is assigned to each instruction in the instruction set. A binary operation code is assigned to each instruction, based on the probability of occurrence for the instruction. The instructions having the highest probability of occurrence are assigned operation codes that require fewer signal transitions. As a result, the power consumption of the microprocessor is reduced.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. §119, of German application DE 10 2011 005 630.0, filed Mar. 16, 2011; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to a hydrophobic ABS plastics material, to a process for production of the same and to use of the same as a casing material, and also to an electrical device made of the material.
[0003] Acrylonitrile-butadiene-styrene copolymer (abbreviated to ABS) is a plastic with high surface hardness for scratch-resistant and matt-luster surfaces, and has good impact resistance. It is used for the production of casings, in particular casings of electrical devices.
[0004] Electrical devices, e.g. hearing aids, mobile phones, and the like, have exposure to dirt, moisture, and sweat during daily use. Moisture which penetrates into the device and reaches electronic components can cause corrosion and finally damage to the components, and indeed can cause the device to fail. It is therefore known that entire casings or individual device components can be provided at the surface with a moisture-repellant and/or dirt-repellant protective layer. The effect is best when all of the casing components have been provided with this type of surface.
[0005] Since device casings mostly contain various plastics parts, liquids can penetrate through joints between the casing parts, and are attracted by capillary forces into the device. The wetting properties of the casing material can be described by using the water contact angle (WCA) and the receding contact angle (RCA). If water contact angles are small (e.g. from 0 to 45°), the surface is termed hydrophilic, if angles are around 90° it is termed hydrophobic, and if angles are even larger it is termed superhydrophobic. The contact angle can be altered through surface treatment. The receding angle can be considered to be a measure of the dewetting properties of a surface, and gives an indication of easy cleaning. This value describes the force or energy required to remove a substance which has already adhered to the relevant surface. It is mostly somewhat smaller than the water contact angle, but here again the rule is that as a material becomes more hydrophobic the receding angle mostly increases.
[0006] Although the surface properties of ABS can give the casing material an adequate initial level of hydrophobic properties (WCA about 75°, RCA about 50°), the surface properties rapidly become poorer in a moist environment (RCA<20) or in contact with sweat (RCA<30).
[0007] For improvement of surface properties, published European patent application EP 1 432 281 A2, corresponding to U.S. Pat. No. 7,702,124, discloses a hearing aid in which constituents of the casing have a hydrophobic and/or oleophobic and/or biofilm-inhibiting coating.
[0008] However, the coating of individual casing parts leads to a complex production process and is not feasible for all components, since certain process steps during production, e.g. adhesive bonding, lacquering, or printing, are not achievable on hydrophobic surfaces. The application of the coating also requires additional operations (e.g. coating, drying, curing) and appropriate specific production plant. Coatings are moreover disadvantageous because they can be removed through mechanical stress (friction).
SUMMARY OF THE INVENTION
[0009] It is therefore the object of the invention to provide a hydrophobic ABS plastics material, a process for production of the same and to use of the same as casing material, where this can protect sensitive electronic components in a casing from moisture.
[0010] The invention provides a composition containing an ABS plastic and a silicone additive.
[0011] An ABS plastic is a plastic which contains an acrylonitrile-butadiene-styrene copolymer.
[0012] The silicone additive contains a polyorganosiloxane.
[0000] Polyorganosiloxanes are also generally termed “polysiloxanes”, “silicone plastics”, or “silicones”.
[0013] The polyorganosiloxane can have been copolymerized with a further polymer (the term used then being polysiloxane copolymer).
[0014] It is preferable that the invention provides a composition where the silicone additive is a polyorganosiloxane having side chains which have been selected independently of one another from the group consisting of unsubstituted alkyl group, unsubstituted alkenyl group, substituted alkyl group, and substituted alkenyl group, where a substituted alkyl group or alkenyl group has at least one substituent selected from the group consisting of hydroxy group (—OH), epoxy group, ether group (—(CH2)nOR), or primary amino group (—NH2), or secondary amino group (—NHR).
[0015] The polyorganosiloxane can have the structure given in the following formula:
[0000]
[0016] where R1, R2, R3, and R4 are side chains selected independently of one another from the group consisting of unsubstituted alkyl group, unsubstituted alkenyl group, substituted alkyl group, and substituted alkenyl group, where a substituted alkyl group or alkenyl group has at least one substituent selected from the group consisting of hydroxy group (—OH), epoxy group, ether group (—(CH2)nOR), or primary amino group (—NH2), or secondary amino group (—NHR).
[0017] In accordance with the structural formula shown above, there are methyl groups (—CH3) filling the vacant positions on the silicon atoms, to the extent that they do not have bonding to oxygen or to one of the side chains R1 to R4.
[0018] In accordance with one aspect of the invention it is preferable that R1, R2, R3, and R4 indicate an identical side chain.
[0019] In accordance with one aspect of the invention, it is preferable that respectively R1 and R3 indicate an identical side chain, and also that R2 and R4 indicate an identical side chain.
[0020] In accordance with one aspect of the invention, it is preferable that the silicone ether chain of the silicone additive respectively has termination by a side chain in accordance with one of the side chains of R1 to R4.
[0021] In accordance with one aspect of the invention, it is preferable that the proportion by weight of the silicone additive is ≦20% by weight. The proportion by weight of the silicone additive is particularly ≦10% by weight.
[0022] The proportion by weight of the silicone additive is particularly from 2 to 6% by weight. This proportion by weight of the silicone additive gives an adequate improvement of hydrophobic properties of the composition together with low total costs.
[0023] In accordance with one aspect of the invention, it is preferable that the silicone additive is a polyorganosiloxane selected from the group consisting of polyorganosiloxanes having one of the structures given in the following formulae:
[0000]
[0024] In accordance with the structural formulae shown above, there are methyl groups (—CH3) filling the vacant positions on the silicon atoms, to the extent that they do not have bonding to oxygen or to a side chain designated in more detail.
[0025] In accordance with one aspect of the invention, it is preferable that the molecular weight of the polyorganosiloxane is ≦5000. This proportion by weight of the silicone additive gives an adequate improvement of hydrophobic properties of the composition together with low total costs.
[0026] In accordance with one aspect of the invention it is preferable that the number of Si—O— units in the polyorganosiloxane is ≦70.
[0027] The composition of the invention can contain further additives, e.g. dyes, flow agents, and the like.
[0028] The invention further provides a process for production of the composition described above, where the silicone additive is added to an ABS plastics feedstock and is mixed together with the ABS plastics feedstock and optionally heated.
[0029] In accordance with one aspect of the invention, it is preferable that the silicone additive is added to an ABS plastics feedstock and is heated together with the ABS plastics feedstock, and extruded.
[0030] The invention further provides a use of the composition of the invention for the production of a hydrophobic casing material, in particular for the production of a hearing-aid casing.
[0031] The invention further provides a casing for an electrical device which contains the composition of the invention.
[0032] The invention further provides an electrical device with a casing which contains the composition of the invention.
[0033] The invention further provides a hearing aid with a casing which contains the composition of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The invention is based on the idea that, instead of coating a plastics casing, an additive compatible with the ABS plastic is added to the ABS plastics feedstock for a casing, in order to obtain the composition of the invention with improved hydrophobic properties.
[0035] It has been found here that in particular the silicone additives used in accordance with the invention are compatible with the ABS feedstock and moreover are suitable for achieving the desired properties of the material.
[0036] The polyorganosiloxanes used preferably have the following structure:
[0000]
[0037] R1, R2, R3, and R4 here are saturated or unsaturated aliphatic hydrocarbon side chains. The side chains can have substitution, for example by hydroxy groups (—OH), epoxy groups, ether groups (—(CH2)nOR), or a primary amine (—NH2) or secondary amine (—NHR), or a vinyl group.
[0038] In accordance with the structural formula shown above, there are methyl groups (—CH3) filling the vacant positions on the silicon atoms, to the extent that they do not have bonding to oxygen or to a side chain designated in more detail.
[0039] They can respectively have single or multiple substitution.
[0040] R1 to R4 can be identical or respectively different.
[0041] The polyorganosiloxane can have 2, 3, or 4 different side chains of the type described above, and these can alternate in a regular manner (for example aabb, abab, aabbcc, abcabc) or in an irregular manner.
[0042] A preferred polyorganosiloxane is polydimethylsiloxane.
[0043] The side chains can be utilized for cross-linking with the polymer, as shown in the structural formula below, where R1 in the structural formula designates the ABC polymer:
[0000]
[0044] In accordance with the structural formulae shown above, there are methyl groups (—CH3) filling the vacant positions on the silicon atoms, to the extent that they do not have bonding to oxygen or to a side chain designated in more detail.
[0045] In this example, the main silicone chain bears, in alternation, a side chain having an amino group and having an epoxy group.
[0046] Surprisingly, it has been found that polyorganosiloxanes are suitable as additives for ABS plastic and improve the hydrophobic properties thereof. The composition of the invention therefore in particular has particularly good suitability for the use of casings for moisture-sensitive devices, in particular electrical devices.
[0047] The device casing has inter alia the task of protecting the interior of the device from environmental effects. This is particularly important for devices which are used under particular conditions, e.g. in outdoor use, or devices carried on the person. Examples of these are mobile telephones, hearing aids, portable MP3 players, cameras, computers, and similar devices.
[0048] The inventors have surprisingly found that the composition of the invention is suitable for applications of this type, since the casing material has long lasting moisture repellency.
[0049] The main silicone chain contributes to the desired improvement of hydrophobic properties.
[0050] The composition of the invention is therefore particularly suitable for hearing-aid casings, since hearing aids are worn on the person and therefore come into contact with moisture, sweat, body care products or cosmetic products, and cerumen (earwax). It has been shown that the composition of the invention is particularly resistant to the substances and that the hydrophobic properties of the casing material can be retained over a greatly prolonged period.
[0051] Use of the silicone additive can provide long lasting improvement of hydrophobic properties (measured via WCA and RCA), i.e. the plastic retains the properties for a markedly longer time than without use of the silicone additive. In contrast to the known processes of surface treatment, the production of the ABS plastics material with silicone additive requires no additional operations. The silicone additive can by way of example be added prior to extrusion, e.g. during compounding. The silicone additive can also be added directly prior to the injection-molding process. The materials costs for silicone additives of this type are low (<20 USD per kg), and total costs can therefore be kept low. Use of existing production processes and of existing production plant can continue.
[0052] An example of a production process can be carried out with the following conditions:
[0053] Compounding Parameters:
[0054] Screw diameter: 25 mm, L/D 40
[0055] Barrel temperatures: 230° C.
[0056] Screw rotation rate: 250 rpm
[0057] Throughput: 8 kg/h
[0058] Torque: about 25-30%
[0059] from 2.5% by weight to 6% by weight of silicone additive.
[0060] The additive is added to the finished plastic. The juncture of addition, i.e. either during the injection-molding itself, or during the previous compounding process, is of no significance.
[0061] In order to investigate hydrophobic properties, WCA and RCA values were determined for ABS plastic without silicone additive, ABS plastic with 6% by weight of polysiloxane-polyester copolymer, and ABS plastic with 2.5% by weight of polyamino organosiloxane and 4% by weight of polysiloxane-polyester copolymer.
[0062] The WCA value for ABS plastic without silicone additive was about 75°, and it was respectively about 85° for ABS plastic with 6% by weight of polysiloxane-polyester copolymer and ABS plastic with 2.5% by weight of polyamino organosiloxane and 4% by weight of polysiloxane-polyester copolymer.
[0063] The RCA value of ABS plastic without silicone additive was about 50°, for ABS plastic with 6% by weight of polysiloxane-polyester copolymer the RCA value was about 60°, and for ABS plastic with 2.5% by weight of polyamino organosiloxane and 4% by weight of polysiloxane-polyester copolymer the RCA value was about 75°.
[0064] After various types of treatment of a plastics specimen, e.g. 40° C. at 100% relative humidity, treatment with sun cream, aftershave, and with various temperature and moisture cycles, and also treatment by abrasion, it was found that the ABS plastic without silicone additive exhibited marked impairment of hydrophobic properties (decrease in RCA value), whereas in the case of ABS plastic with the tested silicone additives there was retention of hydrophobic properties.
[0065] The RCA value of the ABS plastic without silicone additive decreased from about 50° to about 15° after treatment with 40° C. at 100% relative humidity for 3 weeks.
[0066] In contrast, the RCA value of ABS plastic with 6% by weight of polysiloxane-polyester copolymer decreased from about 60° only to about 50-55° after treatment with 40° C. at 100% relative humidity for 3 weeks.
[0067] The RCA value of ABS plastic with 2.5% by weight of polyamino organosiloxane and 4% by weight of polysiloxane-polyester copolymer decreased from about 75° only to about 65° after treatment with 40° C. at 100% relative humidity for 3 weeks.
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A hydrophobic ABS plastics material is formed from an acrylonitrile-butadiene-styrene copolymer (ABS) plastic feed stock and a silicone additive. The hydrophobic ABS plastics material is used to produce a casing material, and also an electrical device. The hydrophobic ABS plastics material is ideally suited for protecting sensitive electronic components from moisture via a casing.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a method of spatially separating the two orthogonal polarization states of an incident optical signal. Its primary use is in integrated optics, where it is often desirable to split and manipulate an optical signal's orthogonal polarizations independently (polarization diversity). It can also be used in polarization mode dispersion (PMD) compensating devices, where the two orthogonal polarizations must be split, processed then recombined.
(2) Brief Description of Related Art
Light is a vector field that has two primary and orthogonal polarization states or vector directions. These are sometimes referred to as the S and P polarizations in free space optics, or the TE (Transverse Electric) and TM (Transverse Magnetic) modes of optical waveguides. The performance of optical waveguides and optical devices is often sensitive to the polarization state. That is, the response of the device changes as the polarization state changes. This is particularly pronounced in integrated optical waveguides that are fabricated on dielectric substrates.
Typically, it is desirable to have optical components that are insensitive to the input state of polarization. This criteria arises from the fact that in fiber optic telecommunications, the polarization state of an optical signal that has traveled down any length of fiber is unknown, random, and time varying (due to perturbations in the environment). Great care is often taken in the design and fabrication of optical components so that they behave in a polarization insensitive manner. Despite this effort, most devices remain polarization sensitive to some degree, and this affects ultimate performance, yield, and cost. On the other hand, there are some special applications where the two polarization states of an input optical signal needs to be spatially split so each can be manipulated independently. This is the case for example, in PMD (Polarization Mode Dispersion) compensators, where the dispersion of the signal on the two states needs to be equalized. In applications where the polarizations need to be split, the extinction ratio, which is the ratio of wanted to unwanted polarization in either of the two branches, must be high
Another general way to handle polarization in a device that is required to behave as if it were polarization insensitive is to split the input polarization into two branches having orthogonal states, process each branch independently with devices that are optimized for each polarization respectively, and then recombine the processed signals together. This scheme is referred to as “polarization diversity”. It has the advantage that each branch can be specifically optimized for its respective polarization, giving the best performance without having to comprise the ability to give adequate performance over two polarization states simultaneously. The drawbacks are that twice the number of devices are required, and two polarization splitters are needed to split then recombine the signals. Naturally this adds cost and complexity, but the objective is to net an overall superior performing or higher yielding component.
Traditionally, optical components have been quite large, and polarization diversity schemes have not been popular because of the added size and cost associated with packaging twice the componentry plus the splitters. Prospects for polarization diversity improve for integrated optics fabricated on substrates, where the objective is to shrink the size of components and to integrate various functionalities on a common die or chip, similar in concept to integrated electronic circuits (ICs). In this case the polarization splitters and two sets of components are fabricated all at once. Future integrated optical components are miniaturized by the use of high-index contrast waveguides. High-index waveguides themselves are more susceptible to polarization sensitivity. Polarization diversity may be the only path forward for these future high-index contrast components.
PRIOR ART
Most polarization beam splitters are bulk optic, and make use of birefringent wave plates. We will not discuss bulk optic polarization splitters here, but only emphasize integrated optic versions.
U.S. Pat. No. 5,946,434 discusses an integrated optic Y-coupler polarization splitter. The splitter works by taking advantage of the difference in waveguide-to-waveguide coupling strengths for two orthogonal polarizations. The optimum structure is a result of an optimized coupling length. Both the coupling length, and the propagation constants are wavelength dependent, and therefore the polarization splitter will have a wavelength dependence, which is undesirable.
U.S. Pat. No. 5,475,771 discusses an integrated optic Y-branching waveguide where one of the branches contains an anisotropic material. The structure requires the integration of an anisotropic material on to the integrated substrate. Such integration is not desirable because the two materials are not well matched in index (leading to scattering loss). Also the fabrication introduces additional steps that impact performance, cost, and yield. Most anisotropic materials can not be deposited by methods used to form the dielectric waveguides.
U.S. Pat. No. 5,293,436 discusses an integrated optic Mach-Zehnder interferometer wherein one branch contains a polable material. Polable materials do not have long term stability, and are not used widely in telecom grade components. The polled materials tend to relax with a certain time constant (that is also affected by environmental conditions), and the performance degrades over time. Further, only certain materials are potable, and very few such materials make good passive low loss optical waveguides.
U.S. Pat. No. 5,151,957 discusses an integrated optic delta-beta coupler configuration in X-cut Lithium Niobate. This method only works in Lithium Niobate, and is therefore not compatible with general integrate optic waveguides and materials.
U.S. Pat. No. 5,133,029 discusses an integrate optic 2×2 beam splitter wherein the set of Y-junctions comprise waveguides of different widths. The waveguides forming the Y-junctions of this device must be comprised of anisotropic materials, and therefore limits the scope of this invention to those integrated optic waveguides using such materials (which is few).
U.S. Pat. No. 5,111,517 discusses an integrated optic Mach-Zehnder in X-cut Lithium Niobate. This method only works in Lithium Niobate, and is therefore not compatible with general integrate optic waveguides and materials.
U.S. Pat. No. 5,056,883 discusses an integrated optic Y-branching waveguide where in one branch contains a glassy potable polymer. This invention is similar to U.S. Pat. No. 5,475,771 above, where the anisotropic material is specifically an anisotropic polymer material (or a potable polymer material) that is deposited over only one branch of the Y-branching waveguide.
U.S. Pat. No. 4,772,084 discusses an integrated optic 3×3 coupler. This invention is similar in its physical mechanism for polarization splitting as that described in U.S. Pat. No. 5,946,434 above, except that it uses a three-waveguide coupler instead of a two-waveguide coupler, and provides electrodes for post fabrication thermal or electro-optic trimming.
SUMMARY OF THE INVENTION
FIG. 1 shows a schematic of an asymmetric four-port Mach-Zehbder interferometer comprised of two 3-dB couplers 11 , 14 or power splitters and two branches 12 , 13 of lengths L 1 and L 2 as indicated. Consider the case where the structure is lossless, the waveguides in each branch are identical, and the TE and TM propagation constants of the waveguides are identical. Then the responses at the two output ports are sinusoidal as a function of the branch length difference L 1 −L 2 , and are identical for both the TE and TM polarization states.
More generally, consider the asymmetric four-port Mach-Zehnder in FIG. 1 wherein the waveguides in paths 1 and 2 are not identical, and the respective propagation constants of each of the waveguides are polarization sensitive. Then the responses are sinusoidal functions of the optical phase difference between the two paths for each polarization, given as
Δϕ e = 2 π λ ( N 1 e L 1 - N 2 e L 2 ) ( 1 ) Δϕ h = 2 π λ ( N 1 h L 1 - N 2 h L 2 ) ( 2 )
where Δφ e and Δφ h are the phase differences for the TE and TM modes respectively, N e 1 and N e 2 are the modal effective indexes of the TE mode in branch 1 and branch 2 respectively, N h 1 and N h 2 are the modal effective indexes of the TM mode in branch 1 and branch 2 respectively, and λ is the wavelength. In the lossless case, ports 1 and 2 are complementary. That is, the sum of the power at the two output ports is equal to the input power.
The objective of a polarization splitter in this invention is to have one polarization appear at port 1 , and the orthogonal polarization to appear at port 2 . It is also an objective to minimize the unwanted polarizations at each port. A figure of merit commonly used is the Extinction Ratio (E.R.). This is the ratio of wanted to unwanted power in each polarization for each port. In the Mach-Zehnder configuration, one output port for one polarization will have maximum transmission when the phase difference between paths is equal to
Δφ e =π+2 N π, where N is some integer (3)
The other output port, for the second polarization will have a maximum when the phase difference is equal to
Δφ h =2 M π, where M is some integer (4)
When the transmission is a maximum in one output port, it will be a minimum in the other output port. The design criteria for constructing a polarization splitter is to chose the path lengths L 1 and L 2 , and the effective indexes N h 1 , N e 1 , N h 2 , and N e 2 in such a way that equations (3) and (4) are simultaneously satisfied for some set of integers N and M.
In any polarization splitter design based on a Mach-Zehnder configuration, one must be able to design and fabricate waveguides that have substantially different propagation constants for the TE and TM modes. The term “birefringent” is used to describe the condition where the TE and TM modes of a single waveguide have different propagation constants. “Small” and “large” birefringence are terms used to describe conditions where the TE and TM modes are nearly identical, and far from identical, respectively. In the literature and in patent disclosures, birefringence is typically induced by poling a material having certain symmetries, such as Lithium Niobate, or by the anisotropic electro-optic effect in certain materials such as Lithium Niobate or Indium Phosphide. These types of birefringences are termed material birefringence because the material exhibits different indexes of refraction depending on the polarization state.
The invention described here makes use of form birefringence, also known as waveguide birefringence, and does not rely on material birefringence. Form birefringence is related to the waveguide geometry and structure, and can be induced in a number of ways, including the following.
1, Changing the width of a waveguide. ( FIG. 2 ) Changing the width of a waveguide with a lower chadding 21 , a core 221 , an upper chadding 23 , and a cover 24 (while its thickness remains the same) changes both the average effective index, and the difference between the TE and TM effective indexes. In low index contrasts waveguides (where the core-to-cladding refractive index difference is less than about 0.02), the birefringence induced by changing the waveguide width is very small. However, as the index contrast increases, so does the change in birefringence. For index contrasts larger than 0.05, the induced birefringence is large enough to realize robust polarization splitters, as we demonstrate. FIG. 2 shows a non-birefringent square waveguide 221 , and a waveguide 222 having birefringence induced by narrowing the width. 2. Creating non-homogeneous waveguides. A homogeneous waveguide is one where the refractive index of the waveguide core is the same everywhere within the guiding core, and the refractive index of the cladding is the same everywhere within the vicinity of the core (practically, within 10 um of the core). Non-homogeneous means that the index within the core, or within the cladding, has a spatial variation. Layered or striated materials are also considered non-homogeneous. A non-birefringent waveguide can be made birefringent by placing a thin high-index layer 223 (higher index than the core) above or beneath the guide, as shown in FIG. 3 . 3. Birefringent Material Overlay. The method of 2 above can be generalized to a thin layer 224 of any index, but having a material birefringence. Example of overlays are stressy SiN, or polymers, as shown in FIG. 4 .
Form birefringence is a method to design the effective indexes N h 1 , N e 1 , N h 2 , and N e 2 independently. This design freedom, in addition to the ability to specify L 1 and L 2 , means that equations (3) and (4) can be satisfied simultaneously, and therefore, polarization splitters can be realized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic of an asymmetric four-port Mach-Zehnder interferometer.
FIG. 2 shows the cross-section of a birefrigent waveguide with narrower core.
FIG. 3 shows the cross-section of a birefrigent waveguide with then high index layer.
FIG. 4 shows the cross-section of a biregrigent waveguide with a thin borefrigent layer.
FIG. 5 shows the design of a form-birefrigent waveguide.
FIG. 6 shows the top-down view of the first embodiment of the waveguides for the polarization splitter of the present invention,
FIG. 7 shows the top-down view of the second embodiment of the waveguides for the polarization splitter with a heated section.
FIG. 8 shows the top-down view of the third embodiment of the waveguides for the polarization splitter using a Mach-Zehnder balanced coupler as 3-dB couplers.
FIG. 9 shows data taken from a fabricated polarization-splitter shown in FIG. 8 .
FIG. 10 shows the top-down view of a fourth embodiment of the waveguides for the polarization splitter.
DETAILED DESCRIPTION OF THE INVENTION
Consider the waveguide structure that is shown in cross section in FIG. 5 . The core material is silicon oxynitride (SiON) with a refractive index of n co =1.70. The upper and lower claddings are silica (SiO 2 ) and thermal oxide (thermally grown SiO 2 ) respectively, both with an index of n cl =1.45. SiON and SiO 2 can be deposited by chemical vapor deposition (CVD), which is well known in the integrated optics and semiconductor fields. Silica can also be deposited by flame hydrolysis (FHD), or by sputtering. Other suitable core materials include silicon nitride (SN), silicon (Si), and Tantalum oxide-silica (Ta 2 O 5 :SiO 2 ) that is sputter deposited. Preferably the core to cladding index contrast (n co −n cl ) is larger than 0.05, and we call such contrasts “high-index contrast”. The desired waveguide height h can vary between 0.5 um to 4.0 um for high index contrast guides operating at a wavelength near λ=1.55 um. Here it is selected as h=1.5 um. The height is typically chosen so that the waveguide is single moded at the wavelength of interest. The width w will be varied to give a certain amount of form birefringence.
Using rigorous numerical models (Apollo Photonics, Inc. OWMS Suite), it is found that the effective indexes for the TE mode (N e ) and the TM mode (N h ) at a wavelength of 1.55 um follow the relations below as a function of waveguide width w,
N e =1.64233−0.325 exp[−1.5456 w] (5)
N h =1.63563−0.325 exp[−1.5456 w]+ 0.0547 exp[−1.339 w] (6)
The birefringence, which is the difference between the TE and TM effective indexes is,
N e −N h =0.0067−0.0547 exp[−1.339 w] (7)
For a waveguide width of w=1.50 um (square waveguide), the birefringence approaches zero.
The waveguide structure described above is used in the Mach-Zehnder configuration depicted in FIG. 6 . The Mach-Zehnder consists of two directional coupler type 3-dB couplers 111 , 112 and 141 , 142 . The nominal waveguide width in the couplers is 1.50 um. The coupler lengths are chosen from simulation to be 45 um, and the cores are separated by 0.7 um. All the waveguide bends have radii of 300 um. The nominal width of the waveguides is 1.5 um. The path lengths in the Mach-Zehnder branches are set equal here, L 1 =L 2 =L mz . There is a section of waveguide 122 (labeled w 2 ) having a width of 0.8 um in one arm of the interferometer. In this section the waveguide is tapered from a width of 1.5 um to 0.8 um over a length of 8 um. By narrowing the waveguide to a width of 0.8 um, a certain amount of birefringence is induced according to equation (7). The length of the narrowed section is chosen to be the polarization beat length, L p . The polarization beat length is the length over which the TE and TM modes accumulate a phase difference of π. It is given by the relation,
L p = λ 2 ( N e - N h ) ( 8 )
From (7) L p is calculated to be 64 um at λ=1.55 um. As outlined earlier in equations (3) and (4) two conditions must be met to have a high extinction ratio. Relation (8) is one condition. In order to satisfy (3) and (4) simultaneously, one can vary the waveguide width W 2 simultaneously with varying L p . Another method is to change the difference in path lengths between the upper and lower branches of the Mach-Zehnder (L 1 and L 2 from FIG. 1 ). A third method is to change the index of one of the branches by use of the thermal optic effect. FIG. 7 shows the forgoing polarization splitter with a resistive heater 132 placed over one of the arms. Current injected into the resistor will heat that arm and can be used as a tuning or trimming mechanism. The heater changes the effective indexes of both polarizations by nearly the same amount, and does not itself induce significant birefringence. The heater used in the demonstration consisted of 200 nm of platinum deposited by an evaporator.
A further improvement is shown in FIG. 8 , where the simple directional coupler type 3-dB couplers depicted in FIGS. 6 an 7 are replaced by Mach-Zehnder balanced coupler 1 113 , 114 and 143 , 144 . The balanced couplers are 3-dB couplers with improved fabrication latitude and are more wavelength-independent compared to conventional directional couplers. 1 B. E. Little et. al. “Design rules for maximally-flat wavelength-insensitive optical power dividers using Mach-Zehnder structures”, Optics Lett. Vol., pp. 1998.
Data taken from the fabricated device in FIG. 8 is shown in FIG. 9 . The numeric labels correspond to the port labeling of FIG. 8 . The graph is a plot of extinction ratio as a function of thermal tuning power applied to the resistive heater. Extinction ratio is the ratio of the power in one polarization state compared to the other state. As seen, the extinction ratios can be tuned up to 25 dB. Thus the heater gives a post fabrication method to optimize the performance. These polarization splitters can be cascaded output-to-input to increase the extinction ratios.
FIG. 10 shows the top view of the invention. The structure is similar to that shown in FIG. 6 . Compared to FIG. 6 , in this case there is no narrow section of waveguide on the upper branch. Instead, there is a section 123 of waveguide on the upper branch that has a thin layer of additional material. The material can be a thin high index layer as described in conjunction with FIG. 3 , or a thin birefringent layer as described in conjunction with FIG. 4 . The length of waveguide having this material layer is L p . This thin layer of high index or birefringent material can replace the narrow section of waveguide of width w 2 in FIGS. 7 and 8 .
While the preferred embodiments have been described, it will be apparent to those skilled in the art that various modifications may be made to the embodiments without departing from the spirit of the present invention. Such modifications are all within the scope of this invention.
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A method for separating the orthogonal polarization components of an incident optical signal into two spatially separated output ports is described. The method comprises a Mach-Zehnder interferometer where one of the two branches has a section of waveguide that exhibits form-birefringence. This integrated optic Polarization Beam Splitter (PBS) is broadband, has high extinction ratio, and has characteristics that are tunable.
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CROSS REFERENCE TO RELATED APPLICATION
This application is the National Phase filing of International Application No. PCT/JP2011/062799, filed Jun. 3, 2011, which claims priority to Japanese Application No. 2010-129169, filed Jun. 4, 2010. The entire content of each prior application is hereby incorporated by reference.
TECHNICAL FIELD
The present invention is related to a method for detecting metabolic syndrome or life-style related disease and a kit for detecting metabolic syndrome or life-style related disease.
BACKGROUND ART
Recently, it is known that the life-style related diseases such as arteriosclerosis, hyperlipemia, diabetes, hypertension, and central obesity, are developed based on a common metabolic abnormality, which has been referred to as a metabolic syndrome. According to the Ordinance of the Ministry of Health, Labour and Welfare No. 157 “Practice guideline for special health checkups and special health-maintenance guidance (Dec. 28, 2007)”, a special health check-up was given to insured persons aged between 40 and 74. Examinations of waist circumference, blood pressure, serum triglyceride (neutral fat) level, high-density lipoprotein cholesterol (HDL-C) level, and blood glucose were carried out from April, 2008. As health guidance is given to the persons diagnosed with metabolic syndrome, health awareness in people has been increased. Thus, it is becoming popular to prevent life-style related disease in a positive manner.
Hitherto, as a risk marker for development of arteriosclerosis, high-density lipoprotein cholesterol (HDL-C) level, low-density lipoprotein cholesterol (LDL-C) level, small, dense LDL (sdLDL), apolipoprotein A, adiponectin, CRP (C-reactive Protein), and AIP (Atherogenic Index of Plasma), and the like are known.
sdLDL is a LDL which contains a high proportion of triglyceride, and has a smaller particle size than normal LDL. sdLDL is more susceptible to oxidation compared to normal LDL, and it is known that sdLDL strongly causes the development of arteriosclerosis. Apolipoprotein A constitutes HDL, and promotes the removal of cholesterol from cells. Adiponectin is a hormone released from adipocyte, and it is known that adiponectin exhibits functions to promote insulin sensitivity, prevent arteriosclerosis, and inhibit inflammation. Further, the blood concentration of adiponectin is negatively correlated with the amount of visceral fat. CRP is produced when an inflammatory reaction is developed in the body. CRP has attracted attention as a marker of arteriosclerosis with a chronic vascular inflammation. AIP is an index in serum for arteriosclerosis which is calculated by a formula, “log (triglyceride concentration/HDL-C concentration)”, using a triglyceride concentration and HDL-C concentration.
Further, it is said that oxidation of LDL is the greatest contributor to the development of arteriosclerosis. LDL which is oxidized through abnormalities of metabolism or transport of cholesterol, leads to a conversion of macrophages to foam cells, and induces the production of superoxide from neutrophil, whereby the oxidized LDL further induces lipid peroxidation and lipid accumulation at vascular subendothelium so as to progress arteriosclerosis. Therefore, in order to prevent the development of arteriosclerosis, it is remarkably effective to inhibit the oxidation of LDL.
Plasmalogen is a kind of glycerophospholipid, and has an olefinyl chain (vinyl ether bond) at the sn-1 position, an acyl chain at the sn-2 position, and a base-bound phosphoric acid at the sn-3 position of the glycerol backbone. In the plasmalogen present in a living body, the number of carbon atoms of the major olefinyl chain is 16 to 18, and the major acyl chain is a fatty acid having 16 to 22 carbon atoms. The major base bound to phosphoric acid is choline or ethanolamine, and the corresponding plasmalogens are referred to as choline plasmalogen (hereinafter sometimes referred to as a “CP”) or ethanolamine plasmalogen (hereinafter sometimes referred to as an “EP”), respectively. It is known that the proportion of CP is high in the heart and skeletal muscle of mammals, and a proportion of EP is high in the brain and kidneys of mammals.
The concentration of phospholipids in human plasma is 2 to 3 mM, and the phospholipids are contained therein as a constituent of lipoprotein. 60 to 75% of the total phospholipids are choline glycerophospholipid, 2 to 5% thereof are ethanolamine glycerophospholipid, and 10 to 20% thereof are sphingomyelin phospholipid.
The concentration of plasmalogen in human plasma is 0.1 to 0.3 mM, and proportions of CP and EP are 40% and 60% respectively. That is, about 5% of choline glycerophospholipid and about 60% of ethanolamine glycerophospholipid are plasmalogen, and there are very few plasmalogen having a base other than choline and ethanolamine, in blood.
Reported physiological roles of plasmalogen are: a function of membrane fusion in cell fusion or secretory action, an involvement in signal transduction or transport of biological macromolecule, a role as a reservoir of polyunsaturated fatty acid which is easily oxidized, and a role as an endogenous antioxidant. Further, it is reported that an inherited plasmalogen deficiency in humans exhibits symptoms of profound mental retardation, adrenal disorder, cataracts, hearing disorder, stunted growth, or the like. It is also reported that the serum plasmalogen level in Alzheimer's disease patients and aged persons is decreased. These findings suggest that plasmalogen plays an important role in the body (non-patent literature 1). In addition, it is known that plasmalogen synthesized in liver is preferentially incorporated into lipoprotein component. Furthermore, it is considered that plasmalogen acts as an antioxidative factor for LDL due to the endogenous antioxidant activity thereof.
Patent literature 1 discloses that choline plasmalogen level and ethanolamine plasmalogen level in the blood of persons of middle or advanced age including hyperlipemia patients were measured, and the CP/EP ratio is significantly correlated to fasting triglyceride level, which means the neutral fat level, and LDL size, which means the sdLDL level, respectively (the corresponding correlation coefficients are −0.359 and 0.402 respectively). Further, patent literature 1 discloses that the CP/EP ratio can be used as a biomarker for preventing life-style related disease. In addition, non-patent literature 1 discloses that the amount of total CP or the amount of total EP is correlated to HDL-C, apolipoprotein A-I, and apolipoprotein A-II (the correlation coefficients are more than 0.28).
However, the correlations between the CP/EP ratio and fasting triglyceride (neutral fat) or LDL size (sdLDL), disclosed in patent literature 1; and the correlations between the total CP amount or the total EP amount and HDL-C, apolipoprotein A-I, or apolipoprotein A-II disclosed in non-patent literature 1, are not sufficiently strong, and therefore these biomarkers for detecting life-style related disease are by no means satisfactory.
PATENT LITERATURE
[Patent literature 1] Japanese Unexamined Patent Publication (Kokai) No. 2007-33410
NON-PATENT LITERATURE
[Non-patent literature 1] Journal of Atherosclerosis and Thrombosis, 2007, Japan, vol. 14, p. 12-18
SUMMARY OF INVENTION
Technical Problem
Patent literature 1 discloses that clinical test items, i.e. presence or absence of coronary stenosis, abnormal glucose tolerance, significant stenosis, age, sex, CAG, OGTT, hyperlipemia, abnormal glucose tolerance, body height, body weight, BMI, cigarette smoking (number of cigarette smoked per day, duration of smoking), family history, hypertension, gout, or the like are tested, and clinical measurement items, i.e. plasmalogen level in plasma, uric acid level, TC, TG (fasting), HDL, LDL, FBS, HbA1c, TC — 2, TG — 2, HDL — 2, LDL — 2, apoprotein A-I, apoprotein A-II, apoprotein B, apoprotein C-II, apoprotein apoprotein E, LP(A), LP-F_PGR, lipoprotein α (HDL), lipoprotein β (LDL), lipoprotein preβ (VLDL), RLP-C, S — 0′, S — 120′, IRI — 0′, IRI — 120′, IRI — 0′, IRI — 120′, HOMA_IR, LPL, adiponectin, MDA_LDL, LPL following heparin treatment, fasting ApoB48, postprandial ApoB48 LDL size, phospholipid level, choline plasmalogen (CP), ethanolamine plasmalogen (EP), CP/EP, or the like, are measured, and then the correlations among clinical parameters and biochemical data were examined. Further, patent literature 1 discloses that fasting triglyceride level (TG), HDL 2 level, or CP/EP value is significantly correlated to LDL size, and as mentioned above, CP/EP value is significantly correlated to fasting triglyceride level (TG). However, patent literature 1 does not disclose correlations between items other than the above items.
As mentioned above, in patent literature 1, statistically-significant correlations between CP/EP ratio and fasting triglyceride (neutral fat) level, and between CP/EP ratio and sdLDL, are described. However, the correlation coefficients thereof are −0.359 and 0.402, respectively, which are somewhat low. Further, in non-patent literature 1, the correlation coefficients between total CP level, and HDL-C, apolipoprotein A-I, or apolipoprotein A-II are 0.308, 0.435, or 0.241, which are not very high.
The reason for this is presumed to be as follows. In patent literature 1 and non-patent literature 1, the method for measuring a plasmalogen level in the blood is a method wherein a radioactive iodine is specifically bound to plasmalogens contained in lipid components by reacting extracted lipids with a triiodide ion, and the resulting plasmalogens are fractionated into CP and EP, and measured by chromatography. The accuracy of the above method is not sufficient due to the effects of radioactive decay, or the like. That is, the use of radioactive iodine is one of the reasons that accuracy is insufficient.
Further, on the method for measuring plasmalogen in patent literature 1 and non-patent literature 1, an internal standard material is not used. Therefore, obtained measurement values are variable between measurement tests, measurement dates, and measurers, whereby there may be a possibility that the above correlation coefficients are reduced.
Accordingly, the object of the present invention is to provide a biomarker which is highly correlated to the conventional biomarkers of metabolic syndrome or life-style related disease in a wide range of subjects including subjects of special health check-ups aged between 40 and 74, or an advantageous method for detecting metabolic syndrome or life-style related disease. Further, the object of the present invention is to provide a biomarker capable of determining the risk or degree of seriousness of metabolic syndrome or life-style related disease, and a method for analyzing the risk or degree of seriousness of metabolic syndrome or life-style related disease.
Solution to Problem
With the aim of solving the aforementioned problems, the present inventors have conducted intensive studies into a method for analyzing plasmalogen capable of quantifying blood plasmalogen level with greater accuracy, and as a result, found that the method described in patent literature 1 can be much improved by using 1-alkenyl cyclic phosphatidic acid (1-alk-1′-enyl-sn-glycerol-2,3-cyclic phosphate; hereinafter sometimes referred to as a cAP) as an internal standard material, resulting in a method with greater accuracy. Further, the present inventors found that it is possible to analyze a fatty acid bound at the sn-2 position of CP (i.e. molecular species of CP) with high accuracy, by using a synthetic choline plasmalogen as the internal standard, and by analyzing plasmalogen using liquid chromatography-tandem mass spectrometer (hereinafter referred to as a LC-MS/MS) mass spectrometer (hereinafter referred to as a LC-MS/MS)
451 subjects aged from their 20s and their 60s, not including severe patients, are examined by means of the above two analyzing methods using the internal standard. As a result, compared to the amount of total serum plasmalogen, the amount of CP, particularly the amount of a CP in which the fatty acid bound at the sn-2 position is oleic acid (hereinafter referred to as a C18:1 CP), or the amount of a CP in which the fatty acid bound at the sn-2 position is linoleic acid (hereinafter referred to as a C18:2 CP) is strongly correlated to arteriosclerosis-related factors, such as waist circumference, adiponectin, or AIP, as well as HDL-C, triglyceride, or sdLDL.
In addition, the present inventor found that the ratio of CP to total phospholipids (hereinafter referred to as a “CP/PL ratio”) is more strongly correlated to the above arteriosclerosis-related factors, than the CP itself is.
The present inventor also found that a ratio of CP to body weight (hereinafter referred to as a “CP/body weight ratio”), or a ratio of CP to triglyceride (hereinafter referred to as a “CP/triglyceride ratio”) is more strongly correlated to the above arteriosclerosis-related factors, than the CP itself is.
Correlation coefficients between each of the above three ratios and each measurement item are higher than those between the CP/EP ratio which is the biomarker disclosed in patent literature 1, and each measurement item, and the above three ratios are correlated to more measurement items than the CP/EP ratio. In particular, as the above three ratios are correlated to waist circumference or adiponectin which are obesity-related factor, it was found that these ratios are highly effective as a biomarker which can be correlated to overall disorder of lipid metabolism.
Namely, the present invention relates to:
[1] a method for detecting metabolic syndrome or life-style related disease characterized by comprising the step of measuring the concentration of choline plasmalogen in a sample to be tested,
[2] the method for detecting metabolic syndrome or life-style related disease of the item [1], wherein the choline plasmalogen is a choline plasmalogen having oleic acid at the sn-2 position or a choline plasmalogen having linoleic acid at the sn-2 position,
[3] the method for detecting metabolic syndrome or life-style related disease of the item [1] or [2], further comprising the steps of measuring at least one value selected from the group consisting of: the phospholipid concentration in the sample to be tested, the triglyceride concentration in the sample to be tested, and the body weight of the subject; and calculating the ratio of the value of choline plasmalogen concentration, to the phospholipid concentration in the sample to be tested, the triglyceride concentration in the sample to be tested, or a value of body weight of the subject
[4] the method for detecting metabolic syndrome or life-style related disease of any one of the items [1] to [3], the life-style related disease is selected from the group consisting of dyslipidemia, hypertension, and arteriosclerosis,
[5] the method for detecting metabolic syndrome or life-style related disease of any one of items [1] to [3], wherein the method is for preventing development of metabolic syndrome or life-style related disease, or monitoring a treatment effect against metabolic syndrome or life-style related disease,
[6] the method for detecting metabolic syndrome or life-style related disease of any one of items [1] to [5], wherein at least one compound selected from the group consisting of 1-alkenyl cyclic phosphatidic acid of the general formula (1):
wherein R 3 is an alkyl group having 4 to 26 carbon atoms or an alkenyl group having 4 to 26 carbon atoms, and M is a hydrogen atom or a counter cation, and a compound of the general formula (2):
wherein R 1 is an alkyl group having 7, 9, 11, 13, 15, 17, 19, or 21 carbon atoms, and R 2 is an alkyl group having 8 to 21 carbon atoms or an alkenyl group having 8 to 21 carbon atoms, is used as an internal standard material for analyzing plasmalogen,
[7] a kit for detecting metabolic syndrome or life-style related disease, characterized by comprising a 1-alkenyl cyclic phosphatidic acid of the general formula (1):
wherein R 3 is an alkyl group having 4 to 26 carbon atoms or an alkenyl group having 4 to 26 carbon atoms, and M is a hydrogen atom or a counter cation, as an internal standard material for analyzing plasmalogen, and
[8] a kit for detecting metabolic syndrome or life-style related disease, characterized by comprising a compound of the general formula (2):
wherein R 1 is an alkyl group having 7, 9, 11, 13, 15, 17, 19, or 21 carbon atoms, and R 2 is an alkyl group having 8 to 21 carbon atoms or an alkenyl group having 8 to 21 carbon atoms, as an internal standard material for analyzing plasmalogen.
Advantageous Effects of Invention
According to the method or kit for detecting metabolic syndrome or life-style related disease, metabolic syndrome or life-style related disease can be detected at high detection rates, compared to the conventional method or kit. In particular, metabolic syndrome can be detected at high rates. Further, the measurement value obtained by the detection method or detection kit of the present invention is highly correlated to the biomarkers of life-style related disease i.e. it is a measurement value of HDL-C, sdLDL, AIP, waist circumference, body weight, or adiponectin. Furthermore, in the method or kit for detecting metabolic syndrome or life-style related disease, the use of 1-alkenyl cyclic phosphatidic acid or synthetic choline plasmalogen as an internal standard makes it possible to accurately measure the amount of choline plasmalogen, and further makes it possible to accurately analyze molecular species of choline plasmalogens.
Therefore, the detection method or the detection kit of the present invention can diagnose the risk or degree of seriousness of metabolic syndrome or life-style related disease, more accurately than ever before. A biomarker founded by the present inventor more accurately shows the risk or degree of seriousness of metabolic syndrome or life-style related disease, compared to conventional biomarkers.
DESCRIPTION OF EMBODIMENTS
[1] Method for Detecting Metabolic Syndrome or Life-Style Related Disease
The method for detecting metabolic syndrome or life-style related disease of the present invention comprises the step of measuring the concentration of choline plasmalogen in a sample to be tested. The method for detecting metabolic syndrome or life-style related disease of the present invention can be used for diagnosing metabolic syndrome or life-style related disease. The method for diagnosing metabolic syndrome or life-style related disease is an in vitro diagnostic method. That is, the diagnostic method comprises the step of in vitro measurement of choline plasmalogen contained in the sample isolated from mammals including humans.
In the detection method of the present invention, the total amount of choline plasmalogen or concentrations of molecular species of choline plasmalogen is measured. If the total amount of choline plasmalogen or the concentrations of molecular species of choline plasmalogen is analyzed and measured without adding an internal standard to the sample, it is impossible to correct for variations of extraction efficiencies between samples, or variations of ionization efficiencies between sample injections to the mass spectrometer, which are normally-occurring on the analysis. Therefore, in order to correct the above variations, an internal standard is added to sample. Hitherto, cholic acid, or the like is used as the internal standard. However, the polar character and the ionization efficiency of cholic acid are very different from those of choline plasmalogen, and thus it cannot be said that the measurement values thereof are accurate values of the plasmalogen amount.
The present inventors found that it is possible to measure accurately the amount of choline plasmalogen in the sample by using 1-alkenyl cyclic phosphatidic acid (1-alk-1′-enyl-sn-glycerol-2,3-cyclic phosphate; hereinafter, sometimes referred to as a cAP) or synthetic choline plasmalogen as a novel internal standard material. 1-alk-1′-enyl-sn-glycerol-2,3-cyclic phosphate and synthetic choline plasmalogen which may be used as the internal standard in the present invention, will be explained in detail hereinafter.
<<Internal Standard Material>>
(1-Alkenyl Cyclic Phosphatidic Acid)
In the detection method of the present invention, 1-alkenyl cyclic phosphatidic acid (cAP) which may be used as the internal standard, is a compound of the general formula (1):
wherein R 3 is an alkyl group having 4 to 26 carbon atoms or an alkenyl group having 4 to 26 carbon atoms, and M is a hydrogen atom or a counter cation.
In the 1-alkenyl cyclic phosphatidic acid, R 3 is an alkyl group or an alkenyl group having 4 to 26 carbon atoms, preferably an alkyl group or an alkenyl group having 8 to 22 carbon atoms, more preferably an alkyl group or an alkenyl group having 12 to 18 carbon atoms and most preferably an alkyl group or an alkenyl group having 14 to 16 carbon atoms. Further, as the R 3 , an alkyl group is more preferable than an alkenyl group. Most side chains of plasmalogen at the sn-1 position are hydrocarbon groups having vinyl ether bonds of 16:0, 18:0, and 18:1. Therefore, if R 3 is an alkyl group having 3 or fewer, or 27 or more carbon atoms, there is a possibility that the behavior of the 1-alkenyl cyclic phosphatidic acid having such R 3 is different from that of plasmalogen in vivo. Thus, 1-alkenyl cyclic phosphatidic acid having 3 or fewer, or 27 or more carbon atoms, is not preferable.
The cAP can be prepared by a chemical synthetic procedure or an enzymatic synthesis procedure. The enzymatic synthesis procedure can be carried out in accordance with a method described in Japanese Unexamined Patent Publication (Kokai) No. 2001-178489. Together with 1-lysophosphatidic acid plasmalogen, cAP is produced by the reaction of 1-lysoplasmalogen (for example, 1-lyso-choline plasmalogen) and phospholipase D (for example, phospholipase D derived from Actinomadura sp. Strain No. 362). Further, the present inventors found that 1-lysophosphatidic acid plasmalogen can be removed from the product by a re-extraction using ether/ethanol mixed solvent so as to obtain highly-pure cAP.
cAP can be used as an internal standard material in a method for measuring total CP amount as described below.
(Synthetic Choline Plasmalogen)
In the detection method of the present invention, the synthetic choline plasmalogen which may be used as the internal standard material, is a compound of the general formula (2):
wherein R 1 is an alkyl group having 7, 9, 11, 13, 15, 17, 19, or 21 carbon atoms, and R 2 is an alkyl group having 8 to 21 carbon atoms or an alkenyl group having 8 to 21 carbon atoms.
In the synthetic choline plasmalogen, R 1 is an alkyl group having 7, 9, 11, 13, 15, 17, 19, or 21 carbon atoms, preferably an alkyl group having 7, 9, 11, 19, or 21 carbon atoms, more preferably an alkyl group having 7, 9, 19, or 21 carbon atoms and most preferably an alkyl group having 19 or 21 carbon atoms. Most side chains of plasmalogen at the sn-1 position are hydrocarbon groups having vinyl ether bonds of 16:0, 18:0, and 18:1, and there are very few plasmalogen with hydrocarbon groups containing odd-numbers of carbon atoms in the living body. Therefore, if the synthetic choline plasmalogen wherein R 1 is an alkyl group having odd-numbered carbon atoms, is used as the internal standard compound for analysis of plasmalogen, the elute position of the synthetic choline plasmalogen may be separated from those of plasmalogen in a living body, in various analysis methods. Therefore, the synthetic choline plasmalogen can be clearly distinguished from the plasmalogen in a living body.
The compound of the general formula (2) is described in a specification of Japanese patent application 2009-296744 by the present inventors. The compound can be used as the internal standard in a method for measuring plasmalogen using gas chromatography, a method for measuring plasmalogen using high-performance liquid chromatography, and a method for measuring plasmalogen using mass spectrometry. In particular, when the compound is used in a method for measuring plasmalogen using a liquid chromatography-tandem mass spectrometer, it is possible to accurately measure molecular species of choline plasmalogen.
In particular, a preferable embodiment of the synthetic choline plasmalogen includes a compound of the general formula (3):
The synthetic choline plasmalogen of the general formula (3) can be prepared according to the formula of reaction process (4) shown schematically below:
The synthetic choline plasmalogen can be used as the internal standard in a method for measuring total CP amount, and a method for measuring molecular species of CP, as mentioned below. Further, it is considered that the synthetic choline plasmalogen is more similar to the plasmalogen to be measured than cholic acid, which is conventionally used as the internal standard, in all aspects of the polar character, extraction efficiency, and ionization efficiency in a mass spectrometer. Therefore, the synthetic choline plasmalogen is superior to cholic acid as the internal standard. That is, it is possible to obtain accurate measurement values without variability of the data, by using the synthetic choline plasmalogen as the internal standard.
<<Extraction of Plasmalogen from Sample to be Tested>>
In the measurement of the concentration of plasmalogen in the detection method of the present invention, firstly plasmalogen is extracted from a sample to be tested. The method for extracting plasmalogen from sample to be tested, is not limited so long as a phospholipid can be recovered from the sample by the method, but includes Bligh & Dyer method, Folch method, a method using hexane/ethanol mixed solvent, a method using ether/ethanol mixed solvent, or a method wherein the sample is freeze dried and extracted using a solvent such as chloroform/methanol mixed solvent. Among these extraction methods, Bligh & Dyer method is complicated in its procedure, and the collection rate by the method using hexane/ethanol mixed solvent is low, and therefore, the method using ether/ethanol mixed solvent, and the method wherein the sample is freeze dried and extracted using a solvent such as chloroform/methanol mixed solvent, are preferable. Further, in the method wherein a radioactive iodine reagent is used and plasmalogen is analyzed by HPLC as mentioned below, another aqueous substance may be mixed in the extraction sample due to the freeze-dry procedure. Therefore, the method using ether/ethanol mixed solvent is preferable.
In the method using ether/ethanol mixed solvent, ether/ethanol mixed solvent is added to the sample to be tested so as to extract lipid, and then water is added to the whole so as to separate the ether layer. Then, the separated ether layer is collected as a lipid extract liquid. Specifically, 0.2 to 2.0 mL of ether (preferably, 0.5 to 1.5 mL of ether) and 1.0 to 4.0 mL of ethanol (preferably, 2.0 to 3.0 mL of ethanol) are added to 11.0 mL of sample such as serum or plasma, and the lipid therein is extracted. Here, the ether/ethanol ratio is preferably 1:2 to 1:4. Subsequently, 2.0 to 10 mL of ether and 4.0 to 10 mL of water are added to the whole so that the ether layer and the water layer are separated from each other. Here, the added ether/water ratio is preferably 1.0 to 2.5. According to the above procedure, the separated ether layer is collected as a lipid extract liquid. In order to further increase the collection rate, 2.0 to 5.0 mL of ether may be further added to the remaining water layer and the remaining lipid extracted.
The method wherein a sample is freeze dried and then lipid is extracted using chloroform/methanol mixed solvent, for example, can be carried out as follows. An obtained sample to be tested, such as plasma, is freeze-dried and 0.5 mL of a mixture of chloroform and methanol (with a ratio of chloroform to methanol of 2 to 1) is added thereto. Resulting solution is centrifuged and a supernatant (1) is collected. To the remaining lower layer, 1 mL of the mixture of chloroform and methanol (with a ratio of chloroform to methanol of 2 to 1) is added. The resulting solution is further centrifuged and a supernatant (2) is collected. The supernatants (1) and (2) are mixed, and the solvents are removed therefrom by spraying with nitrogen gas. The obtained solid body is dissolved in 1 mL of methanol so that an extracted sample containing plasmalogen is obtained.
The sample to be tested is not particularly limited, so long as it is derived from an animal, for example a human, but includes liquid samples derived from animals including humans (for example, blood, serum, plasma, lymph fluid, tissue fluid, spinal fluid, saliva, urine, tear, sudor, or the like), organ, cell, tissue, or the like. The sample to be tested is preferably blood, serum, or plasma (hereinafter sometimes referred to as blood or the like). When human plasma is used as the sample to be tested, blood is collected using a blood collection tube containing a blood coagulant such as EDTA. Then, blood cells are removed from the collected blood by a centrifugation, and the obtained supernatant may be used as the plasma. Further, when human serum is used as the sample to be tested, blood is allowed to stand at room temperature after blood withdrawal and a separated serum may be used. Furthermore, when an organ, tissue or cells are used as the sample to be tested, a sample liquid containing plasmalogen may be obtained by using an extraction liquid for organ, tissue or cells. Then, plasmalogen can be extracted from the sample liquid by using the aforementioned extraction methods.
The extracted plasmalogen may be used in the method for measuring total CP amount and the method for measuring for molecular species of CP, as described below.
<<Method for Measuring Total CP Amount>>
The method for measuring total CP amount is not particularly limited, so long as CP and EP can be measured separately by the method, but includes the method using gas chromatography, the method using high-performance liquid chromatography, and the mass spectrometry method. In particular, the method using high-performance liquid chromatography (HPLC), or the mass spectrometry method are preferable.
Hitherto, as the method for quantifying CP amount in the sample to be tested such as serum or plasma, there exist only: a method wherein dimethyl acetal derived from the sn-1 position of plasmalogen are analyzed and regarded as CP amount, and a method wherein phospholipids in a sample are fractionated into phospholipid classes by TLC, and molecular species are analyzed by gas chromatography. Recently, however, a method using liquid chromatography is widely used, because this method allows many samples to be quickly analyzed with high sensitivity. In the present invention, liquid chromatography (HPLC) can be used. Further, a method for analyzing molecular species of plasmalogen using mass spectrometry is also known. In the present invention, the mass spectrometer can be used. These methods will now be explained in detail.
(Measurement of Total CP Amount by HPLC)
As a method for quantifying total CP amount in a sample to be tested (such as serum or plasma) using HPLC, the following method is preferable. Firstly, cAP as the internal standard is added to the sample and lipids are extracted, or cAP as the internal standard is added to the extracted lipids. Then, the whole is reacted with radioactive iodine reagent in methanol, and an obtained radioactive iodine-bound CP is eluted by HPLC and the radioactivity thereof is measured.
The radioactive iodine reagent can be prepared as follows. Commercially available radioactive iodine (Na 125 I) is oxidized using an oxidizing agent such as hydrogen peroxide over night at room temperature, under acidic conditions of pH5.5 to 6.0 in methanol. 70% or more of the resulting reagent is radioactive triiodide (I 3− ) which can specifically bind to plasmalogen.
The reaction between the extracted lipids from the sample to be tested and radioactive iodine reagent is performed as follows. Sample dissolved in methanol containing CP (for example, 0.001 to 0.1 mL of sample extracted from serum, which is estimated to contain 0.1 to 400 nmol of CP) and radioactive iodine reagent (for example, 0.001 to 0.1 mL of reagent containing 10 mM iodine atom) are mixed, and allowed to stand at a predetermined temperature, in general between 4° C. and 30° C., for a predetermined period of time, in general, for between 12 hours and 24 hours.
The elution of lipids by HPLC is performed as follows. Lipids may be eluted by using a column capable of distinguishing choline glycerophospholipid, ethanolamine glycerophospholipid, and the internal standard material (for example, a Diol column, and an appropriate elution solvent (for example, acetonitrile/water/acetic acid/ammonia).
CP (strictly, an iodine-bound choline glycerophospholipid derived from CP) can be detected by measuring radioactivity by a gamma counter, preferably a flow-type gamma counter.
The internal standard material used together with radioactive iodine reagent is not limited, so long as it can stoichiometrically bind to iodine and it is fat-soluble compound, but includes, for example, vinyl ether compounds such as 2-Hydroxyethyl vinyl ether or diethylene glycol divinyl ether; lysoplasmalogen or serine plasmalogen which hardly exist in a living body; the above synthetic choline plasmalogen which does not exist in a living body, in particular choline plasmalogen wherein R 3 is an alkyl group having 4 to 6 or 22 to 24 carbon atoms; and 1-alkenyl cyclic phosphatidic acid. Preferably, 1-alkenyl cyclic phosphatidic acid (cAP) may be used. This is because the physicochemical characteristics of cAP are similar to those of choline glycerophospholipid. Further, cAP can be easily separated by HPLC, and has highly preservation stability.
(Measurement of Total CP Amount by Mass Spectrometry)
A method for analyzing total CP amount using mass spectrometry can perform in accordance with the method for measuring molecular species of CP as described below. The method of extraction of plasmalogen from the sample to be tested, internal standard material, and mass spectrometer are not particularly limited. Concentrations of the main 30 types of plasmalogens presented in a living body can be measured by the method for measuring molecular species of CP described below. Therefore, the total CP amount in the sample to be tested can be calculated by adding together obtained the concentrations of molecular species of CP.
<<Method for Measuring Molecular Species of CP>>
The method for measuring molecular species of CP is not particularly limited, so long as molecular species of CP can be measured separately, but includes, for example, the method using gas chromatography, the method using high-performance liquid chromatography, and the mass spectrometry method. In particular, the mass spectrometry method is preferable. The mass spectrometry method is not particularly limited, but includes, for example, a method using high-performance liquid chromatography (HPLC) (hereinafter referred to as a LC/MS method), a method using gas chromatography (GC) (hereinafter referred to as a GC/MS method), and a method using capillary electrophoresis (CE) (hereinafter referred to as a CE-MS method). Specifically, a method of liquid chromatography-tandem mass spectrometry (hereinafter referred to as a LC-MS/MS method) which is one of the LC/MS methods may be used. This is because the sensitivity of the LC/MS method is high, and further various molecular species of plasmalogen can be analyzed according to the LC/MS method.
The method for extracting plasmalogen from the sample to be tested is not particularly limited, and thus the aforementioned extraction method can be used. However, the preferable extraction method is the method wherein a sample is freeze dried and extracted using chloroform/methanol mixed solvent. The internal standard material is not limited, so long as all calibration curves of each molecular species of CP can be made using the internal standard material. But the synthetic choline plasmalogen is preferable, because it has a structure similar to CP. The method of preparation of the synthetic choline plasmalogen is not limited, but the synthetic choline plasmalogen can be prepared by the chemical synthetic procedure or the enzymatic synthesis procedure. Types of the synthetic choline plasmalogen is not particularly limited, so long as it does not exist in a living body, For example, the choline plasmalogen of above formula (3) which has tricosanoic acid at the sn-1 position and oleic acid at the sn-2 position (hereinafter sometimes referred to as a p23:0/18:1).
The synthetic choline plasmalogen may be added to the sample to be tested before or after extracting plasmalogen. However, preferably, the synthetic choline plasmalogen is added to the sample to be tested before extracting plasmalogen, because it is possible to correct for the extraction efficiency of plasmalogen.
In the mass spectrometry method for measuring plasmalogen, the correction method using the internal standard compound is not particularly limited, but a correction method wherein a calibration curve is prepared from serially-diluted and known concentrations of plasmalogen and serially-diluted and known concentrations of the internal standard compound, can be preferably used. That is, the calibration curve can be prepared using standard samples wherein internal standard compound is added to the standard solutions containing plasmalogen of various concentrations.
When the calibration curve is prepared in the mass spectrometry method by LC-MS/MS method, the ratio of the area of the fragment peak of the internal standard compound and the area of the fragment peak of plasmalogen are measured. Then, a high-integrity calibration curve can be prepared by plotting the resulting ratios on a graph. In the measurement of the sample to be tested, the internal standard compound is added at known concentration to the sample derived from a living body, and plasmalogens and the internal standard compound are measured. Then, an accurate measurement value can be obtained by applying the resulting ratio of the area of the fragment peak of the internal standard compound and the area of the fragment peak of plasmalogen, to the calibration curve.
It is known that when a plasmalogen is analyzed by mass spectrometry, some fragments are produced from plasmalogen. A fragment for preparing calibration curve is not to particularly limited, but, a fragment of the general formula (5):
derived from choline phosphoric acid (hereinafter referred to as a choline phosphoric acid fragment) is preferably used as a fragment peak of the synthetic choline plasmalogen and plasmalogen in the sample. That is, the calibration curve can be prepared by plotting ratios of the area of choline phosphoric acid of the synthetic choline plasmalogen and the area of choline phosphoric acid of plasmalogen in the sample.
Each concentration of molecular species of plasmalogen can be measured by using the prepared calibration curve. In the main molecular species of choline plasmalogens in the sample to be tested, there are three types of molecules at the sn-1 position, i.e. 16:0, 18:0, or 18:1, and ten types of molecules at the sn-2 position i.e. 16:0, 18:0, 18:1, 18:2, 18:3, 20:4, 20:5, 22:4, 22:5, or 22:6. Thus, there are thirty types of main molecular species of choline plasmalogens in a living body. In connection to this, molecules at the sn-1 position and molecules at the sn-2 position of ethanolamine plasmalogens are the same as those of choline plasmalogens. Therefore, there are also thirty types of main molecular species of ethanolamine plasmalogens in a living body. Accordingly, the total CP amount can be calculated by adding together all the concentrations of molecular species of choline plasmalogens in the sample.
The term “side chain at the sn-1 position” as used herein means “—CH═CH—R 1 ” of plasmalogen. Regarding the number of carbon atoms and the number of double bond contained in the side chain, the description “16:1”, for example, means that the number of carbon atoms is 16 and the number of double bonds, except for vinyl ether bonds, is 1. Further, the term “side chain at the sn-2 position” as used herein means “—CO—R 2 ” of plasmalogen. Regarding the number of carbon atoms and the number of double bond contained in the side chain, the description “20:4”, for example, means that the number of carbon atoms is 24 and the number of double bonds is 4.
<<Detection of Metabolic Syndrome or Life-Style Related Disease Using Total CP Amount>>
As described in the Examples, the measurement values of total CP amount obtained by the method for measuring total CP amount are highly correlated to body weight (correlation coefficient: −0.334), waist circumference (correlation coefficient: −0.375), triglyceride (correlation coefficient: −0.327), HDL-C (correlation coefficient: 0.714), sdLDL (correlation coefficient: −0.224), AIP (correlation coefficient: −0.576), and adiponectin (correlation coefficient: 0.314) (Table 3 and Table 4).
Further, the total CP amount of the normal human group is 65.9 μM, whereas the total CP amount of metabolic syndrome group is 56.5 μM. That is, in the metabolic syndrome group, the total CP amount is significantly lower (Table 5).
<<Detection of Metabolic Syndrome or Life-Style Related Disease Using Concentrations of Molecular Species of CP>>
In the detection method of the present invention, concentrations of each CP molecular species, rather than the total CP amount, can be used for detecting metabolic syndrome or life-style related disease. For example, in accordance with the differences of side chains at the sn-1 position and the sn-2 position, the concentration of each of the thirty types of CP molecular species may be used for detection. Further, the concentration of each of the three types of CP molecular species may be used for detection according to the differences of side chains at the sn-1 position, and the concentration of each of the ten types of CP molecular species may be used for detection according to the differences of side chains at the sn-2 position. However, the concentration of choline plasmalogen having oleic acid at the sn-2 position (hereinafter sometimes referred to as a C18:1 CP), or a concentration of choline plasmalogen having linoleic acid at the sn-2 position (hereinafter sometimes referred to as a C18:2 CP) is preferable, and particularly the concentration of C18:1 CP is more preferable.
As described in the Examples, the measurement values of C18:1 CP are highly correlated to body weight (correlation coefficient: −0.438), waist circumference (correlation coefficient: −0.461), triglyceride (correlation coefficient: −0.415), HDL-C (correlation coefficient: 0.757), sdLDL (correlation coefficient: −0.319), AIP (correlation coefficient: −0.641), and adiponectin (correlation coefficient: 0.446)(Table 4). Further, the concentration of C18:1 CP in the normal human group is 6.3 μM, whereas the total CP amount in the metabolic syndrome group is 4.8 μM. That is, in the metabolic syndrome group, the concentration of C18:1 CP is significantly low (Table 5).
<<Detection of Metabolic Syndrome or Life-Style Related Disease Using a Ratio of CP Concentration and Phospholipid Concentration>>
According to another embodiment of the detection method of the present invention, metabolic syndrome or life-style related disease can be detected using the ratio of the measurement value of choline plasmalogen concentration and the measurement value of phospholipid concentration in the sample to be tested. As the choline plasmalogen concentration, the total CP amount or the concentration of a particular CP molecular species can be used, but a concentration of C18:1 CP or C18:2 CP is preferably used.
Further, the calculating formula for the ratio of the measurement value of choline plasmalogen concentration and the measurement value of phospholipid concentration in sample to be tested, is not particularly limited. For example, the ratio may be calculated by the formula “CP concentration/phospholipid concentration”. In the above formula, the calculated value means the concentration of total choline plasmalogen with respect to phospholipid concentration, or the concentration of molecular species of CP with respect to phospholipid concentration.
A measurement of total phospholipid amount in the sample to be tested may be carried out in accordance with conventional methods. For example, there may be mentioned: a method wherein phosphorus amount produced by an asking treatment of extracted lipid is measured using phosphomolybdic acid reaction, or the like; HPLC method; or choline oxidase DADS method (for example, Phospholipid C-test WAKO: WAKO Chemicals).
<<Detection of Metabolic Syndrome or Life-Style Related Disease Using Ratio of CP Concentration and Body Weight of Subject>>
According to another embodiment of the detection method of the present invention, metabolic syndrome or life-style related disease can be detected using the ratio of the measurement value of choline plasmalogen concentration and the measurement value of body weight of a subject. As the choline plasmalogen concentration, the total CP amount or the concentration of a particular CP molecular species can be used, but a concentration of C18:1 CP or C18:2 CP is preferably used.
Further, the calculating formula for the ratio of the measurement value of choline plasmalogen concentration and the measurement value of body weight of the subject, is not particularly limited. For example, the ratio may be calculated by the formula “CP concentration/body weight of subject (kg)”. The value obtained by the above formula means the concentration of choline plasmalogen with respect to 1 kg of body weight. Measurement of the body weight of the subject may be carried out in accordance with conventional method.
<<Detection of Metabolic Syndrome or Life-Style Related Disease Using Ratio of CP Concentration and Triglyceride Concentration>>
According to another embodiment of the detection method of the present invention, metabolic syndrome or life-style related disease can be detected using the ratio of CP concentration and triglyceride concentration in a sample to be tested. As the choline plasmalogen concentration, the total CP amount or the concentration of a particular CP molecular species can be used, but a concentration of C18:1 CP or C18:2 CP is preferably used.
Further, the calculating formula for the ratio of the measurement value of choline plasmalogen concentration and the measurement value of triglyceride concentration, is not particularly limited. For example, the ratio may be calculated by the formula “CP concentration/triglyceride concentration”. Measurement of the triglyceride concentration in the sample to be tested may be carried out in accordance with a conventional method.
Each ratio of: the CP concentration to phospholipid concentration, the ratio of CP concentration to body weight of the subject, the ratio of CP concentration to triglyceride concentration, is highly correlated to body weight, waist circumference, triglyceride, HDL-C, sdLDL, AIP, and adiponectin (Table 3 and Table 4). That is, the above ratios are significantly different between the normal human group and the metabolic syndrome group. In particular, the differences between the normal human group and the metabolic syndrome group in order of decreasing significance are: the ratio of CP concentration to triglyceride concentration, the ratio of CP concentration to body weight of the subject, and the ratio of CP concentration to phospholipid concentration.
In the detection method of the present invention, the concentration of choline plasmalogen or the concentration of molecular species of choline plasmalogen in the sample to be tested are measured. Then, the resulting measurement value is compared to the reference value which is established from measurement values of choline plasmalogen concentrations in the samples of normal humans, so that metabolic syndrome or life-style related disease can be detected.
The reference value of normal humans and the cut-off point for detecting metabolic syndrome or life-style related disease are determined by a controlled clinical trial.
The detection method of the present invention can be used for preventing a development of metabolic syndrome or life-style related disease, or monitoring the effect of treatment. Further, the detection method of the present invention can be used as a biomarker of risk or degree of seriousness of metabolic syndrome or life-style related disease. In particular, high measurement values of triglyceride, sdLDL, and AIP indicate the risk of development of arteriosclerosis, and low measurement values of HDL-C and adiponectin also indicate the risk of development of arteriosclerosis. The concentration of choline plasmalogen, the concentration of molecular species of choline plasmalogen, the ratio of CP concentration and phospholipid concentration, the ratio of CP concentration and body weight of the subject, and the ratio of CP concentration and triglyceride concentration, obtained by the detection method of the present invention, are highly correlated to triglyceride, HDL-C, sdLDL, adiponectin, and AIP, and thus, can be used for preventing the development of arteriosclerosis or as a risk marker of arteriosclerosis.
<<Life-Style Related Disease>>
The life-style related disease detected by the method of the present invention, is not limited, so long as it is a disease mainly caused by food, a sleeping, or articles such as cigarettes or alcohol. There may be mentioned, for example, diabetes, dyslipidemia (hyperlipemia), hypertension, obesity, cancer, stroke, arteriosclerosis, cardiomyopathy, cardiac infarction, arrhythmia, fatty liver, alcohol liver disease, gastric ulcer, duodenal ulcer, cholecystolithiasis, periodontics, draft, hyperuricemia, and osteoporosis. According to the detection method of the present invention, dyslipidemia, hypertension, and arteriosclerosis can be detected at high rates.
<<Metabolic Syndrome>>
The term “metabolic syndrome” as used herein means a symptom wherein waist circumference of the subject is 85 cm or more in man, or 90 cm or more in woman, which is “caution should be exercised”; and the subject has two of the following three items: (1) serum lipid abnormality (i.e. 150 mg/dL or more of triglyceride value), (2) high-blood pressure (130 mmHg or more of systolic blood pressure, and 85 mmHg or more of diastolic blood pressure), (3) elevated blood glucose (110 mg/dL or more of fasting blood glucose level).
[2] Kit for Detecting Metabolic Syndrome or Life-Style Related Disease
The kit for detecting metabolic syndrome or life-style related disease of the present invention comprises a 1-alkenyl cyclic phosphatidic acid of the general formula (1):
wherein R 3 is an alkyl group having 4 to 26 carbon atoms or an alkenyl group having 4 to 26 carbon atoms, and M is a hydrogen atom or a counter cation, as an internal standard material for analyzing plasmalogen, or a compound of the general formula (2):
wherein R 1 is an alkyl group having 7, 9, 11, 13, 15, 17, 19, or 21 carbon atoms, and R 2 is an alkyl group having 8 to 21 carbon atoms or an alkenyl group having 8 to 21 carbon atoms, as an internal standard material for analyzing plasmalogen.
The kit for detecting metabolic syndrome or life-style related disease of the present invention can be used for the method of detecting metabolic syndrome or life-style related disease of the present invention. Therefore, the kit may contain an extraction agent for extracting plasmalogen from a sample to be tested. Examples of the extraction agent include: an extraction agent for Bligh & Dyer method, an extraction agent for Folch method, a hexane/ethanol mixed solvent, an ether/ethanol mixed solvent, or a chloroform/methanol mixed solvent. Further, the kit of the present invention may contain a manual that describes its use for detection of metabolic syndrome or life-style related disease. In addition, these descriptions may also be attached to the container of the kit. Furthermore, the detection kit of the present invention can be used for diagnosis of metabolic syndrome or life-style related disease.
EXAMPLES
The present invention will now be further illustrated by, but is by no means limited to, the following Examples.
Example 1
Sera isolated from bloods of 451 subjects aged between 21 and 66 (382 men, 69 women, average age: 39.6, 216 subjects aged 40 years or older) were prepared. Lipid was extracted from the serum and the amount of CP (hereafter referred to as the CP amount) was quantified. Further, the concentration of phospholipid in serum was measured using a kit “Phospholipid C-test WAKO”.
Quantification of the CP amount was carried out by the following measuring method using HPLC.
Extraction of total lipids from blood was carried out according to the following procedure. 0.12 mL of ether and 0.36 mL of ethanol were added to 0.15 mL of serum obtained by centrifuging blood, and they were mixed for 10 minutes. Further, 0.9 mL of 2M sodium chloride solution, and 0.48 mL of ether were added to the mixture, and they were mixed for 5 minutes. The mixture was centrifuged at 3000 rpm for 15 minutes and the upper layer collected. Further, 0.3 mL of ether was added to the lower layer and they were mixed for 5 minutes. This mixture was further centrifuged at 3000 rpm for 15 minutes to collect a new upper layer. The two collected upper layers were mixed and the solvents were removed by spraying with nitrogen gas. Then, the total lipids extracted were dissolved in 0.1 mL of methanol containing 0.1 mM internal standard material (cAP).
The cAP, which is the internal standard material, was prepared according to the following procedure. About 5 mg of lyso-choline plasmalogen (Funakoshi) which is dissolved in chloroform was poured into a 50 mL-volume screw-top test tube. The chloroform was evaporated by spraying with nitrogen gas, to obtain a solid body. Immediately, 1.5 mL of ether, 1.5 mL of 100 mM sodium acetate-40 mM calcium chloride buffer (pH5.6) and 10 U of phospholipase D were added thereto, and the mixture was incubated at 40° C. in a hot-water bath, while shaking. After reacting for about 3 hours, it was confirmed by thin layer chromatography (TLC) that most lyso plasmalogen had been disappeared. The ether was evaporated from the reaction liquid by spraying with nitrogen gas. Then, 1.2 mL of ether and 3.6 mL of ethanol were added to the resulting solid body, and they were mixed for 10 minutes. Further, 9.0 mL of 2M sodium chloride solution and 4.8 mL of ether were added to the mixture and it was further mixed for 5 minutes. The mixture was centrifuged at 3000 rpm for 15 minutes and the upper layer collected. 0.3 mL of ether was added to a lower layer and they were mixed for 5 minutes. The mixture was centrifuged at 3000 rpm for 15 minutes and the upper layer collected. The two collected upper layers were mixed and the solvents were removed by spraying with nitrogen gas. Then, the obtained solid body was dissolved in an appropriate volume of methanol, to be 0.1 mM of cAP solution.
The reagent containing triiodide ion (I 3− ) was prepared according to the following procedure. A commercially available radioactive iodine (Na 125 I, 37 MBq/0.01 mL), 1 mL of 50 mM sodium hydroxide-20 mM potassium iodide-methanol solution, 0.3 mL of 2.0M acetic acid-methanol solution, 0.6 mL of 1.0M hydrogen peroxide-methanol solution and 0.1 mL of methanol were mixed, and allowed to stand overnight at room temperature. The resulting mixture was kept at room temperature and used as a 10 mM radioactive iodine reagent.
0.04 mL of each extracted serum lipid sample and 0.01 mL of 10 mM radioactive iodine reagent were mixed and incubated at 4° C. for 16 hours. HPLC was applied to 0.02 mL of the reaction sample containing 1.74 nmole of cAP as the internal standard in accordance with the following conditions. As an eluting buffer, acetonitrile/water/acetic acid/ammonia (93:6.895:0.07:0.035) was used, and an isocratic elution was carried out at a flow rate of 1 ml/min. As a column, Lichrospher 100 Diol 250-4(Merck) was used. The measurement time was 15 minutes or more. As a detector, flow type γ counter (BIOSCAN) was used.
Data were analyzed using SMARTCHROM (KYA Technologies), to quantify the CP amount using the predetermined calibration curve prepared from peak areas of CP and cAP. Iodine molecules specifically bind to a vinyl ether bond of plasmalogen in methanol, and thus a measured value can be obtained by the decrease in the absorbance of iodine molecule due to the reaction with plasmalogen. The calibration curve was prepared using the measured value and peak area obtained by SMARTCHROM.
Firstly, the effect of use of the internal standard was validated by 4 quantitative tests. An extracted serum sample was obtained in accordance with the above method of extraction of total lipids, except that 0.02 mL of serum was used instead of 0.015 mL of serum. Subsequently, the extracted sample was reacted with the radioactive iodine reagent, and HPLC was applied to the resulting reaction sample. Then, a correction coefficient (i.e. (A)/(B)) was calculated from the added cAP amount contained in 0.02 mL of reaction sample (A) and a measured cAP amount (B). The measured CP amount was multiplied by the correction coefficient to calculate a corrected CP amount. Standard deviations and variation coefficients of the 4 quantitative tests are shown in Table 1. Further, in cases wherein the internal standard was not used, i.e. when the correction coefficient was not used, standard deviations and variation coefficients of the 4 quantitative tests are also shown in Table 1. Furthermore, EP amounts were also measured in accordance with a similar procedure and the results are shown in Table 1.
TABLE 1
Additive
amount of cAP
1.74 nmol (A)
CP value
EP value
cAP value
correction
Without
Correction by
Without
Correction by
(B)
coefficient =
correction
internal std.
correction
internal std.
nmol
(A)/(B)
nmol
nmol
nmol
nmol
Measurement 1
1.71
1.02
1.33
1.36
2.04
2.08
Measurement 2
1.54
1.13
1.25
1.41
1.84
2.08
Measurement 3
1.67
1.04
1.27
1.33
1.92
2.00
Measurement 4
1.45
1.20
1.16
1.39
1.63
1.95
Mean
1.59
—
1.25
1.37
1.86
2.03
standard
0.12
—
0.071
0.038
0.17
0.06
deviation
variation
7.39
—
5.65
2.78
9.22
3.08
coefficient %
As shown in Table 1, the standard deviations and variation coefficients of the measurement values obtained using cAP as the internal standard were significantly lower, compared to those obtained not using cAP. That is, as a method for measuring plasmalogen in serum, this method is, superior.
Therefore, the cAP was used as the internal standard in the following measurements of the CP amount.
Example 2
In this Example, molecular species of choline plasmalogen in sera of the 451 subjects aged between 21 and 66 (382 men, 69 women, average age: 39.6, and 216 of the subjects were aged 40 years or more) of Example 1, were measured using LC-MS/MS.
An extraction of total lipids from blood was carried out in accordance with the following procedure. 0.15 mL of serum obtained by centrifuging blood, was lyophilized, and then 0.5 mL of a mixture of chloroform and methanol (2:1) containing 50 pmol of synthetic choline plasmalogen having tricosanoic acid at the sn-1 position and oleic acid at the sn-2 position as the internal standard (p23:0/18:1), was added. The whole was mixed for 10 minutes, and allowed to stand at a room temperature for 30 minutes. The mixture was centrifuged at 3000 rpm for 15 minutes and the upper layer collected. Further, 1 mL of mixture of chloroform and methanol (2:1) was added to the lower layer, and they were mixed and allowed to stand. The mixture was centrifuged and the upper layer collected. The two collected upper layers were mixed and the solvents were removed by spraying with nitrogen gas. Then the obtained solid body was dissolved in 1 mL of methanol and the resulting solution was filtrated with a filter. The solution was appropriately diluted with methanol, and analyzed using LC-MS/MS.
A measurement condition for LC-MS/MS is as follows.
<Conditions of LC (High-Performance Liquid Chromatography)>
LC system: Accela UHPLC System
Eluent A: 5 mM ammonium formate solution
Eluent B: acetonitrile
Column: Waters ACQUITY UPLC BEH C8 (2.1×100 mm, 1.7 μm)
Temperature of column: 60° C.
Flow rate: 0.6 mL/min
Condition of UHPLC eluent is shown in Table 2.
TABLE 2 Time (min) Eluent A (%) Eluent B (%) 0 80 20 1 40 60 1.5 20 80 9 15 85 11 10 90 12.2 5 95 14.8 5 95 15 80 20
<Conditions for MS/MS (Tandem Mass Spectrometry)>
MS system: TSQ Quantum system
Ionization mode: Heated ESI, positive
Capillary voltage: 3.2 kV
Corn voltage: 35V
Desolvation temperature: 400° C.
Source temperature: 80° C.
Collision energy: 32 eV (choline plasmalogen)
A calibration curve for quantifying choline plasmalogen in a sample to be tested was prepared as follows. A synthetic choline plasmalogen (p16:0/20:4) was dissolved in methanol to prepare a standard stock solution (1.7 μmol/mL). The standard stock solution was diluted with methanol to prepare four concentration standard solutions, i.e. standard solutions of 0.085 pmol, 0.17 pmol, 0.34 pmol, and 0.51 pmol. Next, 100 pmol of synthetic choline plasmalogen (p23:0/18:1) was added to each standard solution. Each standard solution is analyzed in accordance with the above measurement conditions for LC-MS/MS. The peak area ratio of choline phosphoric acid fragment of p16:0/20:4 and choline phosphoric acid fragment of p23:0/18:1 in each standard solution was calculated to prepare a calibration curve. Choline plasmalogen in human plasma samples was quantified using the calibration curve.
Average values and standard deviations of measured amounts of choline plasmalogen in serum samples, using: the method wherein the synthetic choline plasmalogen having tricosanoic acid at the sn-1 position and oleic acid at the sn-2 position (p23:0/18:1) was used as the internal standard, the method wherein cholic acid was used as the internal standard, and the external standard method, were compared. As a result, when the synthetic choline plasmalogen having tricosanoic acid at the sn-1 position and oleic acid at the sn-2 position (p23:0/18:1) was used as the internal standard, a corrected measurement value is high and a variation (standard deviation) is low, compared to the external standard method and the method wherein cholic acid was used as the internal standard. That is to say, the measurement value corrected by using the plasmalogen as the internal standard was highly accurate.
There are three types of molecule that can be at the sn-1 position of plasmalogen i.e. 16:0, 18:0, or 18:1, and there are ten types of molecule that can be at the sn-2 position of plasmalogen i.e. 16:0, 18:0, 18:1, 18:2, 18:3, 20:4, 20:5, 22:4, 22:5, or 22:6. Thus, there are thirty types of measured molecular species of choline plasmalogens. From among these thirty molecular species, analysis data of the plasmalogen having oleic acid at the sn-2 position (18:1), and the plasmalogen having linoleic acid at the sn-2 position (18:2), are shown in Table 4.
Example 3
The above 451 subjects were examined for the following clinical test items; age, sex, body height, body weight, BMI, waist circumference, blood pressure, GOT, GPT, γ-GTP, uric acid, triglyceride, HDL-C, LDL-C, blood glucose level, adiponectin, sdLDL, hsCRP, AIP, or the like. Then, correlations between serum plasmalogen amount, CP amount, EP amount, CP/PL (phospholipid), CP/body weight, CP/triglyceride, or CP/EP; and the above clinical test items, were analyzed.
Of the above correlations, the correlations between body weight, waist circumference, triglyceride, HDL-C, sdLDL, adiponectin, or AIP; and CP amount, CP/PL, CP/body weight, CP/triglyceride, CP/EP, are shown in Table 3.
TABLE 3
Body
Waist
weight
circumference
Triglyceride
HDL-C
sdLDL
AIP
Adiponectin
Total CP amount
−0.334
−0.375
−0.327
0.714
−0.224
−0.576
0.314
CP/PL
−0.374
−0.408
−0.542
0.506
−0.458
−0.675
0.319
CP/Body weight
—
−0.672
−0.398
0.732
−0.347
−0.631
0.413
CP/Triglyceride
−0.406
−0.452
—
0.676
−0.544
—
0.358
CP/EP
−0.185
−0.196
−0.265
0.167
−0.242
−0.241
0.172
Further, the correlations between body weight, waist circumference, triglyceride, HDL-C, sdLDL, adiponectin, or AIP; and CP amount, C18:1 CP, C18:1 CP/PL, C18:1 CP/triglyceride, C18:1 CP/body weight, C18:2 CP, C18:2 CP/PL, C18:2 CP/triglyceride, C18:2 CP/body weight, or CP/EP, are shown in Table 4.
TABLE 4
Body
Waist
weight
circumference
HDL-C
HDL-C
sdLDL
AIP
Adiponectin
Total CP amount
−0.334
−0.375
−0.327
0.714
−0.224
−0.576
0.314
C18:1CP
−0.438
−0.461
−0.415
0.757
−0.319
−0.641
0.446
C18:1CP/PL
−0.463
−0.479
−0.572
0.593
−0.5
−0.715
0.453
C18:1CP/Triglyceride
−0.443
−0.477
—
0.702
−0.544
—
0.408
C18:1CP/Body weight
—
−0.666
−0.426
0.731
−0.385
−0.641
0.474
C18:2CP
−0.334
−0.407
−0.339
0.651
−0.265
−0.562
0.371
C18:2CP/PL
−0.361
−0.423
−0.508
0.475
−0.444
−0.634
0.365
C18:2CP/Trigiycende
−0.454
−0.496
—
0.588
−0.492
—
0.391
C18:2CP/Body weight
—
−0.611
−0.345
0.600
−0.371
−0.553
0.435
CP/EP
−0.185
−0.196
−0.265
0.167
−0.242
−0.172
0.241
As a result, the CP amount was highly correlated to some of the clinical test items which are risk factors of arteriosclerosis. For example, the correlation coefficient between CP amount and body weight was −0.334, the correlation coefficient between CP amount and waist circumference was −0.375, the correlation coefficient between the CP amount and triglyceride was −0.327, the correlation coefficient between CP amount and HDL-C was 0.714, the correlation coefficient between the CP amount and sdLDL was −0.224, the correlation coefficient between the CP amount and AIP was −0.576, and a correlation coefficient between the CP amount and adiponectin was 0.314.
Further, it was found that the ratio of total phospholipid amount to the total CP amount (hereinafter referred to as a “CP/PL ratio”) was more strongly correlated to these factors, than the total CP amount was. For example, the correlation coefficient between CP/PL ratio and body weight was −0.374, the correlation coefficient between CP/PL ratio and waist circumference was −0.408, the correlation coefficient between CP/PL ratio and triglyceride was −0.542, the correlation coefficient between CP/PL ratio and sdLDL was −0.458, the correlation coefficient between CP/PL ratio and AIP was −0.674, and the correlation coefficient between CP/PL ratio and adiponectin was −0.319.
It was found that ratios of the total CP amount, to body weight or triglyceride, which are certainly contained in general clinical test items, were more strongly correlated to these factors, than the total CP amount was. For example, the correlation coefficient between CP/body weight ratio and waist circumference was −0.672, the correlation coefficient between CP/body weight ratio and triglyceride was −0.398, the correlation coefficient between CP/body weight ratio and HDL-C was 0.732, the correlation coefficient between CP/body weight ratio and sdLDL was −0.347, the correlation coefficient between CP/body weight ratio and AIP was −0.631, and the correlation coefficient between CP/body weight ratio and adiponectin was 0.413. The correlation coefficient between CP/triglyceride ratio and body weight was −0.406, the correlation coefficient between CP/triglyceride ratio and waist circumference was −0.452, the correlation coefficient between CP/triglyceride ratio and sdLDL was −0.544, and the correlation coefficient between CP/triglyceride and adiponectin was 0.358.
Next, as a result of a analysis of CP molecular species, the amount of choline plasmalogen having oleic acid at the sn-2 position (hereinafter referred to as “C18:1 CP amount”) or the amount of choline plasmalogen having linoleic acid at the sn-2 position (hereinafter referred to as “C18:2 CP amount”) was more strongly correlated to arteriosclerosis-related factors and metabolic syndrome-related factors, than the total CP amount was. For example, the correlation coefficient between C18:1 CP amount and body weight was −0.438, the correlation coefficient between C18:1 CP amount and waist circumference was −0.461, the correlation coefficient between C18:1 CP amount and HDL-C was 0.757, the correlation coefficient between C18:1 CP amount and triglyceride was −0.415, the correlation coefficient between C18:1 CP amount and sdLDL was −0.319, the correlation coefficient between C18:1 CP amount and adiponectin was 0.446, and the correlation coefficient between C18:1 CP amount and AIP was −0.641.
Further, it was found that the ratio of the total amount of phospholipid to the CP18:1 amount (hereinafter referred to as a “CP18:1/PL”) was more strongly correlated to these factors, than the total CP amount was. For example, the correlation coefficient between CP18:1/PL and body weight was −0.463, the correlation coefficient between CP18:1/PL and waist circumference was −0.479, the correlation coefficient between CP18:1/PL and triglyceride was −0.572, the correlation coefficient between CP18:1/PL and sdLDL was −0.500, the correlation coefficient between CP18:1/PL and adiponectin was 0.453, and the correlation coefficient between CP18:1/PL and AIP was 0.715.
It was found that the ratios of the total CP18:1 amount, to body weight or triglyceride, which are certainly contained in general clinical test items, were more strongly correlated to arteriosclerosis-related factors and metabolic syndrome-related factors, than the total CP amount was. For example, the correlation coefficient between CP18:1/triglyceride ratio and waist circumference was −0.477, the correlation coefficient between CP18:1/triglyceride ratio and sdLDL was −0.544, the correlation coefficient between CP18:1/triglyceride ratio and body weight was −0.443, and the correlation coefficient between CP18:1/triglyceride ratio and adiponectin was 0.408. Further, the correlation coefficient between CP18:1/body weight ratio and HDL-C was 0.731, the correlation coefficient between CP18:1/body weight ratio and waist circumference was 0.666, the correlation coefficient between CP18:1/body weight ratio and AIP was −0.641, and the correlation coefficient between CP18:1/body weight ratio and adiponectin was 0.474. These correlation coefficients were far higher than those of total CP amount.
Further, correlation coefficients between total CP18:2 amount and the above factors were equal to those of C18:1 CP. For example, the correlation coefficient between C18:2 CP amount and body weight was −0.334, the correlation coefficient between C18:2 CP amount and waist circumference was −0.407, the correlation coefficient between C18:2 CP amount and HDL-C was 0.651, the correlation coefficient between C18:2 CP amount and triglyceride was −0.339, the correlation coefficient between C18:2 CP amount and sdLDL was −0.265, the correlation coefficient between C18:2 CP amount and adiponectin was 0.371, and the correlation coefficient between C18:2 CP amount and AIP was −0.562.
It was found that the CP18:2/PL ratio was more strongly correlated to these factors, than the total CP18:2 amount was. For example, the correlation coefficient between C18:2 CP/PL ratio and body weight was −0.361, the correlation coefficient between C18:2 CP/PL ratio and waist circumference was −0.423, the correlation coefficient between C18:2 CP/PL ratio and triglyceride was −0.508, the correlation coefficient between C18:2 CP/PL ratio and sdLDL was −0.444, and the correlation coefficient between C18:2 CP/PL ratio and AIP was −0.634.
It was found that ratios of total CP18:2 amount, to body weight or triglyceride, which are certainly contained in general clinical test items, were more strongly correlated to arteriosclerosis-related factors and metabolic syndrome-related factors, than the total CP amount was. For example, the correlation coefficient between CP18:2/triglyceride ratio and waist circumference was −0.496, the correlation coefficient between CP18:2/triglyceride ratio and sdLDL was −0.492, the correlation coefficient between CP18:2/triglyceride ratio and body weight was −0.454, the correlation coefficient between CP18:2/triglyceride ratio and adiponectin was 0.391. Further, the correlation coefficient between CP18:2/body weight ratio and waist circumference was −0.611, and the correlation coefficient between CP18:2/body weight ratio and adiponectin was 0.435. These correlation coefficients were far higher than those related to the total CP amount.
Example 4
From among the 451 subjects in Example 1, 156 subjects which were 40 years or more of age, and persons subject to health checks for metabolic syndrome, were classified into three groups in accordance with diagnosis criterion of metabolic syndrome.
That is, a person wherein waist circumference is 85 cm or more in man, or 90 cm or more in woman, is “caution should be exercised”; and subjects having two from among the following three items; (1) serum lipid abnormality (i.e. 150 mg/dL or more of triglyceride value), (2) high-blood pressure (130 mmHg or more of systolic blood pressure, and 85 mmHg or more of diastolic blood pressure), (3) elevated blood glucose (110 mg/dL or more of fasting blood glucose level), were classified into the “metabolic syndrome group”, subjects having one item from the group were classified into the “pre metabolic syndrome group”, and the remaining subjects were classified into the “normal human group”.
Average values of serum plasmalogen amount, CP amount, EP amount, CP/PL(Phospholipid), CP/Body weight, CP/triglyceride, CP/EP, C18:1 CP amount, C18:1 CP/PL(Phospholipid), C18:1 CP/triglyceride, C18:1 CP/Body weight, C18:2 CP amount, C18:2 CP/PL(Phospholipid), C18:2 CP/triglyceride, and C18:2 CP/Body weight of the above three groups are shown in Table 5.
The main fatty acid at the sn-2 position of plasmalogen was C20:4 (arachidonic acid). Thus, C20:4 CP amount, C20:4 CP/PL(Phospholipid), C20:4 CP/triglyceride, and C20:4 CP/Body weight also were measured and calculated. Further, each value of the “normal human group” is scaled to be 1, and the relative values of the above items with respect to each value of the “normal human group”, are shown in Table 6.
Among the serum plasmalogens, C20:4 (i.e. plasmalogen having arachidonic acid at the sn-2 position) was 33.8%, C18:2 was 20.8%, and C18:1 was 6.4%.
TABLE 5
Pre
Normal
Metabolic
metabolic
human
syndrome
syndrome
Serum plasmalogen(μM)
140.9
136.7
133.3
EP amount(μM)
75.1
80.3
72.5
CP amount(μM)
65.9
56.5
60.8
CP/Phospholipid(μM/mM)
21.6
16.5
19.5
CP/Body weight(μM/kg)
1.06
0.72
0.78
CP/Triglyceride (μM/(mg/dL))
0.91
0.32
0.65
CP/EP(μM/μM)
0.91
0.72
0.86
C18:1CP(μM)
6.3
4.8
5.6
C18:1CP/Phospholipid(μM/mM)
0.21
0.14
0.18
C18:1CP/Triglyceride (μM/(mg/dL))
0.088
0.028
0.061
C18:1CP/Body weight(μM/kg)
0.103
0.061
0.072
C18:2CP(μM)
19.3
15.2
17.9
C18:2CP/Phospholipid(μM/mM)
0.63
0.44
0.58
C18:2CP/Triglyceride(μM/(mg/dL))
0.27
0.09
0.19
C18:2CP/Body weight(μM/kg)
0.31
0.19
0.23
TABLE 6
Measurement value
Metabolic
Normal
syndrome
human (A)
(B)
(B)/(A)
C18:1CP(μM)
6.3
4.8
0.76
C18:2CP(μM)
19.3
15.2
0.79
C20:4CP(μM)
19.6
18.2
0.92
C18:1CP/Phospholipid(μM/mM)
0.21
0.14
0.67
C18:2CP/Phospholipid(μM/mM)
0.63
0.44
0.70
C20:4CP/Phospholipid(μM/mM)
0.64
0.53
0.82
C18:1CP/Triglyceride (μM/(mg/dL))
0.088
0.028
0.32
C18:2CP/Triglyceride (μM/(mg/dL))
0.27
0.09
0.32
C20:4CP/Triglyceride (μM/(mg/dL))
0.27
0.10
0.37
C18:1CP/Body weight(μM/kg)
0.103
0.061
0.59
C18:2CP/Body weight(μM/kg)
0.31
0.19
0.62
C20:4CP/Body weight(μM/kg)
0.31
0.23
0.73
There was little difference found in the serum plasmalogen amount and EP amount among the three groups. On the other hand, there were significant differences found in other makers. There were more significant differences found in the markers associated with C18:1 CP amount or C18:2 CP amount, in particular the C18:1 CP amount, compared to the markers associated with CP amount. Further, there were more clear differences in the order of the ratio of the above amounts to triglyceride, the ratio of the above amounts to body weight, and the ratio of the above amounts to phospholipid. There was a difference found in EP/CP, as well as other markers, between the “metabolic syndrome group” and the “normal human group”, but there was little difference found in EP/CP between the “pre-metabolic syndrome group” and the “normal human group”. Therefore, the EP/CP ratio was inferior to other markers, in terms of an expectation of the symptoms of metabolic syndrome.
Further, values of (B)/(A) were significantly low in markers associated with C18:1 CP amount or C18:2 CP amount, in particular C18:1 CP amount, compared to the markers associated with C20:4 CP amount. Therefore, it was found that there were significant differences in markers associated with C18:1 CP amount or C18:2 CP amount between the “metabolic syndrome group” and the “normal human group”.
INDUSTRIAL APPLICABILITY
The method and kit for detecting metabolic syndrome or life-style related disease of the present invention can be used as a marker for detecting metabolic syndrome or life-style related disease in health checkups and the like.
Although the present invention has been described with reference to specific embodiments, various changes and modifications obvious to those skilled in the art are possible without departing from the scope of the appended claims.
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The object of the present invention is to provide a biomarker which is highly correlated to the conventional biomarkers of metabolic syndrome or life-style related disease in a wide range of subjects to be tested, including subjects of special health check-up aged between 40 and 74, or an advantageous method for detecting metabolic syndrome or life-style related disease. The object can be solved by a method for detecting metabolic syndrome or life-style related disease by measuring the concentration of choline plasmalogen in a sample to be tested.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/494,684, filed Aug. 13, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates to a process for producing highly plasticized polyamide blends containing additional additives such as tougheners and/or fillers.
BACKGROUND OF THE INVENTION
[0003] It is well known that tougheners such as grafted rubbers or ionic polymers can be employed to improve the toughness of polyamides; see for example U.S. Pat. Nos. 4,174,358 and 3,845,163. It is also well known that plasticizers can be incorporated into polyamide blends to decrease their stiffness. N-butylbenzenesulfonamide (hereinafter BBSA) is an example of a well-known, effective plasticizer for polyamides; see, for example, Kohan, M. I. Ed. Nylon Plastics Handbook , Hanser: Munich, 1995; p. 365. Plasticized, toughened polyamide compositions such as ZYTEL® 350PHS2 NC010, manufactured by E.I. du Pont de Nemours, have been available for a number of years. Such resins are useful, for example, as jacketing for cables. However, while pipes and tubing can be made from such materials, it would be desirable to have available resins for making polyamide-containing pipes and tubing that possessed a lower flexural modulus, as such pipes and tubing would have great flexibility.
[0004] One method for lowering the flexural modulus would be to introduce higher levels of plasticizer to the polyamide composition. Thermoplastic polyamides are solids that are most efficiently blended on a molecular level with other materials by melting the polyamide in a suitable melt-processing apparatus such as an extruder and adding the additional materials to the molten polyamide and thoroughly mixing the resulting blend. When the blend is allowed to cool, the additional materials will be uniformly dispersed throughout the polyamide. As a result of high temperatures required for the melt-processing of polyamides, this method is not effective when large amounts of a volatile material must be added to the polyamide, as a significant portion of the volatile materials will be lost through the atmospheric pressure or vacuum vent port of the extruder. This requires that large excesses of the volatile material be added to the extruder to compensate for these losses, increasing the expense and complexity of the process.
[0005] Plasticized polyamide compositions are typically prepared by compounding the polyamide and other desired ingredients with the plasticizer in an extruder. However, because polyamide plasticizers are typically volatile relative to polyamides at the temperatures required to compound polyamides, it is difficult to incorporate large amounts of plasticizer using this method. For example, polyamide 6,12, a relatively low-melting polyamide, has a melting point of about 214° C. and BBSA has a boiling point of 340° C. Since it is necessary to compound polymers at temperatures well above their melting point, polyamide 6,12 is compounded at temperatures at which BBSA has a significant vapor pressure, and a significant portion of the BBSA introduced to the extruder would be lost through the vent port during compounding, making it impossible or very inefficient to achieve high loadings of BBSA. Other polyamides having higher melting points are compounded at even higher temperatures and will experience correspondingly higher losses of plasticizer. Plasticizers may be incorporated into polyamides during the polymerization process, but it is not practical or in some cases possible to incorporate additives such as tougheners or fibers or fillers during polymerization.
[0006] Higher molecular weight, less volatile plasticizers are available but they are not as efficient as BBSA, requiring even higher additive amounts. This negatively impacts other properties, such as tensile strength. Additionally, it is often desirable that plasticized polyamide resin compositions have a polyamide component with a high average molecular weight, and hence high melt and solution viscosity. Such compositions are often used for extrusion processes that form pipes, tubing, sheeting, etc where a high melt viscosity is desirable. When high molecular weight polyamides are passed through an extruder or otherwise melt-processed to incorporate other desired ingredients, however, these polyamides often are reduced in molecular weight, particularly when moisture is present in the polyamide, other ingredients, or extruder or other melt-processing equipment. Thus it is desirable to have a process that allows for the preparation of highly plasticized polyamides with a high average molecular that also contain additives. Such a process has been heretofore unknown and though they have long been desired, highly plasticized, high average molecular weight polyamides containing additives such as tougheners, reinforcing agents, and fillers are commercially unavailable, due to the difficulties that have been encountered when attempting to add both such additives and plasticizers to polyamides while efficiently using conventional melt-processing methods. These difficulties have been particularly acute when it is also necessary to maintain the molecular weight of high average molecular weight polyamides during the incorporation of plasticizer and additives.
[0007] It is an object of the present invention to provide an efficient process for producing a highly plasticized polyamide composition containing additives. It is a feature of the present invention to produce highly plasticized polyamide compositions containing additives such as tougheners and fillers. It is an advantage of the present invention to produce highly plasticized polyamide compositions containing additives wherein the polyamide has a high average molecular weight.
SUMMARY OF THE INVENTION
[0008] There is disclosed and claimed herein a process for producing a plasticized polyamide blend, comprising the steps of
(a) polymerizing monomers in the presence of plasticizer to produce particles of plasticized polyamide, (b) melt-blending polyamide with one or more additives to produce particles, (c) cube-blending particles of plasticized polyamide and particles of polyamide melt-blended with one or more additives.
[0012] The additives used can include tougheners, fillers, and reinforcing agents. The polyamide blends produced in the present invention may be formed into articles such as tubing and pipes.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The process of the present invention comprises the steps of synthesizing a polyamide in the presence of a polyamide plasticizer to produce component (A), melt-blending polyamide with one or more additives to produce component (B) and cube-blending the components (A) and (B) to produce cube-blend (C). The additives used are materials that can dispersed uniformly throughout a polyamide resin composition by melt-processing. Examples of additives include tougheners, which can optionally be grafted to the polyamide via reactive extrusion and fillers and reinforcing agents such as mineral fillers and glass fibers.
[0014] Component (A) of the present invention is a polyamide containing a plasticizer. Component (A) is prepared by synthesizing the polyamide in the presence of the plasticizer, thus ensuring that the plasticizer is uniformly dispersed throughout the polyamide. The polyamide of component (A) is prepared by the polycondensation of dicarboxylic acid or dicarboxylic derivative monomers with diamine monomers, the polycondensation of aminocarboxylic acid monomers, the polymerization of lactam monomers, or a combination of any of the foregoing. Dicarboxylic acid derivatives can include diesters, acid esters, amides, and acid halides.
[0015] Aliphatic, alicyclic, and aromatic dicarboxylic acid and their derivatives may be used. Preferred are aliphatic diacids with 4 to 16 carbon atoms. Examples of suitable dicarboxylic acids or dicarboxylic acid derivatives include adipic acid, azelaic acid, sebacic acid, decanedioic acid, dodecanedioc acid, isophthalic acid, terephthalic acid and their derivatives. Aliphatic, alicyclic, and aromatic diamines may be used. Preferred are aliphatic diamines with 4 to 16 carbon atoms. Examples of suitable diamines are hexamethylenediamine, 2-methylpentamethylenediamine, dodecanediamine, m-xylylenediamine, p-xylylenediamine, and bis(p-aminocyclohexyl)methane. Examples of suitable lactams include caprolactam, and laurolactam. Examples of suitable aminocarboxylic acids include 6-aminocaproic acid, 7-aminoheptanoic acid, and 11-aminoundecanoic acid. Mixtures of monomers may be used to prepare the polyamide of component (A). Preferred monomers for the preparation of component (A) include caprolactam; hexamethylenediamine and adipic acid; hexamethylenediamine and dodecanedioic acid; 11-aminoundecanoic acid; and laurolactam.
[0016] Preferred plasticizers are miscible with the polyamide used in component (A). Examples of plasticizers suitable for use in the present invention include sulfonamides, including N-alkyl benzenesulfonamides and toluenesufonamides. Suitable examples include N-butylbenzenesulfonamide, N-(2-hydroxypropyl)benzenesulfonamide, N-ethyl-o-toluenesulfonamide, N-ethyl-p-toluenesulfonamide, o-toluenesulfonamide, p-toluenesulfonamide. Preferred is N-butylbenzenesulfonamide.
[0017] The polyamide of component (A) may be prepared by any means known to those skilled in the art, such as in an autoclave or using a continuous process. See, for example, Kohan, M. I. Ed. Nylon Plastics Handbook , Hanser: Munich, 1995; pp. 13-32. When preparing component (A), the polyamide monomers (i.e. the dicarboxylic acids or dicarboxylic acid derivatives and diamines and/or lactams and/or aminocarboxylic acids) are blended with one or more plasticizers prior to polymerization. Additional additives may optionally be added to the polymerization mixture, such as lubricants, antifoam, end-capping agents. When polymerization is complete, the resulting component (A) is a blend containing polyamide with plasticizer evenly dispersed throughout. Component (A) is removed from the polymerization vessel and, as will be understood by those skilled in the art, formed into a discrete, free-flowing particle form such as pellets, cubes, beads, or flakes, by, for example, forcing molten polymer through a die into strands and cooling and cutting the strands into the particles. The plasticizer will be present in from about 10 to about 30 weight percent, or preferably, from about 15 to about 25 weight percent of component (A). The inherent viscosity (IV) of the polyamide of component (A) will preferably be about 1.4 to about 1.8 when measured in m-cresol using ASTM 2857.
[0018] Component (B) of the present invention is a polyamide containing additives such as one or more of tougheners, reinforcing agents, and fillers. Component (B) is prepared by melt-blending polyamide with one or more additives or modifiers using any melt-blending technique known to those skilled in the art, such as a single or twin-screw extruder, blender, kneader, Banbury mixer, etc. Preferred are twin-screw extruders. Component (B) is, as will be understood by those skilled in the art, formed into a discrete, free-flowing particle form such as pellets, cubes, beads, or flakes, by, for example, forcing molten polymer through a die into strands and cooling and cutting the strands into the particles. The one or more additives may be present in preferably about 5 to about 50 weight percent, or more preferably in about 10 to about 30 weight percent based on the total weight of component (B).
[0019] Examples of suitable tougheners include partially neutralized copolymers of ethylene with acrylic acids and/or methacrylic acids (such as those available from E.I. DuPont de Nemours and Co. as Surlyn® ionomers) and polyolefins such as polyethylene, polypropylene, and ethylene/propylene/diene (EPDM) rubbers that are grafted with compatibilizing agents such as dicarboxylic acids, dicarboxylic acid esters and diesters, and anhydrides. Suitable compatibilizing agents include maleic anhydride, fumaric acid, and maleic acid. Tougheners grafted with compatibilizing agents can be used blended with other polyolefins such as polyethylene, polypropylene, and/or EPDM rubbers. Polyolefins derived from anhydride-containing comonomers may also be used. As will be appreciated by those skilled in the art, other tougheners for polyamides may also be used in the invention.
[0020] Reinforcing agents and fillers include glass fibers, carbon fibers, metal fibers, glass beads, milled glass, amorphous silica, talc, kaolin, wollastonite, mica, aluminum silicate, magnesium carbonate powdered quartz, feldspar, nanocomposites, and the like. Preferable among them is glass fiber. Glass fibers suitable for use in the present invention are those generally used as a reinforcing agent for thermoplastics resins and thermosetting resins. Preferred glass fiber is in the form of glass rovings, glass chopped strands, and glass yarn made of continuous glass filaments 3-20 micron meters in diameter.
[0021] Component (B) may optionally include additional additives such as thermal, oxidative, and/or light stabilizers; lubricants; mold release agents; flame retardants; and the like. Representative oxidative and thermal stabilizers include halide salts, e.g., sodium, potassium, lithium with copper salts, e.g., chloride, bromide, iodide; hindered phenols, hydroquinones, and varieties of substituted members of those groups and combinations thereof. Representative ultraviolet light stabilizers, include various substituted resorcinols, salicylates, benzotriazoles, benzophenones, and the like. Representative lubricants and mold release agents include stearic acid, stearyl alcohol, and stearamides. Representative organic dyes include nigrosine, while representative pigments, include titanium dioxide, cadmium sulfide, cadmium selenide, phthalocyanines, ultramarine blue, carbon black, and the like. Flame retardants may include halogenated organic compounds such as decabromodiphenyl ether, halogenated polymers such as poly(bromostyrene) and brominated polystyrene, melamine pyrophosphate, melamine cyanurate, melamine polyphosphate, red phosphorus, and the like.
[0022] The components (A) and (B) are blended in solid form by tumbling, stirring, or otherwise homogeneously mixing the particles at a temperature below the melting point of either component to form cube blend (C). Cube blend (C) may be formed by tumbling components (A) and (B) in a drum, mixing them in an orbital or twin-cone blender, feeding them from separate loss-in-weight feeders into a common vessel, and other techniques that will be known to those skilled in the art. The particles of components (A) and (B) are preferably similar in size and shape to avoid segregation of the components in cube blend (C).
[0023] Cube blend (C) may be further melt processed to form articles. Examples of suitable melt processing techniques include extrusion, blow molding, injection blow molding, and injection molding. Examples of articles formed include pipes, tubing, films, and sheets. The inherent viscosity of the articles is preferably about 1.20 to about 1.60, or more preferably about 1.35 to about 1.55 when measured m-cresol using ASTM 2857.
EXAMPLES
Example 1
[0024] Component (A) was prepared in a batch autoclave polymerization process. An aqueous polyamide 6,12 salt solution (2571 kg), prepared from hexamethylenediamine and dodecanedioic acid in water, with a pH of about 7.6 and a salt concentration of 45%, was charged into an evaporator. An aqueous solution containing 10 weight percent antifoam agent (250 g), hexamethylenediamine (4000 g), and N-butylbenzensulfonamide (222 kg) were added to the solution in the evaporator, which was then concentrated by increasing the temperature to 134° C. and allowing the pressure to rise to 35 psia. The concentrated solution was then charged into an autoclave along with 82 g of aqueous 76% phosphoric acid solution. The solution was heating while allowing the pressure to rise to 265 psia. Steam was vented and heating was continued until the temperature of the batch reached 255° C. The pressure was then reduced slowly to 18.9 psia, while the batch temperature was held at 235° C. Pressure was then lowered to 3 psia while the batch temperature rose to 264° C. and was held at that temperature and pressure for 30 minutes. Finally, the polymer melt was extruded into strands, cooled, cut into pellets, and dried at 160° C. under nitrogen.
[0025] Component (B) was prepared by melt-blending an anhydride-functionalized EPDM toughener (FUSABOND® N MF521 D, available from E.I. du Pont de Nemours & Co., Inc., Wilmington, Del.) with polyamide 6,12 (ZYTEL® 158 NC010, also available commercially from E. I. DuPont de Nemours & Co.) and the thermal and oxidative stabilizers Chimassorb 944F, Irgafos 168, Irganox 1098, and Tinuvin 234 (all available from Ciba Specialty Chemicals, Tarrytown, N.Y.).
[0026] Polyamide 6,12 (59.2 kg), Chimassorb 944F (1287 g), Irgafos 168 (1693.9 g), Irganox 1098 (1693.9 g), and Tinuvin 234 (2096.4 g) were well-mixed as dry ingredients by tumbling them together in a drum. This blend was introduced to the rear barrel of a ten-barrel 57 mm Werner & Pfleiderer twin-screw extruder at a rate of 65.48 lb/hr using a loss-in-weight feeder. The anhydride-functionalized EPDM toughener was also added to the rear barrel at a rate of 25.27 lb/hr using an additional loss-in-weight feeder. Polyamide 6,12 was also introduced to the sixth barrel from the rear of the extruder at a rate of 58.8 lb/hr using a loss-in weight feeder and a side feeder.
[0027] The extruder was operated at a screw rpm of 250, and vacuum of about 0.47-0.51 bar was applied at barrel 9. The barrel temperatures were set at about 240° C. and a die temperature was set at about 250° C. The melt temperature during the extrusion process were between 280 and 285° C. The polymer strands coming from the extruder were quenched in water and fed to a cutter. The hot pellets were collected in a vessel that was continuously swept with nitrogen gas to avoid moisture absorption from the air.
[0028] Pellets of component (A) (5.9 kg) and component (B) (3.2 kg) were combined in a drum and cube-blended by tumbling the drum at room temperature. The moisture in the pellets of the resulting cube blend was adjusted to between 0.1 weight percent and 0.2 weight percent by drying or adding additional water as required. Test bars were molded from the cube blend in an injection molding machine according to ISO methods. The molded bars were tested in their dry-as-molded state using ISO methods. Inherent viscosity was measured in m-cresol using ASTM 2857. The data are shown in Table 1.
TABLE 1 Example 1 Elongation at break (%) 281 Flexural modulus MPa 753 Notched Izod impact (0° C.) 19.5 Notched Izod impact (23° C.) 40.7 Tensile strength MPa 52.1 Inherent viscosity in m-cresol 1.539
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A process for producing plasticized polyamide blends containing additives such as tougheners, reinforcing agents, and/or filler. High average molecular weight plasticized blends containing additives may be made using the process of the invention. Pipes and tubing may be made from the blends prepared using the process of the invention.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 10/879,441, filed on Jun. 29, 2004 now abandoned, the disclosure of which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
The invention relates to power supplies, and more particularly, to testing of power supplies.
A typical conventional large-capacity “on-line” UPS may include an AC/DC converter (e.g., a rectifier) that is configured to be coupled to an AC power source, such as a utility source, and a DC/AC converter (e.g., an inverter) that is coupled to the AC/DC converter by a DC link and which produces an AC voltage at an output (load) bus of the UPS. The UPS may further include a bypass circuit, e.g., a static switch, which can be used to couple the AC power source directly to the output bus of the UPS, such that the AC/DC converter and DC/AC converter are bypassed. The bypass circuit can be used, for example, to provide an economy mode of operation and/or to provide power to the load when either or both of the converters are damaged or inoperative.
Factory testing of such a UPS is often performed with a resistive, reactive load and/or a non-linear test load. Performing such tests may require extensive infrastructure, including the loads themselves and a sufficiently high-capacity utility infrastructure to supply the power for the testing. Additionally, significant energy costs may be entailed in such testing, as the energy delivered to the test load in load testing is often dissipated as heat. Such costs may be replicated when the UPS is installed at the customer's premises, where a commissioning test may be performed at installation to ensure that the UPS and associate power delivery components, e.g., lines, switches, breakers and the like, operate as intended at rated load.
Techniques for recycling energy in UPS bum-in testing are described in articles entitled “The Burn-in Test of Three-Phase UPS by Energy Feedback Methods,” by Chen et al., PESC 93 in Seattle Wash., U.S.A., (1993), and “Self-load bank for UPS testing by circulating current method,” by Chu et al., IEE Proc.-Electr. Power Appl., Vol. 141, No. 4 (July 1994). Each of these techniques, however, utilize specialized test equipment that can lead to extra cost, and which can make the test techniques less useful for field testing.
SUMMARY OF THE INVENTION
Some embodiments of the present invention provide methods of operating a power supply apparatus including first and second parallel-connected uninterruptible power supplies (UPSs), each including an AC/DC converter circuit and a DC/AC converter circuit having an input coupled to an output of the AC/DC converter circuit by a DC link, inputs of the AC/DC converter circuits of the first and second UPSs connected in common to an AC source and outputs of the DC/AC converter circuits of the first and second UPSs connected in common to a load. In such methods, the first UPS is test loaded by transferring power from the output of the DC/AC converter circuit of the first UPS to the output of the DC/AC converter circuit of the second UPS. Power may be provided to the load from the first UPS concurrent with test loading the first UPS by transferring power from the output of the DC/AC converter circuit of the first UPS to the output of the DC/AC converter circuit of the second UPS. Power may be transferred from the input of the AC/DC converter circuit of the second UPS to the input of the AC/DC converter circuit of the first UPS concurrent with test loading the first UPS by transferring power from the output of the DC/AC converter circuit of the first UPS to the output of the DC/AC converter circuit of the second UPS.
Further embodiments of the present invention provide power supply apparatus including first and second parallel-connected uninterruptible power supplies (UPSs), each including an AC/DC converter circuit and a DC/AC converter circuit having an input coupled to an output of the AC/DC converter circuit by a DC link, inputs of the AC/DC converter circuits of the first and second UPSs connected in common to an AC source and outputs of the DC/AC converter circuits of the first and second UPSs connected in common to a load. The first and second UPSs are configured to support a test mode wherein the first UPS is test loaded by transferring power from the output of the DC/AC converter circuit of the first UPS to the output of the DC/AC converter circuit of the second UPS. The first UPS may be configured to provide power to the load concurrent with test loading the first UPS by transferring power from the output of the DC/AC converter circuit of the first UPS to the output of the DC/AC converter circuit of the second UPS. The second UPS may be configured to control the AC/DC converter circuit of the second UPS to transfer power from the input of the AC/DC converter circuit of the second UPS to the input of the AC/DC converter circuit of the first UPS concurrent with test loading the first UPS by transferring power from the output of the DC/AC converter circuit of the first UPS to the output of the DC/AC converter circuit of the second UPS.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-3 are schematic diagrams illustrating power supply apparatus according to various embodiments of the invention.
FIG. 4 is a schematic diagram illustrating an exemplary inverter control configuration according to further embodiments of the invention.
FIG. 5 is a schematic diagram illustrating power supply apparatus according to further embodiments of the invention.
FIGS. 6-10 are schematic diagrams illustrating a UPS and exemplary test operations thereof according to further embodiments of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Specific exemplary embodiments of the invention now will be described with reference to the accompanying drawings. 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. In the drawings, like numbers refer to like elements. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include wirelessly connected or coupled. As used herein the term “and/or” includes any and all combinations of one or more of the associated listed items.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes,” “comprises,” “including” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Unless otherwise defined, all terms (including 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. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
As will be appreciated by one of skill in the art, the invention may be embodied as apparatus, methods and computer program products. Embodiments of the invention may include hardware and/or software. Furthermore, the 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.
Computer program code for carrying out operations of the 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 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).
Embodiments of the invention include circuitry configured to provide functions described herein. It will be appreciated that such circuitry may include analog circuits, digital circuits, and combinations of analog and digital circuits.
The invention is described below with reference to block diagrams and/or operational illustrations of methods, apparatus and computer program products according to various embodiments of the invention. It will be understood that each block of the block diagrams and/or operational illustrations, and combinations of blocks in the block diagrams and/or operational illustrations, can be implemented by analog and/or digital hardware, and/or computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, ASIC, and/or other programmable data processing apparatus, such that the instructions, which execute via the processor of the computer and/or other programmable data processing apparatus, create means for implementing the functions/acts specified in the block diagrams and/or operational illustrations. In some alternate implementations, the functions/acts noted in the figures may occur out of the order noted in the block diagrams and/or operational illustrations. For example, two operations shown as occurring in succession may, in fact, be executed substantially concurrently or the operations may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
FIG. 1 illustrates a power supply apparatus 100 according to some embodiments of the invention. The apparatus 100 , which may be incorporated in, for example, an on-line UPS, includes an AC/DC converter circuit 110 (e.g., a rectifier) having an input 112 configured to be coupled to an AC source (not shown), and an output 114 coupled to a DC link 115 . The AC/DC converter circuit 110 is operative to power the DC link 115 from AC power provided at its input 112 . The apparatus 100 also includes a DC/AC converter circuit 120 (e.g., an inverter) having an input 122 coupled to the DC link 115 and an output 124 configured to be coupled to a load (not shown). The DC/AC converter circuit 120 is operative to provide AC power at its output from DC power provided via the DC link 115 . The apparatus 100 further includes a bypass circuit (e.g., a static switch) 130 that is operative to couple and decouple the input 112 of the AC/DC converter circuit 110 and the output 124 of the DC/AC converter circuit 120 .
The apparatus 100 also includes a test control circuit 140 that controls the AC/DC converter circuit 110 and/or the DC/AC converter circuit 120 (i.e., either or both, as shown by dashed lines), and which also controls the bypass circuit 130 . More particularly, the test control circuit 140 is operative to cause the bypass circuit 130 to couple the output 124 of the DC/AC converter circuit 120 to the input 112 of the AC/DC converter circuit 110 , and to control the AC/DC converter circuit 110 and/or the DC/AC converter circuit 120 to cause power transfer from the output 124 of the DC/AC converter circuit 120 to the input 112 of the AC/DC converter circuit 110 via the bypass circuit 130 to thereby conduct a test, e.g., a burn-in, commissioning, or other test, of the apparatus 100 .
FIG. 2 illustrates a power supply apparatus 200 according to further embodiments of the invention. The apparatus 200 , which may be, for example, an on-line UPS, includes an AC/DC converter circuit a rectifier circuit 210 having an input 212 configured to be coupled to an AC source (not shown), and an output 214 coupled to DC link 215 . The rectifier circuit 110 is operative to transfer power between the DC link 215 and an AC power source (not shown) at its input 212 . The apparatus 200 also includes an inverter circuit 220 having an input 222 coupled to the DC link 215 and an output 224 configured to be coupled to an AC load (not shown). The inverter circuit 220 is operative to transfer power between the DC link 215 and the AC load. The apparatus 200 further includes a bypass circuit (e.g., a static switch) 230 that is operative to couple and decouple the input 212 of the rectifier circuit 210 and the output 224 of the inverter circuit 220 .
The apparatus 200 also includes a test control circuit 240 that controls the inverter circuit 220 and the bypass circuit 230 . The test control circuit 240 includes a bypass control circuit 242 that is operative to cause the bypass circuit 230 to couple the output 224 of the inverter circuit 220 to the input 212 of the rectifier circuit 210 , and a power control circuit 244 operative to control the inverter circuit 220 to cause power transfer from the output 224 of the inverter circuit 220 to the input 212 of the AC/DC converter circuit 210 via the bypass circuit 230 to conduct a test of the apparatus 200 . In particular, the power control circuit 244 is operative to generate a command signal 243 for control circuitry (e.g., current mode PWM control loop circuitry) of the inverter circuit 220 responsive to a power command signal 241 , which may, for example, include a real and/or reactive component. For example, the power command signal 241 may command the inverter circuit 220 to transfer power so as to effect a desired loading of the inverter circuit 220 , such that components of the UPS, such as power transistors in the rectifier circuit 210 and/or the inverter circuit 220 and associated control electronics and sensors, may be tested at the desired load.
During such testing, the rectifier circuit 210 may operate as it would during normal operation of the UPS, e.g., the rectifier circuit 210 may operate to regulate a DC voltage on the DC link 215 in both normal and test modes. It will be appreciated that, in such an implementation, the rectifier circuit 210 may respond to current demands at the DC link 215 created by the power transfer operations of the inverter circuit 220 . Alternatively, as discussed in detail below with reference to FIG. 5 , the rectifier circuit 210 may also be controlled by the test control circuit 240 to provide desired power transfer or other characteristics during testing.
FIG. 3 illustrates an exemplary control configuration for an implementation of a power supply apparatus along the lines of FIG. 2 according to further embodiments of the invention. FIG. 3 illustrates a power supply apparatus 300 that includes a rectifier circuit 310 having an input 312 configured to be coupled to an AC power source (not shown). The rectifier circuit 310 is operative to transfer power between a DC link 315 and the AC power source. The apparatus 300 also includes an inverter circuit 320 coupled to the DC link 315 and an output 324 configured to be coupled to a load (not shown). The inverter circuit 320 is operative to transfer power between its output 324 and the DC link 315 , and includes a bridge circuit 321 (e.g., an active bridge including one or more pairs of insulated gate bipolar transistors (IGBTs) arranged in a half-bridge configuration) coupled to the DC link 315 and an impedance (e.g., an inductor) 323 coupled to the output 324 . The apparatus 300 further includes a bypass circuit (e.g., a static switch) 330 that is operative to couple and decouple the input 312 of the rectifier circuit 310 and the output 324 of the inverter circuit 320 .
The apparatus 300 also includes test control circuitry for the inverter circuit 320 and the bypass circuit 330 implemented as functional blocks embodied in a processor 350 , such as a microprocessor, microcontroller, DSP, or combination thereof. The control circuitry includes a PWM control block 358 that provides one or more pulse-width modulation control signals 357 to the inverter circuit 320 to control operation of the bridge circuit 321 . The PWM control block 358 operates responsive to an inverter command signal 355 and one or more feedback signals 359 (e.g., signals representative of voltage and/or currents) associated with operation of the inverter circuit 320 . The inverter command signal 355 represents a reference for operation of a control loop for the inverter circuit 320 implemented by the PWM control block 358 .
One or more of the feedback signals 359 are also provided to a power control block 356 , also implemented in the processor 350 , which also receives a power command signal 353 , e.g., a signal representative of a real and/or reactive power to be produced by the inverter circuit 320 . Responsive to the power command signal 353 and the one or more feedback signals 359 , the power control block 356 produces the inverter command signal 355 that is supplied to the PWM control block 358 . In this manner, a voltage magnitude and phase at a node 325 of the bridge circuit 321 may be varied to effect a desired power transfer at the output 324 of the inverter circuit 320 . A test executive block 352 produces the power command signal 353 , and also provides a bypass command signal 351 to a bypass control block 354 implemented in the processor 350 . The bypass control block 354 responsively controls the bypass circuit 330 to couple and decouple the output 324 of the inverter circuit 320 and the input 312 of the rectifier circuit 312 .
It will be appreciated that the test executive block 352 may be configured to provide various configurations and operations of the apparatus 300 needed to conduct tests, such as loading tests, of the apparatus 300 . The test executive block 352 may be further configured to monitor status of components of the apparatus 300 during testing, such as voltages and/or current produced by the apparatus 300 , failures of components of the apparatus 300 , temperatures of various locations in the apparatus, and the like. It will also be understood that several of the component blocks implemented in processor 350 may serve functions other than the test control functions described above. For example, the power control block 356 and/or the PWM control block 358 may also be used for inverter control during “normal” operations using control blocks other than the test executive block 352 .
FIG. 4 illustrates an exemplary control loop configuration that may be implemented in the power control block 356 of FIG. 3 . Respective real and reactive power computation blocks 415 , 430 compute real and reactive power W inv , VAR inv signals for the output 324 of the inverter circuit 320 responsive to phase current and voltage signals i AC , ν AC (e.g., signals representative of current and voltage at the output 324 of the inverter circuit 320 ). These real and reactive power signals W inv , VAR inv are subtracted from respective real and reactive power reference (command) signals W ref , VAR ref at respective summing junction blocks 405 , 420 to generate respective real and reactive power error signals that are applied to respective compensation blocks 410 , 425 that provide respective transfer functions G w (z), G VAR (Z). The output of the reactive power compensation block 425 is a magnitude reference signal |Ref| that is representative of a voltage magnitude at the output 322 of the bridge circuit 321 of the inverter circuit 320 that will cause the inverter circuit 320 to approach the real power transfer indicated by the reactive power reference signal VAR ref . The output of the real power compensation block 410 is a phase offset signal θ offset that is representative of a phase shift that will cause the inverter circuit 320 to approach the real power transfer indicated by the real power reference signal W ref .
The phase offset signal θ offset is provided to another summing junction block 440 , where it is subtracted from a phase error signal θ error produced by a phase/frequency detector block 435 responsive to a comparison of a signal ν bypass , which is representative of a voltage at the input 312 of the rectifier circuit 310 (and, due to the closed state of the bypass circuit 330 , of the output 324 of the inverter circuit 320 ), to a reference signal ν ref provided to the inverter PWM control circuit 358 . The summing junction block 440 produces an adjusted error signal to an error controlled oscillator block 445 , which also receives a frequency error signal ω error from the phase/frequency detector block 435 .
The error controlled oscillator block 445 responsively produces a frequency signal that is scaled by a gain block 450 before provision to an accumulator (integrator) including a summing junction block 455 and a zero-order hold (ZOH) block 460 . In particular, the error controlled oscillator block 445 produces a signal representative of a desired frequency for the inverter reference signal ν ref , and the gain block converts this frequency signal into an angle per step signal θ step signal that represents the number of degrees of a sine wave that corresponds to a computational interval of the accumulator including the summing junction block 455 and the ZOH block 460 . The accumulator produces an angle reference signal θ ref , which is converted into a sinusoidal reference signal Ref sin by a sine function block 465 , i.e., a block that computes sine values corresponding to the angle values of the angle reference signal θ ref . This sinusoidal reference signal Ref sin is multiplied by the magnitude reference signal |Ref| in a multiplier block 470 to produce the inverter reference signal ν ref .
It will be appreciated that the functional blocks in FIGS. 3 and 4 may be implemented in a number of different ways, such as software modules or objects. It will also be appreciated that the control structures of FIGS. 3 and 4 are provided for illustrative purposes, and that a variety of different inverter control structures may be used with the invention. Such control structures generally may include digital control structures, analog control structures and combinations thereof. For example, all or some of the digital function blocks illustrated in FIGS. 3 and 4 may be replaced with analog circuits that perform equivalent functions.
As shown in FIG. 5 , according to further embodiments of the invention, additional control may be provided for a rectifier of a power supply apparatus, such as the apparatus 300 of FIG. 3 , such that real and/or reactive power transfer through the rectifier can be controlled in a manner similar to the inverter control described above. In particular, FIG. 5 illustrates a power supply apparatus 500 that includes a rectifier circuit 510 having an input 512 configured to be coupled to an AC source (not shown) and including a bridge circuit 511 coupled to the input 512 by an impedance 513 . The rectifier circuit 510 is operative to provide power to a DC link 515 from AC power provided at its input 512 . The apparatus 500 also includes an inverter circuit 520 coupled to the DC link 515 and an output 524 configured to be coupled to a load (not shown). The inverter circuit 520 is operative to provide AC power at its output from DC power provided via the DC link 515 , and includes a bridge circuit 521 coupled to the DC link 515 and an impedance (e.g., an inductor) 523 that couples the bridge circuit 521 to the output 524 . The apparatus 500 further includes a bypass circuit (e.g., a static switch) 530 that is operative to couple and decouple the input 512 of the rectifier circuit 510 and the output 524 of the inverter circuit 520 .
The apparatus 500 also includes a processor 550 configured to provide control circuitry for the inverter circuit 520 and the bypass circuit 530 , including a PWM control block 553 , a power control block 552 and a bypass control block 556 , which may operate along the lines discussed above with reference to FIGS. 3 and 4 . The processor 550 is further configured to provide control circuitry for the rectifier circuit 510 , including a PWM control block 555 and a power control block 554 , which control the bridge circuit 511 of the rectifier circuit 510 responsive to feedback signals associated with the rectifier circuit 510 . The power control block 554 and the PWM control block 555 are configured to vary a voltage magnitude and phase at a node 525 of the bridge circuit 511 responsive to a power command signal 561 to effect desired real and/or reactive power transfer at the input 512 . A test executive block 551 provides the rectifier and inverter power command signals 557 , 561 , and also provides a bypass command signal 563 to the bypass control block 556 .
FIGS. 6-10 are schematic diagrams that illustrate exemplary operations according to some embodiments of the invention that may be performed by an uninterruptible power supply (UPS) apparatus along the lines described above with reference to FIGS. 1-5 . A power supply apparatus 600 includes a rectifier circuit 610 and an inverter circuit 620 coupled by a DC link 615 . The apparatus 600 further includes a bypass circuit 630 , and a battery (or other DC source) coupled to the DC link 615 . It will be appreciated that the battery 640 may be directly coupled to the DC link 615 , or may be coupled by a power converter circuit, e.g., a charger/converter circuit.
Still referring to FIG. 6 , when an AC source 10 is coupled to the input of the apparatus 600 , the bypass circuit 630 , the rectifier circuit 610 and the inverter circuit 620 may be configured such that a circulating current is established therethrough. By controlling power transfer by the rectifier circuit 610 and the inverter circuit 620 , the circulating current may be used to emulate load test current for components of the apparatus 600 , including the rectifier, inverter and bypass circuits 610 , 620 , 630 , as well as other components associated with the circulating current path, such as current and temperature sensors. In this manner, various bum-in, commissioning and/or other tests may be conducted. This approach can allow testing without an actual load connected to the apparatus 600 , and can provide testing with minimal energy loss, as the AC source need only supply sufficient current to make up for losses in the apparatus 600 . As shown in FIG. 7 , according to further embodiments of the invention, such testing make even take place while the apparatus 600 is supplying power to a load 20 . Such a technique may be particularly useful for performing maintenance tests in the field while still supporting critical loads. As shown in FIG. 8 , the apparatus 600 may be tested by circulating power from the battery 640 , without connection to an external AC source 10 . As shown in FIG. 9 , a discharge test of the battery 640 may be effected by disabling the rectifier circuit 610 and allowing current from the battery 640 flow through the inverter circuit 620 and the bypass circuit 630 into the external AC source 10 .
FIG. 10 illustrates a test configuration for parallel-connected UPSs 1010 , 1020 according to further embodiments of the invention. In particular, desirable loading of components of the UPSs 1020 , 1020 can be achieved by establishing a circulating current that passes through both of the UPSs 1010 , 1020 . Such a circulating test current could be established by operating one UPS 1020 in a “normal” fashion, while controlling the inverter and/or rectifier of the second UPS 1020 to provide synthetic additional loading of the first UPS 1010 .
It will be appreciated that a variety of self-testing schemes fall within the scope of the invention. In some embodiments, if a rectifier of a UPS (or other power supply apparatus) has active components (e.g., along the lines illustrated in FIG. 5 ), the rectifier's reactive power transfer may be controlled to match reactive power transfer from the UPS's inverter, such that reactive loading of the utility if desired. Further enhancements can be made to produce circulating currents that represent other types of loads such as harmonic or non-linear loads using inverter and/or rectifier control. For example, the inverter and rectifier could be controlled with current commands such that the inverter produces harmonic test currents (e.g., to simulate a non-linear load), and the rectifier generates harmonic currents that cancel the harmonic test currents generated by the inverter to reduce or prevent degradation of a utility source.
Power supply configurations according to various embodiments of the invention, such as those described above with reference to FIGS. 6-10 , shown can be used by a manufacturing facility, customer, or service organization to perform integrity testing. Power supply apparatus components that can be tested include, but are not limited to, inverter power train and control connections, rectifier power train and control connections, bypass module, contactors, breakers, feedback signals, control circuitry, control processors located inside the UPS. Further embodiments may test breakers or other switchgear. In some embodiments, thermal controls, such as fans, heat sinks, and temperature sensors may be tested. Embodiments of the invention may verify system performance requirements, such as efficiency.
According to additional embodiments, a manufacturing facility, customer, or service organization may perform load testing while using reduced or minimal power to enable energy savings. A manufacturing facility that is load testing one of more UPS' would not be required to install a large utility feed that would normally have to supply enough energy for all the UPSs that are tested, as the utility feed would only need to be large enough to cover the losses in the UPS. Testing may be controlled remotely via modem, network, internet, wireless or other communications device.
According to further aspects of the invention, UPS calibration could be automated. For example, if a bypass circuit is used to measure voltage and current and was known to be accurate, this information could be used to calibrate voltage and current measurements in other portions of the UPS. For example, the inverter and rectifier could be turned off but connected via a bypass. In this case no current would be circulating and one could adjust voltage measurements made by the inverter and rectifier so that they match the known accurate bypass voltage. Using a configuration as illustrated in FIG. 6 , a circulating current could then be commanded, and rectifier and inverter current measured and sensor gains adjusted to match bypass current.
In the drawings and specification, there have been disclosed exemplary embodiments of the invention. 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 defined by the following claims.
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A power supply apparatus includes first and second parallel-connected uninterruptible power supplies (UPSs), each including an AC/DC converter circuit and a DC/AC converter circuit having an input coupled to an output of the AC/DC converter circuit by a DC link, inputs of the AC/DC converter circuits of the first and second UPSs connected in common to an AC source and outputs of the DC/AC converter circuits of the first and second UPSs connected in common to a load. The first and second UPSs are configured to support a test mode wherein the first UPS is test loaded by transferring power from the output of the DC/AC converter circuit of the first UPS to the output of the DC/AC converter circuit of the second UPS. The first UPS may be configured to provide power to the load concurrent with test loading by the second UPS.
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This is a division of application Ser. No. 08/791,966, filed Jan. 31, 1997, such prior application being incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
The present invention relates generally to tools used in subterranean wells and, in a preferred embodiment thereof, more particularly provides a proppant slurry screen apparatus for use in formation fracturing operations.
Oftentimes, a potentially productive geological formation beneath the earth's surface contains a sufficient volume of valuable fluids, such as hydrocarbons, but also has a very low permeability. "Permeability" is a term used to describe that quality of a geological formation which enables fluids to move about in the formation. All potentially productive formations have pores, a quality described using the term "porosity", within which the valuable fluids are contained. If, however, the pores are not interconnected, the fluids cannot move about and, thus, cannot be brought to the earth's surface.
When such a formation having very low permeability, but a sufficient quantity of valuable fluids in its pores, is desired to be produced, it becomes necessary to artificially increase the formation's permeability. This is typically accomplished by "fracturing" the formation, a practice which is well known in the art and for which purpose many methods have been conceived. Basically, fracturing is achieved by applying sufficient pressure to the formation to cause the formation to crack or fracture, hence the name. The desired result being that the cracks interconnect the formation's pores and allow the valuable fluids to be brought out of the formation and to the surface.
A conventional method of fracturing a formation begins with drilling a subterranean well into the formation and cementing a protective tubular casing within the well. The casing is then perforated to provide fluid communication between the formation and the interior of the casing which extends to the surface. A packer is set in the casing to isolate the formation from the rest of the wellbore, and hydraulic pressure is applied to the formation via tubing which extends from the packer to pumps on the surface.
The pumps apply the hydraulic pressure by pumping fracturing fluid down the tubing, through the packer, into the wellbore below the packer, through the perforations, and finally, into the formation. The pressure is increased until the desired quality and quantity of cracks is achieved. Much research has gone into discerning the precise amount and rate of fracturing fluid and hydraulic pressure to apply to the formation to achieve the desired quality and quantity of cracks.
The fracturing fluid's composition is far from a simple matter itself. Modern fracturing fluids may include sophisticated man-made proppants suspended in gels. "Proppant" is the term used to describe material in the fracturing fluid which enters the formation cracks once formed and while the hydraulic pressure is still being applied (that is, while the cracks are still being held open by the hydraulic pressure), and acts to prop the cracks open. When the hydraulic pressure is removed, the proppant keeps the cracks from closing completely. The proppant thus helps to maintain the artificial permeability of the formation after the fracturing job is over. Fracturing fluid containing suspended proppant is also called a slurry.
A proppant may be nothing more than a very fine sand, or it may be a particulate material specifically engineered for the job of holding formation cracks open. Whatever its composition, the proppant must be very hard and strong to withstand the forces trying to close the formation cracks. These qualities also make the proppant a very good abrasive. It is not uncommon for holes to be formed in the protective casing, tubing, pumps, and any other equipment through which a slurry is pumped.
Particularly susceptible to abrasion wear from pumped slurry is any piece of equipment in which the slurry must make a sudden or significant change in direction. The slurry, being governed by the laws of physics, including the principles of inertia, tends to maintain its velocity and direction of flow, and resists any change thereof. An object in the flowpath of the slurry which tends to change the velocity or direction of the slurry's flow will soon be worn away as the proppant in the slurry incessantly impinges upon the object.
Of particular concern in this regard is the piece of equipment attached to the tubing extending below the packer which takes the slurry as it is pumped down the tubing and redirects it radially outward so that it exits the tubing and enters the formation through the perforations. That piece of equipment is known to those skilled in the art as a crossover. Assuming, for purposes of convenience, that the tubing extends vertically through the wellbore, and that the formation is generally horizontal, the crossover must change the direction of the slurry by ninety degrees. Because of this significant change of direction, few pieces of equipment (with the notable exception of the pumps) must withstand as much potential abrasive wear as the crossover.
In addition, the crossover is frequently called upon to do several other tasks while the slurry is being pumped through it. For example, the crossover typically contains longitudinal circulation ports through which fracturing fluids that are not received into the formation after exiting the crossover are transmitted back to the surface through an annular area between the tubing and the wellbore casing above the packer.
Space limitations in the wellbore dictate that the circulation ports are not far removed from the flowpath of the slurry through the crossover. If the crossover is worn away such that the slurry flowpath achieves fluid communication with the circulation ports in the crossover, the fracturing job must cease while the tubing is removed from the wellbore to replace the crossover at great loss of time and money. Otherwise, the slurry may enter the circulation ports in the crossover, flow into the annular area between the tubing and the wellbore casing above the packer or a screen annulus area below the packer, and possibly stick the tool in the well.
A major reason for the service tool sticking when the crossover becomes eroded between the slurry flowpath and the circulation ports is that, unless the pumps are stopped immediately after the slurry flowpath achieves fluid communication with the circulation ports, the slurry will be pumped through the circulation ports to the annular area above the packer. This results in the proppant in the slurry settling out in the annular area above the packer and around the tubing from which the service tool is suspended. It is not uncommon for such pumping of the slurry into the annular area above the packer to go unnoticed and, consequently, large volumes of proppant to be deposited around the tubing.
For the above reasons and others, the crossover has commonly been considered a critical piece of equipment, whose failure during slurry delivery usually means failure of the entire fracturing job. Extensive measures have been employed in the past to avoid failure of the crossover, that is, to retard abrasive wear of the crossover and the resultant communication between the slurry flowpath and circulation ports. None, however, have solved the problem of how to prevent sticking of the service tool after the crossover has failed by preventing the deposition of proppant in the annular area above the packer.
From the foregoing, it can be seen that it would be quite desirable to provide a proppant slurry screen apparatus which prevents depositing of proppant around the tubing above or below the packer following the failure of the crossover. It is accordingly an object of the present invention to provide such a proppant slurry screen apparatus and associated methods of using same.
SUMMARY OF THE INVENTION
In carrying out the principles of the present invention, in accordance with a preferred embodiment thereof, a proppant slurry screen apparatus and method of using same are provided, which apparatus and method are specially adapted for utilization in formation fracturing operations in subterranean wellbores. The apparatus prevents proppant from entering the annular area above the packer if a crossover portion of the apparatus fails by erosion due to the abrasive slurry being forced through it.
In broad terms, a proppant slurry screen apparatus which is operatively positionable in a subterranean wellbore wherein a packer is set, the packer having an axial internal bore extending from a first to a second side of the packer, the bore receiving the apparatus thereinto from the first side of the packer, is provided, the apparatus including a tubular outer housing having an axial portion and inner and outer side surfaces, the outer housing extending from the packer first side to the packer second side, the outer housing outer side surface slidably engaging the packer bore, and the axial portion extending axially outward from the packer first side, the axial portion having a radially extending port formed therethrough, a tubular inner mandrel axially disposed within the outer housing, the inner mandrel having inner and outer side surfaces, the inner mandrel inner side surface defining an axial flow passage therein, and the inner mandrel outer side surface and the outer housing inner side surface defining a circulation flow passage therebetween, the circulation flow passage being in fluid communication with the outer housing port, and a screen disposed adjacent the outer housing port, the screen being capable of filtering fluid flowing from the circulation flow passage to the wellbore on the packer first side.
A proppant slurry screen apparatus operatively positionable in a subterranean wellbore during flow thereinto of a slurry, the slurry including a fluid portion and a plurality of particles, is also provided, the apparatus including a first tubular structure having first and second opposite ends, an exterior surface, and a first flow passage through which the slurry may be axially flowed from the first tubular structure first opposite end to the first tubular structure second opposite end, the first tubular structure being axially disposed within the wellbore, and a second tubular structure having first and second opposite ends, interior and exterior surfaces, an opening formed axially intermediate the second tubular structure first and second opposite ends and extending from the second tubular structure interior surface to the second tubular structure exterior surface, the opening having at least one dimension which permits fluid portion flow therethrough but prevents the particles from flowing therethrough, and the second tubular structure axially and exteriorly overlying the first tubular structure such that a second flow passage is formed radially intermediate the first tubular structure exterior surface and the second tubular structure interior surface.
Yet another proppant slurry screen apparatus is provided, the apparatus being operatively positionable in a subterranean wellbore during flow thereinto of a slurry, the slurry including a fluid portion and a plurality of abrasive particles. The apparatus includes a first tubular structure having first and second opposite ends, an exterior surface, and a first flow passage through which the slurry may be axially flowed from the first tubular structure first opposite end to the first tubular structure second opposite end, the first tubular structure being axially disposed within the wellbore, a second tubular structure having first and second opposite ends, interior and exterior surfaces, an opening formed axially intermediate the second tubular structure first and second opposite ends and extending from the second tubular structure interior surface to the second tubular structure exterior surface, and first and second seal surfaces, the first and second seal surfaces being formed on the second tubular structure interior surface such that the opening is axially intermediate the first and second seal surfaces, the second tubular structure axially and exteriorly overlying the first tubular structure such that a second flow passage is formed radially intermediate the first tubular structure exterior surface and the second tubular structure interior surface, a filter structure having first and second opposite end portions, and interior and exterior surfaces, the filter structure being capable of filtering the abrasive particles from the fluid portion in the second flow passage, the filter structure first and second opposite end portions having first and second seal surfaces formed respectively thereon, and first and second seal structures, the first seal structure sealingly engaging the first tubular structure first seal surface and the filter structure first seal surface, and the second seal structure sealingly engaging the first tubular structure second seal surface and the filter structure second seal surface.
For use in a subterranean wellbore wherein a packer is set, the packer having an axial internal bore extending from a first to a second side of the packer, in conjunction with an abrasive slurry delivery structure having a crossover structure disposed in the wellbore on the second side of the packer with an internal flow passage through which an abrasive slurry containing abrasive particles may be axially flowed, a side wall outlet opening bounded by a peripheral side wall edge portion and outwardly through which abrasive slurry material from the internal flow passage may be discharged, and an internal circulation passage formed adjacent the peripheral side wall edge portion, a method of filtering abrasive particles in the internal circulation passage after slurry erosion of the peripheral side wall edge portion is provided, the method including the steps of providing a tubular outer housing having an axial portion and inner and outer side surfaces, the axial portion having a radially extending port formed therethrough, inserting the outer housing into the packer such that the outer housing extends from the packer first side to the packer second side and the outer housing axial portion extends axially outward from the packer first side, providing a tubular inner mandrel having inner and outer side surfaces, the inner side surface defining an axial flow passage therein, the inner mandrel axial flow passage being in fluid communication with the crossover structure internal flow passage, disposing the inner mandrel axially within the outer housing such that the inner mandrel outer side surface and the outer housing inner side surface define a circulation flow passage therebetween and the circulation flow passage is in fluid communication with the outer housing port and the crossover structure internal circulation passage, providing a screen capable of filtering the abrasive particles from the abrasive slurry, and disposing the screen such that fluid flowing from the circulation flow passage to the outer housing port must pass through the screen.
A method of screening proppant delivered to a subterranean wellbore in a pressurized slurry is also provided, the method including the steps of providing a first tubular structure having first and second opposite ends, an exterior surface, and a first flow passage through which the slurry may be axially flowed from the first tubular structure first opposite end to the first tubular structure second opposite end, disposing the first tubular structure axially within the wellbore, providing a second tubular structure having first and second opposite ends, interior and exterior surfaces, an opening formed axially intermediate the second tubular structure first and second opposite ends and extending from the second tubular structure interior surface to the second tubular structure exterior surface, forming first and second seal surfaces on the second tubular structure interior surface such that the opening is axially intermediate the first and second seal surfaces, disposing the second tubular structure axially and exteriorly overlying the first tubular structure, forming a second flow passage radially intermediate the first tubular structure exterior surface and the second tubular structure interior surface, providing a filter structure having first and second opposite end portions, and interior and exterior surfaces, the filter structure being capable of filtering the abrasive particles from the fluid portion in the second flow passage, forming first and second seal surfaces on the filter structure first and second opposite end portions, respectively, providing first and second seal structures, sealingly engaging the first tubular structure first seal surface and the filter structure first seal surface with the first seal structure, and sealingly engaging the first tubular structure second seal surface and the filter structure second seal surface with the second seal structure.
A method of screening abrasive particles in a subterranean wellbore during pressurized particle slurry delivery into the wellbore is also provided, the method including the steps of providing a first tubular structure having first and second opposite ends, an exterior surface, and a first flow passage through which the slurry may be axially flowed from the first tubular structure first opposite end to the first tubular structure second opposite end, disposing the first tubular structure axially within the wellbore, providing a second tubular structure having first and second opposite ends, and interior and exterior surfaces, forming an opening axially intermediate the second tubular structure first and second opposite ends and extending from the second tubular structure interior surface to the second tubular structure exterior surface, the opening having at least one dimension which permits slurry flow therethrough but prevents the particles from flowing therethrough, disposing the second tubular structure axially and exteriorly overlying the first tubular structure, and forming a second flow passage radially intermediate the first tubular structure exterior surface and the second tubular structure interior surface.
The disclosed proppant slurry screen apparatus and method of using same permit fracturing operations to be performed more economically and with less risk of sticking the service tool in the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 (Prior Art) is a cross-sectional view of a prior art service tool operatively positioned within a packer in a subterranean wellbore;
FIGS. 2A-2B are quarter-sectional views of a proppant slurry screen apparatus embodying principles of the present invention;
FIG. 3 is an enlarged scale cross-sectional view of a crossover portion of the proppant slurry screen apparatus, taken along line 3--3 of FIG. 2B;
FIG. 4 is an enlarged scale cross-sectional view of the proppant slurry screen apparatus, taken along line 4--4 of FIG. 2B;
FIG. 5 is a quarter-sectional view of a second proppant slurry screen apparatus embodying principles of the present invention;
FIG. 6 is an enlarged scale cross-sectional view of the second proppant slurry screen apparatus, taken along line 6--6 of FIG. 5; and
FIG. 7 is a quarter-sectional view of a third proppant slurry screen apparatus embodying principles of the present invention.
DETAILED DESCRIPTION
FIG. 1 (Prior Art) shows a conventional service tool 10 operatively positioned in a subterranean wellbore 12 to perform a fracturing and/or gravel packing operation. The following detailed description is given with the assumption that the wellbore 12 is substantially vertical as representatively illustrated in FIG. 1 (Prior Art), with terms such as "upward" and "downward" referring to such orientation. It is to be understood that the service tool 10 may be utilized in otherwise oriented wellbores.
Service tool 10 is inserted partially through the internal bore 14 of a packer 16, circumferential seal 18 on the service tool sealingly contacting the bore. The packer 16 has been set in protective casing 20 so that packer rubber 22 forms a pressure seal between the packer 16 and the casing 20, and packer slips 24 bite into and grip the casing, preventing movement of the packer relative to the casing.
Attached to and suspended from the packer 16 is an outer tubular member 26, in which the service tool 10 is received. Outer tubular member 26 includes a longitudinally (i.e., axially) extending upper portion 28, circumferentially spaced ports 30, an inner seal surface 32, and a lower portion 34.
A sand screen 36 is attached to the outer tubular member lower portion 34 in the wellbore 12 opposite a potentially productive formation 38 which has previously had perforations 40 formed in it. Perforations 40 extend from the wellbore 12 into the formation 38 and provide fluid communication therebetween.
In a typical formation fracturing operation, a proppant slurry 42 is pumped from the earth's surface through tubing (not shown) and into an internal axial flow passage 44 of the service tool 10. The slurry 42 radially exits the service tool 10 through circumferentially spaced exit ports 46 formed on a crossover portion 48 of the service tool 10. Upon exiting the service tool 10, the slurry 42 enters an annular flow passage 50 formed between the service tool 10 and the outer tubular member upper portion 28.
The slurry 42 flows through the annular flow passage 50 and then radially exits the outer tubular member 26 through the ports 30. After exiting the ports 30, the slurry 42 enters the wellbore 12 between the outer tubular member 26 and the casing 20 below the packer 16. Pressure is then increased on the slurry 42 at the earth's surface to force the slurry 42 into the formation 38 through perforations 40.
Not all of the slurry 42 is received into the formation 38, however. A fluid portion 52 of the slurry 42 (i.e., a portion of the slurry minus the proppant) is circulated back to the pumps on the earth's surface. Prior to being circulated back to the pumps, the fluid portion 52 enters the sand screen 36 which removes the proppant from the slurry 42.
The fluid portion 52 then flows through opening 58 and into an internal flow passage 54 formed in a lower portion 56 of the service tool 10. Lower portion 56 is sealingly inserted into the outer tubular member 26. Circumferential seals 60 (only one of which is shown in FIG. 1) provide a fluid seal between the lower portion 56 and the seal surface 32 of the outer tubular member 26.
Flow passage 54 extends through the crossover 48 by means of longitudinally extending and circumferentially spaced apart circulation ports 66. The circulation ports 66 are typically located in the crossover 48 in close proximity to the exit ports 46. Fluid portion 52 flows in flow passage 54 longitudinally upward through the service tool 10 until it exits through ports 62 formed radially through an outer housing 64. Thus, between the outer housing 64 and an inner mandrel 68, the flow passage 54 extends from the crossover 48 circulation ports 66 to the ports 62 in the outer housing 64.
When the fluid portion 52 exits ports 62 and enters the wellbore 12 above the packer 16, it flows in an annular area 70. Annular area 70 is defined as extending radially between the outer housing 64 (and the tubing from which the service tool 10 is suspended) and the casing 20, and longitudinally between the packer 16 and a wellhead (not shown) at the earth's surface. If there is any proppant or debris in the fluid portion 52, it will typically settle out of the fluid portion and come to rest on top of the packer 16 before the fluid portion reaches the wellhead, since it is usually several thousand feet from the ports 62 to the wellhead.
It will be readily apparent to one skilled in the art that proppant and other debris settling out in the annular area 70 above the packer 16 and between the service tool 10 and the casing 20 poses a significant danger of sticking the service tool 10. Even when the wellbore 12 is not substantially vertical as shown in FIG. 1 (Prior Art), an accumulation of proppant and/or debris between the service tool 10 and the casing 20 may cause the service tool 10 to become stuck in the wellbore 12.
The danger of sticking is substantially increased when a very large amount of proppant is pumped into the annular area 70. Such a situation occurs when exit ports 46 are eroded by the proppant slurry 42 to the point that axial flow passage 44 is in fluid communication with flow passage 54 and the slurry 42 is permitted to enter the circulation ports 66 in the crossover 48. When this happens, the slurry 42 may be pumped through the circulation ports 66, into the flow passage 54, and then into the annular area 70 above the packer 16.
Turning now to FIGS. 2A and 2B, a proppant slurry screen apparatus 100 which embodies principles of the present invention is shown. In the following detailed description of the apparatus 100 representatively illustrated in FIGS. 2A and 2B, and subsequent figures described hereinbelow, directional terms such as "upper", "lower", "upward", "downward", etc. will be used in relation to the apparatus 100 as it is depicted in the accompanying figures. It is to be understood that the apparatus 100 may be utilized in vertical, horizontal, inverted, or inclined orientations without deviating from the principles of the present invention.
Apparatus 100, as representatively illustrated in FIGS. 2A and 2B, is specially adapted for use within a service tool string (not shown), which is suspended from tubing extending to the earth's surface, the tubing being longitudinally disposed within protective casing in a subterranean wellbore 102. In FIGS. 2A and 2B, the wellbore 102 is external to the apparatus 100. The service tool string is typically inserted through a packer 103 (shown in phantom) during a fracturing job. A pressurized, abrasive slurry is then pumped through the tubing and into the service tool string. Tubular upper connector 104 and lower connector 106 permit interconnection of the apparatus 100 into the service tool string. Accordingly, upper portion 108 of upper connector 104 is connected to the service tool string above the apparatus 100, and lower portion 110 of lower connector 106 is connected to the remainder of the service tool string extending below the apparatus 100. Note that illustratively cut surface 112 of FIG. 2A is continuous with the same cut surface 112 of FIG. 2B.
Axial flow passage 114 extends longitudinally (i.e., axially) downward from the upper portion 108 of upper connector 104, through the upper connector, and into a generally tubular seal sub 116. Seal sub 116 has three longitudinally spaced apart circumferential seals 118 disposed thereon which sealingly engage the upper connector 104. From the seal sub 116, the axial flow passage 114 extends axially downward through a tubular inner mandrel 120. Inner mandrel 120 is sealingly and threadedly attached to the seal sub 116 at an upper end 122 of the inner mandrel.
At a lower end 124 of the inner mandrel 120, the inner mandrel is sealingly and threadedly attached to an upper portion 128 of a generally tubular connector 126. The axial flow passage 114 extends axially through the tubular connector 126 and into a crossover 132 which is sealingly and threadedly attached to a lower portion 130 of the tubular connector. The axial flow passage 114 terminates at upper radially reduced portion 134 of generally cylindrical plug 136.
Plug 136 is threadedly installed into lower portion 138 of crossover 132 and secured with a pair of set screws 140 (only one of which is visible in FIG. 2B). Sealing engagement between the plug 136 and the lower portion 138 of crossover 132 is provided by seal 142 disposed in circumferential groove 144 externally formed on the plug.
Radially displaced, longitudinally extending, circulation flow passage 146 extends downwardly through tubular connector 126, longitudinally through the crossover 132 in a manner that will be described more fully hereinbelow, through the lower connector 106, and to lower portion 110. Upwardly from the tubular connector 126, the circulation flow passage 146 extends longitudinally through an annulus 148 formed between the inner mandrel 120 and an outer housing 150.
Outer housing 150 includes a tubular extension sub 152 and a tubular ported housing 154 which are threadedly and sealingly joined together in a radially outwardly overlying relationship to the inner mandrel 120. Outer housing 150 may include more than one extension sub 152 as needed to selectively position the crossover 132 with respect to the ported housing 154, in which case a correspondingly extended inner mandrel 120 is also utilized.
When the apparatus 100 is operatively installed in the wellbore 102, the circulation flow passage 146 in the apparatus 100 is sealingly isolated from the wellbore 102 external to the apparatus by seal 156 disposed in circumferential groove 158 internally formed on the upper connector 104, seal 160 disposed in circumferential groove 162 internally formed on extension sub 152, seal 164 disposed in circumferential groove 166 internally formed on tubular connector 126, seal 168 disposed in circumferential groove 170 internally formed on the tubular connector 126, and by seal 172 disposed in circumferential groove 174 internally formed on the lower connector 106.
The circulation flow passage 146 is sealingly isolated from axial flow passage 114 in the apparatus 100 by seal 142, seals 118, and a pair of seals 176, each disposed in one of a pair of circumferential grooves 178 externally formed on an upper portion 184 of the crossover 132 which is threadedly installed coaxially into the tubular connector 126.
In operation, the proppant slurry is pumped downwardly through the longitudinal flow passage 114, radially outward through the crossover 132 and into the wellbore 102, and outwardly into the geological formation being fractured and/or gravel packed (not shown). The fluid portion of the proppant slurry (minus the proppant) which is not retained in the formation is returned to the earth's surface through the circulation flow passage 146.
Annular seal rings 186 are disposed in longitudinally spaced apart external annular recesses 188 formed between upper connector 104 and ported housing 154, between ported housing 154 and extension sub 152, between extension sub 152 and tubular connector 126, between tubular connector 126 and upper portion 184 of crossover 132, and between lower portion 138 of crossover 132 and lower connector 106. The seal rings 186 seal the apparatus 100 within the packer 103 and other equipment into which the apparatus 100 may be inserted.
Four longitudinally extending circumferentially spaced apart slotted outlet openings or exit ports 190 (three of which are visible in FIG. 2B), having external radially extending and circumferentially sloping surfaces 192 formed thereon, provide fluid communication between the axial flow passage 114 and the wellbore 102. It is through these exit ports 190 that the proppant slurry must pass in its transition from longitudinal flow in the axial flow passage 114 to radial flow into the wellbore 102. Because of the substantial change of direction from longitudinal flow to radial flow of the slurry through the exit ports 190, the exit ports are particularly susceptible to abrasion wear from proppant contained in the slurry.
In order to protect the exit ports 190 against abrasion wear, a tubular protective sleeve 194 is coaxially disposed within the crossover 132. The protective sleeve 194 is made of a suitably hard and tough abrasion resistant material, such as tungsten carbide, or is made of a material, such as alloy steel, which has been hardened. If made of an alloy steel, the protective sleeve 194 is preferably through-hardened by a process such as nitriding. The protective sleeve 194 is secured into the crossover 132 by drive pin 196 which extends laterally through the protective sleeve and the upper portion 134 of the plug 136.
Upper portion 198 of protective sleeve 194 extends axially upward past the exit ports 190 in the crossover 132, thereby completely internally overlapping the portion of the crossover 132 in which the exit ports 190 are located. Four circumferentially spaced and longitudinally extending slotted ports 200 are formed radially through the sleeve 194 and are aligned with the exit ports 190 in the crossover 132. The ports 200 in the sleeve 194, however, are smaller in length and width than the ports 190 in the crossover 132, such that the sleeve 194 completely internally overlaps the crossover 132 in the exit ports 190 area of the crossover.
Referring additionally now to FIG. 3, a cross-sectional view may be seen of the apparatus 100 representatively illustrated in FIGS. 2A-2B. The cross-section is taken along line 3--3 of FIG. 2B which extends laterally through the crossover 132. In this view, the manner in which circulation flow passage 146 extends longitudinally through the crossover 132 may be seen.
Eight longitudinally extending and circumferentially spaced circulation ports 202 are disposed radially intermediate inner diameter 204 of the crossover 132 and outer diameter 206 of the crossover. Two each of the circulation ports 202 are disposed in the crossover 132 circumferentially intermediate each pair of exit ports 190. Flow ports 200 in protective sleeve 194, being somewhat smaller in width than the exit ports 190, act to protect the exit ports 190 from abrasion wear due to radially outwardly directed flow of the slurry. It may be clearly seen in FIG. 3 that if exit ports 190 wear appreciably circumferentially outward, or if the protective sleeve 194 and inner diameter 204 of the crossover 132 wear appreciably radially outward, the exit ports 190 and flow passage 114 will eventually be in fluid communication with the circulation ports 202. If such abrasive wear of the crossover 132 does occur, the proppant slurry will be permitted to enter the circulation ports 202.
Referring additionally now to FIG. 4, a cross-sectional view of the apparatus 100, taken laterally along line 4--4 of FIG. 2B may be seen. FIG. 4 further illustrates the manner in which the circulation ports 202 extend longitudinally through the crossover 132. It may thus be clearly seen that circulation ports 202 provide fluid communication for the circulation flow passage 146 from the tubular connector 126 attached to upper portion 184 of the crossover 132 to the lower connector 106 attached to lower portion 138 of the crossover 132. Consequently, if the proppant slurry enters the circulation ports 202 adjacent the crossover exit ports 190 as above described, the proppant slurry will be permitted to enter the circulation flow passage 146 in the annulus 148 between the outer housing 150 and inner mandrel 120.
If the proppant slurry enters the circulation flow passage 146 in the annulus 148 and is permitted to flow out into the wellbore 102 through circumferentially spaced apart and radially extending ports 208 formed on ported housing 154 and disposed above the packer 103, the apparatus 100 will be in danger of becoming stuck. To prevent the apparatus 100 from becoming stuck, even though the proppant slurry has broken through to the circulation flow passage 146 in the crossover 132, apparatus 100 includes specially designed features which prevent passage of the proppant into the wellbore 102 through the ports 208.
Referring specifically now to FIGS. 2A and 2B, a tubular screen 210 is disposed within the ported housing 154, radially inward from the ports 208. The screen 210 inwardly overlaps the ports 208. Screen 210 is also disposed in the circulation flow passage 146 between the inner mandrel 120 and the outer housing 150, but is somewhat radially spaced apart from the inner mandrel 120 so that the circulation flow passage 146 extends axially through the screen 210.
Screen 210 may be made of any suitable material capable of filtering proppant and debris from the fluid portion. Suitable materials for the screen 210 include sintered metal and wire-wrapped sand screen. The preferred material for the screen 210 representatively illustrated in FIG. 2A is sintered metal, but it is to be understood that other materials may be utilized without departing from the principles of the present invention.
Seals 212 and 214 are disposed in circumferential grooves 216 and 218, respectively, internally formed on the ported housing 154, straddling the ports 208. Seals 212 and 214 sealingly engage upper and lower portions 220 and 222, respectively, of the screen 210. Thus, any fluid flowing from the circulation flow passage 146 and through the ports 208 to the wellbore 102 must first pass through the screen 210. In this manner, the screen 210 prevents any proppant or debris in the fluid portion from entering the wellbore 102 above the packer 103.
Thus has been described the proppant slurry screen apparatus 100 which prevents the service tool from becoming stuck in the wellbore 102 after the crossover 132 has been abraded such that the proppant slurry enters the circulation flow ports 202. Use of the above described apparatus 100 prevents proppant from settling out in the wellbore 102 above the packer 103 and between the service tool and the casing.
Illustrated in FIGS. 5 and 6 is another embodiment 100a of the proppant containment apparatus 100. For convenience, elements of the apparatus 100a representatively illustrated in FIGS. 5 and 6 which are substantially similar to those elements illustrated in the foregoing described figures have been given the same reference numerals, with the suffix "a" added thereto. FIG. 6 is a cross-sectional view of the apparatus 100a, taken laterally through ported housing 154a.
Note that in the apparatus 100a as shown in FIGS. 5 and 6, only the ported housing 154a and outer housing 150a portions of the apparatus 100a are representatively illustrated. The remainder of the apparatus 100a is the same as apparatus 100 shown in FIGS. 2A, 2B, 3, and 4. The apparatus 100a shown in FIGS. 5 and 6 differs in one respect from the apparatus 100 shown in FIGS. 2A and 2B in the method utilized to screen the proppant and debris from the fluid portion in circulation flow passage 146a.
In the representatively illustrated embodiment of the apparatus 100a in FIG. 5, a tubular screen 232 is disposed longitudinally in the circulation flow passage 146a between inner mandrel 120a and outer housing 150a. The screen 232 extends axially from a radially inwardly extending internal shoulder 234 formed on the ported housing 154a, through extension sub 152a, to a radially inwardly extending internal shoulder 236 formed on an extension sub 238. A large filtering surface area is thus possible utilizing screen 232 in apparatus 100a, to prevent clogging of the screen 232 with proppant and debris, and to provide less restriction to the fluid portion flow. Each of these benefits produce yet another benefit of reduced differential pressure across the screen 232, which reduces the possibility of failure of the screen. It is to be understood that more than one extension sub 152a may be used, permitting screen 232 to be extended axially as needed to achieve a desired screen surface area.
Screen 232 may be made of any suitable material capable of filtering proppant and debris from the fluid portion. Suitable materials for the screen 232 include sintered metal and wire-wrapped sand screen. The preferred material for the screen 232 representatively illustrated in FIG. 5 is wire-wrapped sand screen, but it is to be understood that other materials may be utilized without departing from the principles of the present invention.
Seals 240 and 242 are disposed in circumferential grooves 244 and 246, respectively, externally formed on the screen 232 upper portion 248 and lower portion 250, respectively. Seals 240 and 242 sealingly engage the ported housing 154a and extension sub 152a, respectively. Thus, any fluid flowing from the circulation flow passage 146a and through ports 208a to wellbore 102a must first pass through the screen 232. In this manner, the screen 232 prevents any proppant or debris in the fluid portion from entering the wellbore 102a above the packer 103a.
FIG. 6 shows the unique manner in which the axially extending screen 232 permits fluid communication from the circulation flow passage 146a to ports 208a. Screen 232 has a polygonal shape, representatively illustrated in FIG. 6 as having six sides, although other shapes may be utilized without departing from the principles of the present invention. Since lower portion 250 of the screen 232 is sealed to the extension sub 152a, the fluid portion flowing in the circulation flow passage 146a must pass between the screen 232 and inner mandrel 120a. Due to the shape of the screen 232, circulation flow passage 146a extends the entire length of the screen, enhancing the benefit described above of the large surface area of the screen.
The shape of the screen 232 also defines a flow passage 252 between the screen and outer housing 150a. The fluid portion flows in flow passage 252 after passing through screen 232. As with the circulation flow passage 146a, flow passage 252 extends the entire length of the screen 232. Thus, maximum utilization is afforded of the screen 232 surface area, due to the shape of the screen.
Referring now specifically to FIG. 5, another difference between apparatus 100a and apparatus 100 shown in FIG. 2A is the shape of the ports 208a in the ported housing 154a. Ports 208a are axially elongated slotted openings. Ports 208a thus maximize the tensile strength of the ported housing 154a as compared to ports 208 of apparatus 100, since ports 208a remove less cross-sectional area of the ported housing 154a for an equivalent port flow area. Alternatively, if it is not desired to increase the tensile strength of ported housing 154a, ports 208a may permit greater port flow area without decreasing the tensile strength of the ported housing 154a. Slotted ports 208a provide the additional benefit of exposing a greater length of the screen 232 to direct fluid communication with the wellbore 102a.
Illustrated in FIG. 7 is another embodiment 100b of the proppant containment apparatus 100. For convenience, elements of the apparatus 100b representatively illustrated in FIG. 7 which are substantially similar to those elements illustrated in the foregoing described figures have been given the same reference numerals, with the suffix "b" added thereto.
Note that in the apparatus 100b as shown in FIG. 7, only the portions of the apparatus 100b from upper connector 104b to extension sub 152b are representatively illustrated. The remainder of the apparatus 100b is the same as apparatus 100 shown in FIGS. 2A, 2B, 3, and 4. The apparatus 100b shown in FIG. 7 differs in one respect from the apparatus 100 shown in FIGS. 2A and 2B in the method utilized to screen the proppant and debris from the fluid portion in circulation flow passage 146b.
In the representatively illustrated embodiment of the apparatus 100b in FIG. 7, a separate screen is not utilized. Instead, a number of very narrow, longitudinally extending slots 262 are formed through sidewall 264 of ported housing 260. Slots 262 have sufficient width to permit flow therethrough of the fluid portion, but are narrow enough to prevent passage therethrough of most proppant and debris. Preferably, slots 262 each have a width of approximately 0.006-0.008 inch, but may also have widths of approximately, 0.003-0.030 inch. Slots 262 may be formed on the sidewall 264 by any suitable method. Applicants' preferred method is to cut the slots 262 through the sidewall 264 with a laser, but it is to be understood that other methods may be utilized without departing from the principles of the present invention.
The slots 262 are circumferentially spaced apart and staggered to maximize the tensile strength of the ported housing 260. Slots 262 cumulatively have sufficient flow area to permit flow of the fluid portion through the sidewall 264. It is to be understood that other quantities, dimensions, and placements of the slots 262 may be utilized without departing from the principles of the present invention.
Many benefits are derived from use of the apparatus 100b having slots 262 formed on ported housing 260. There is no separate screen to install, seal, maintain, etc.; circulation flow passage 146b remains unobstructed within the ported housing 260; a large volume of the circulation flow passage 146b is thus available for accumulation of filtered proppant and debris; the ported housing 260 can withstand large differential pressures if necessary; and the apparatus 100b, having fewer components, is economical to manufacture, and easy to assemble and maintain.
The foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims.
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A proppant slurry screen apparatus and associated method of using it prevent sticking of a service tool during proppant slurry delivery to a subterranean wellbore after failure of a crossover portion of the apparatus. In a preferred embodiment, a proppant slurry screen apparatus has a tubular crossover member with an internal flow passage, circulation port, and side wall outlet openings, first and second coaxial tubular structures, the first tubular structure extending above a packer and having a radial port which provides fluid communication between the wellbore above the packer and an annular flow passage between the first and second tubular structures, and a tubular screen positioned between the first and second tubular structures adjacent the port and operative to screen proppant from the proppant slurry.
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BACKGROUND
[0001] Control of a functional unit may be carried out using a control system. A linear feedback control loop may be used to generate such a signal. Linear feedback loops may be used in various kinds of control, including motors, pumps and electronic components.
[0002] The precision of the input signal to a linear feedback control loop may be determined from the open loop gain of the system. Different technological issues may affect the gain and precision of such a control loop.
[0003] For example, such loops may have an offset error. The offset error may be reduced by increasing the gain of the loop. A loop with infinite gain might have zero offset error. However, the gain of each real life component is subject to physical limitations. This often requires that additional amplifying elements be used within the loop. These amplifying elements may undesirably increase phase delay through the loop. The bandwidth of the loop may need to be reduced in order to slow the response of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] These and other aspects will now be described in detail with reference to the accompanying drawings, wherein:
[0005] [0005]FIG. 1 shows a basic block diagram of an electrical control loop; and
[0006] [0006]FIG. 2 shows a basic block diagram of the control loop in more generic format; and
[0007] [0007]FIG. 3 shows a 2 loop version of the present system which corrects offset errors in a control loop;
[0008] [0008]FIG. 4 shows and n loop version of the control loop;
[0009] [0009]FIG. 5 shows a transistor level schematic of the 2 loop version; and
[0010] [0010]FIG. 6 shows a transistor level diagram of the basic control loop structure.
DETAILED DESCRIPTION
[0011] An embodiment may stabilize control loops. The prior art has often increased a gain within a control loop in order to decrease the offset error, as described above. In contrast, the present system uses a plurality of basic loops which are connected together to decrease the offset error. Each of these loops may have a lower gain than a single loop would have, in order to provide comparable offset error.
[0012] A first loop in the sequence may operate similar to the conventional loop. Each successive loop in the sequence of loops may use information from the previous loops in order to displace offset, and bring the offset as close to zero as possible. As disclosed herein, if n loops are used, each loop having an open loop gain of T, then the offset in the nth loop may be approximately 1/T n times that of a single loop.
[0013] This system may allow offset error to be reduced without significantly changing the stability of the system, or slowing the system, and hence without significantly reducing the bandwidth of the system.
[0014] This system may therefore be used with any of a number of different linear feedback control systems as described herein. The example given herein explains the operation for the embodiment of an electrical circuit implementation. However, other implementations may also be used.
[0015] A standard control loop for a differential amplifier is shown in FIG. 1. Element 100 , labeled as B(•) represents the item to be controlled. The output from the item to be controlled 100 is labeled as V f =B(V c ). This value is fed back to the feedback input 112 of the amplifier 110 .
[0016] The amplifier 110 is a differential amplifier, driven by an input signal V r and by the feedback signal V f in a conventional way, e.g., as a differential amplifier.
[0017] For a well-designed amplifier that operates within a specific range, the amplifier output may be approximated as
V c =V o +G ( V r −V f ), (1)
[0018] where G is the differential amplifier gain, and V o is the quiescent output voltage.
[0019] [0019]FIG. 2 shows a similar basic control loop rewritten in a more generic signal flow graph. This signal flow graph is applicable to both electrical and nonelectrical signals. The system in FIG. 2 includes a first object 200 receiving the feedback and the driving signal, a second object 210 , receiving the signal S o , and the driven object 100 . The system of FIG. 2 may be defined in terms of the equations s c =s o +G(s r −s f ) and s f =B(s c ). In an ideal system with infinite gain, the loop would produce the control signal s c =B −1 (s r ), which is effectively the signal that forces the reference and feedback signals to become equal. However, when G is finite, as it will be in every real system, the solution will deviate from this ideal case. The deviation is quantified by the “input offset error”
e i =s f −s r (2),
[0020] that is the difference between the feedback signal and the input signal.
[0021] This input offset error can be calculated.
[0022] First, the static transfer characteristics of the unit under control are approximated by
s f =B ( s c ) @ B ( s o )+ G B ( s c −s o ) (3),
[0023] where G B =[dB(x)/dx] x=s o is the small-signal gain of the unit under control.
[0024] The offset error can then be calculated as
e i =( B ( s o )− s r )/(1 +G B G ). (4)
[0025] As the equation 4 shows, the offset error originates in the discrepancy between the quiescent output, s o , and the desired control signal, B −1 (s r ). Limited a priori knowledge of s r , s o , and B( ), however, may restrict a designers ability to control the offset error.
[0026] The conventional approach to reducing e i has thus been to increase G, thereby increasing the denominator in equation (4) and reducing e i . However, any given kind of amplifier has a limited gain. Since the gain of a single amplifier stage is limited, the overall gain has typically been increased by cascading multiple stages. In order to maintain the stability of the system, therefore, bandwidth of the system may be restricted. This may increase the response time of the system and may be unacceptable in certain applications.
[0027] The present application may reduce this offset in a new way by adding additional control loops instead of by increasing the system gain. Each additional control loop may reduce the error. For example, the error may be reduced by a factor related to a gain factor of the loop raised to the number of additional control loops beyond the basic loop.
[0028] The embodiment of FIG. 3 shows a 2 loop version of the system, with loop #1 labeled as element 310 , and loop #2 labeled as element 320 . In operation, loop #1 operates to calculate a correction factor which is applied to loop #2.
[0029] The differential amplifier 110 is replaced in the two loop implementation by a more complex differential amplifier. The amplifier 300 in loop No. 1 is a differential amplifier 302 with a first input 304 having a gain G1 and a second input 306 having a gain G2. In the first loop, the second input has its values tied together and connected to the input signal S r . The second input pair 304 includes a first value tied to S r , and a second value receiving the feedback output of the driven device B(.).
[0030] Note that loop No. 1 therefore becomes functionally similar to the system in FIG. 1. As such, it has the same error as in FIG. 1, that is it operates with an input offset error
e i1 =( B ( s o )− S r )/(1 +G B G 1 ).
[0031] Similar components are present in the second loop 320 , and this error from the first loop is used to correct the error in the second loop and thereby provide a corrected output.
[0032] The second loop 320 , loop #2, includes a similar amplifier shown as 330 . This amplifier includes the same gains G 1 and G 2 , but has its inputs configured slightly differently. The loops could be the same, or similar but “scaled”. The inputs to the first differential pair 332 in loop No. 2 include the input value S r and the feedback value S fb . Hence, the difference between the inputs to the first differential pair is e i1 .
[0033] Thus, the output of loop #2 amplifier is
s c2 =s o −G 1 e i1 +G 2 ( s r −s f2 ).
[0034] This is analogous to the single loop, but with an effective quiescent output signal of
s o2 =s o −G 1 e i1 .
[0035] Loop #1, then, is effectively being used to calculate a correction to this quiescent output. The quiescent output of loop #2 is displaced by this amount, based on the positive input to differential pair 334 , to reduce the offset error.
[0036] Assuming that the derivative of B( ) is evaluated and s o and s o2 are approximately equal to the same value G B , the offset error for loop #2 can be considered as
e i2 =( B ( s o )− s r )/[(1 +G B G 1 )(1 +G B G 2 )].
[0037] This compares with the single loop case given above, where the offset error is:
e i =( B ( s o )− s r )/(1 +G B G ).
[0038] Taking all the gains being the same, this becomes equivalent to increasing the gain in the basic loop by a factor of approximately G B G. This is done without increasing the loop order, however, and therefore the dynamics, and specifically, the bandwidth of the system are not affected. Because of this use of second order loops, the overall system can run as fast as the corresponding second order loop; that is, the bandwidth of the original loop is only minimally affected.
[0039] The above has described the situation of the two-loop system. Even further decreases the may be obtained by adding additional loops. FIG. 4 shows a system with n loops. In this n-loop system, each amplifier such as 400 has n differential inputs. Also, in this n-loop system, the input offset error of the n th loop is given by
e m =( B ( s o )− s r )/(1 +G B G ) n .
[0040] The offset error in this n loop case is decreased by the gain G B G raised to the power of the number of loops. In this n-loop system, therefore, the offset error can be made arbitrarily small without increasing G or sacrificing the bandwidth.
[0041] [0041]FIG. 5 shows a transistor level schematic of the two loop version, implemented in the P 858 process. The original circuit of this type, shown in FIG. 6, had an offset error of 4 mv. The FIG. 5 circuit achieves a much lower offset error of 0.3 millivolts: a 13-fold error reduction. Both the original circuit and the new circuit have the same settling time of 6 ns, emphasizing that the bandwidth of the system is not compromised.
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A system of connecting errors in the control loop using multiple additional loops. A first loop carries out control in a desired way, and the additional loops are provided for the purpose of determining a specified error value. That specified error value may be, for example, a quiescent current. The specified error value is then used to correct for errors in the first loop.
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GOVERNMENT LICENSE RIGHTS
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as may be provided for by the terms of Contract Number: N68335-06-C-0086, Contract Title: Development of a Compact Power Generation Turbine and Cooling System, Start Date: Dec. 5, 2005, End Date: Feb. 14, 2010, and Contract Number: N68335-09-C-0384, and Contract Title: Continued Development of a Compact Power Generation Turbine and Cooling System, Start Date: Aug. 5, 2009, End Date: Feb. 4, 2010, the entire disclosure of which are herein expressly incorporated by reference.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to U.S. application Ser. No. 12/333,770, now U.S. Pat. No. 8,192,158 issued Jun. 5, 2012; U.S. application Ser. No. 12/693,535, filed concurrently herewith; U.S. application Ser. No. 12/693,547, now U.S. Pat. No. 8,430,361 issued Jul. 9, 2013; and U.S. application Ser. No. 12/693,564, filed concurrently herewith.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to air driven power generators, particularly to power generation, size, weight, and efficiency improvements of ram-air driven turbines. An aerodynamic secondary flow lobe mixer device mounted on the discharge side of an air-driven turbine has been developed. The invention generates an increased ratio of total-to-static pressure across a Ram Air Turbine (RAT) developed for a Prime Power Generating (PPG) unit, resulting in increased turbine power generation when compared to a RAT without the invention. Improvements in the ram-air turbine design and the functionality of the turbine exhaust ducting provide increased power extraction capability resulting in a smaller and lighter power generator that minimizes the overall system size and weight.
2. Description of the Related Art
A RAT is a turbine driven by free-stream air that flows past an aircraft during flight. RATs can be used to develop mechanical power that can be directly converted into electrical power using a generator, or both. The mechanical shaft power can be used to power any mechanical device, including but not limited to hydraulic systems, vapor-compression cooling system compressors, circulation pumps, or refueling pumps. Electrical power can be used for electronic subsystems, such as onboard avionics equipment, electronic warfare equipment, and auxiliary backup power systems. RATs can be mounted directly onboard an aircraft fuselage or on secondary wing mounted pods or stores. At wing-mounted locations, the RAT can be located either at an external location where the turbine is directly exposed to free-stream air, or an internal location inside a pod, where the free-stream air is ducted to the turbine through an inlet that is exposed to free-stream air. Prior work on internal RAT's have utilized ducts to deliver free-stream air to the turbine, by locating the RAT internally, pressure losses occur in the inlet ducting, which decreases turbine output power. They are also normally limited to ambient static pressure on the turbine discharge. The new invention makes it more feasible to locate a RAT in an interior location and extract additional power relative to a traditional RAT by lowering the turbine discharge pressure below atmospheric pressure.
U.S. Patent Application Publication No. 2009/0263244 A1 teaches the use of a mixer/ejector device that improves the performance of a water turbine through mixing of the turbine discharge and a secondary flow stream, increasing the turbine mass flow rate and overall energy extraction. This device is described as applying to ocean-, tidal-, and river/stream-currents.
U.S. Pat. No. 6,804,948 teaches the use of a lobe mixer for a jet engine that efficiently mixes two streams of gases by contouring of the lobes to reduce the noise normally generated while suppressing thrust losses caused by mixing.
U.S. Pat. No. 4,819,425 teaches the use of a lobe mixer with vent openings located within the lobe surfaces for noise suppression in a high bypass turbofan jet engine.
U.S. Patent Application Publication Nos. 2008/0105487 A1 and 2008/0105488 A1 both teach a curved lobe mixer for a bypass turbomachine comprising circumferentially distributed lobes that mix concentric gas streams within a converging-diverging flow nozzle to achieve noise suppression.
U.S. Pat. No. 4,149,375 teaches the use of a lobe mixer device with “scalloped” side walls that provide efficient mixing of two flow streams for improved noise suppression and/or engine performance with minimal pressure losses.
None of the above-mentioned prior art teaches the use of a lobe mixer device to mix two flow streams to augment the total-to-static pressure ratio across a ram air-driven turbine for the purpose of increasing power.
The mechanical power that can be developed from a RAT is a function of the total-to-static pressure ratio across the turbine rotor. The pressure at the face of the turbine rotor is a function of the aircraft velocity, altitude, and environmental conditions and is specified as the total pressure or the maximum obtainable pressure that can be utilized for power generation. If a method to decrease the static pressure at the turbine discharge is not utilized, the power generating capability of the RAT is limited to the total pressure developed by the aircraft and the ambient static pressure.
SUMMARY OF THE INVENTION
The present invention employing a lobe mixer relates to any air-driven turbine for producing shaft work and/or electric power generation. An axial turbine is used for demonstration purposes, although it will be apparent to anyone skilled in the art that the present invention also applies to radial, impulse, reaction, and other types of turbines.
Therefore, in light of the benefits of an enhanced ram-air turbine, the aforementioned shortcomings in the prior art, this invention has among other things, the following objectives:
To increase the total-to-static pressure ratio across a turbine resulting in increased power extraction, rotational speed, efficiency, and reduced size and weight.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings herein.
FIG. 1 is a side view of an internal air-driven turbine including a secondary flow lobe mixer in accordance with the present invention.
FIG. 2 is a rear view of the current embodiment of the turbine and secondary flow lobe mixer.
FIG. 3 is a perspective view of the air-driven turbine with the lobe mixer, according to the current embodiment.
FIG. 4 a is a perspective view of the triangle-shaped lobe mixer, according to a currently preferred embodiment.
FIG. 4 b is a rear view of the triangle-shaped lobe mixer, according to the currently preferred embodiment.
FIG. 5 a is a perspective view of a sinusoidal-shaped lobe mixer, according to another embodiment of the innovation.
FIG. 5 b is a rear view of the sinusoidal-shaped lobe mixer shown in FIG. 5 a.
FIG. 6 a is a perspective view of a square-shaped lobe mixer, according to yet another embodiment of the innovation.
FIG. 6 b is a rear view of the square-shaped lobe mixer, as shown in FIG. 6 a.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to air-driven turbine, power generation equipment. This invention is not limited to air but can be used with any incompressible or compressible working fluid. This invention is also not limited to aircraft, but may be used with automobiles, submarines, towed body arrays, hydroelectric dams, and other embodiments that may benefit from improved fluid energy extraction.
For systems requiring electrical power, the air-driven turbine and lobed mixer are designed as an integrated unit. The figures provided in the detailed description show an axial-flow turbine, although radial, impulse, reaction, and other types of turbines can be used as well. The following terms are defined to assist with the description of the invention as used the context of the present invention.
An air-driven turbine is a device that generates mechanical shaft power through the expansion of air or other working fluid through a turbine rotor.
An electric generator (or generator) is a generic term for a device that creates electrical power. In the context of the present invention, an electric generator is a machine comprised of the RAT and the alternator combined, with or without other devices attached to the power-producing shaft as well.
A lobe mixer is a device for lowering the pressure of a primary flow stream through the efficient mixing of a high velocity, low static pressure secondary air or other fluid flow with the primary lower velocity, higher static pressure flow stream. The lobe mixer achieves efficient mixing by creating cross-flow rotation of both fluid streams with respect to the other at each lobe, generating significant axial vorticity. The cross-flow rotation is achieved by appropriately shaping the mixer surface from an initially flat cross section to a highly contoured lobe shape which protrudes into and out of both flow streams, as would be known by anyone skilled in the art. The vorticity augmentation increases the level of mixing between the two flow streams over the traditional free shear layer mixing that would occur without a lobe mixer. Increased fluid mixing achieves a lower turbine discharge static pressure nearer to the turbine rotor exit plane than would occur otherwise. This lobe mixer concept is applicable to air, water, or other working fluids.
FIG. 1 is a side view of the primary flow duct 101 and internal air-driven turbine 102 including a secondary flow duct 103 incorporating the lobe mixer 104 . The secondary flow duct 103 is located co-annularly around the primary flow duct 101 such that the secondary flow air discharges around the lobe mixer 104 and mixes efficiently with the primary air flow. The mixed flow stream exits downstream of the turbine in the turbine exhaust region 105 . The secondary flow duct 103 is connected to the free-stream, thus capturing high total pressure fluid within. The primary flow duct 101 is also connected to the free-stream, to provide high total pressure fluid to rotate the air-driven turbine.
FIG. 2 is a front view of the secondary flow stream 103 surrounding the primary flow stream 101 . This view also depicts the air-driven turbine 102 , the lobe mixer 104 between the two flow streams and the lobe centerline 107 (also seen in FIG. 1 ) about which the lobe members can be symmetrically or asymmetrically arranged.
FIG. 3 is a perspective view of the current embodiment showing a cutaway view of the upstream primary flow duct 101 , air-driven turbine 102 , and secondary flow duct 103 . The full circumferential extent of the lobe mixer 104 is also shown downstream of the turbine discharge region. In this embodiment, the pitch and yaw angle orientation of the lobe mixer surface with respect to the axial flow direction may be varied in order to optimize the flow mixing into the turbine discharge section. The total number of mixer lobes and the overall mixer axial length may also be adjusted in order to improve the turbine discharge static pressure.
FIG. 4 a is a perspective view of the lobe mixer cross section shape. In the current embodiment, the cross-sectional shape is triangular; however, other embodiments with different shape configurations are also envisioned in this innovation, not limited to those presented herein.
FIG. 4 b is a rear view of the same triangularly-shaped lobe mixer as shown in FIG. 4 a.
FIG. 5 a depicts a perspective view of a lobe mixer with a sinusoidal lobe shape. Here, the lobe shape is symmetric with respect to the lobe centerline, although, asymmetric or other aperiodic lobe shapes are also envisioned.
FIG. 5 b shows a rear view of the sinusoidal lobe mixer as embodied in FIG. 5 a.
FIGS. 6 a and 6 b depict an isometric and rear view, respectively, of yet another lobe mixer shape conceptualized in this innovation. Here, the lobe mixer shape consists of a square lobe shape.
Referring to FIGS. 4 a through 6 b , the lobe mixers in each embodiment are constructed of lobe height (h) to lobe period (T) of one, as labeled in FIG. 5 b . However, for each embodiment, the height of the lobes with respect to the lobe width may be altered in order to achieve optimal flow mixing. Also, the lobe location, number, pitch angle, yaw angle, and lobe periodicity are not restricted by the current embodiment; these may be varied in order to optimize the static pressure at the turbine discharge plane.
As shown in FIG. 1 , the primary duct 101 , secondary duct 103 , and exhaust duct 105 are shown as straight ducts; however, these can be of varying cross sectional area as necessary for a given embodiment. These duct surfaces can be shaped to accommodate various profiles, such as a flat surface, arced surface, or other geometric shape to modify the conditions around the turbine rotor.
The location of the secondary flow ducting is not required to be circumferentially located 360 degrees around the co-annular primary flow duct. In another embodiment, the secondary flow ducting may only encompass a portion of the full circumferential extent around the primary flow ducting, such that the amount secondary air flow to the turbine discharge is sufficient to suitably lower the turbine exit static pressure below the unmodified discharge pressure. It is apparent to anyone skilled in the art, that any two separated primary and secondary flow passage geometries can be used where the goal is for the secondary passage to lower the static pressure of the primary passage.
Referring to FIG. 1 , the angle between the axial flow direction and the mean lobe mixer surface 106 can be varied by increasing or decreasing the mean mixer trailing edge diameter, such that the lobe mixer protrudes more or less into the high velocity secondary air flow than the primary air flow. This angle may be adjusted accordingly in order to modify the performance of the system.
The present invention is not limited to Ram Air Turbines, but may be utilized on any other power generation system that can benefit with lower static pressures at the discharge point.
The current system may be utilized for mechanical shaft power generation to run hydraulic pumps, aircraft refueling pumps, aircraft refueling pods, cooling compressors, and cooling pumps and additional apparatuses that require mechanical or electrical power for operation. Additionally, the current system is not limited to mechanical shaft power generation. The shaft power may be suitably converted to electrical power through an accompanying alternator or other electricity generating device.
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A secondary flow lobe mixer increases the total-to-static pressure ratio across a Ram Air Turbine (RAT) by developing a localized pressure drop near the discharge of the turbine rotor exhaust. This pressure drop allows for additional power generation for a given free-stream flight condition.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a production method of a polyester by using a microorganism.
[0003] 2. Related Background Art
[0004] Microbial polyesters represented by poly 3-hydroxybutyrate (PHB) have a remarkable feature that they are biologically degradable, differing from the synthetic polymers made from petroleum.
[0005] Synthetic polymers have been used as plastics etc. for a long time. On disposal, however, this feature of hard-to-decompose makes them accumulated in waste-disposal facilities, or when they are burned, harmful substances such as dioxin and endocrine-disruptors are generated to cause environmental pollution.
[0006] On the other hand, polyesters produced by microorganisms (hereinafter referred to as “microbial polyesters”) can be biologically degraded to be incorporated in a natural recycling system, usable as environment-maintaining plastics. They also have a potential as soft materials for medical use (Japanese Patent Application Laid-Open No. 5-159).
[0007] Heretofore, various bacteria have been reported to produce and accumulate PHB or copolymers of other hydroxyalkanoic acids in the cells (Handbook of Biodegradable Plastics, ed. by Biodegradable Plastics Society, published by N.T.S., p. 178-197 (1995)).
[0008] Recently, for industrial use of such poly hydroxyalkanoic acids (PHA), various attempts have been done to make the microorganisms produce modified PHA comprised of unusual monomer units for broader physicochemical properties.
[0009] One of these attempts, Japanese Patent Application Laid-Open No. 5-30980, discloses that Pseudomonas fluorescence FA-031 (FERM P-3433) can produce copolymers of poly hydroxyfatty acid esters made of monomer units of C4 to C16, when the cells are cultured using oleic acid, triolein (olive oil) or triglyceride as a carbon source under nitrogen starvation. The presence of carbon-carbon double bonds were confirmed in C14 and C16 units.
[0010] Further, it discloses that when linoleic acid is used as a substrate, the produced polyester is comprised of units of C4 to C16, the presence of double bond was confirmed in units of C10, C12, C14, and C16, and when α-linolenic acid is used as a substrate, the produced polyester is comprised of units of C4 to C16, the presence of double bonds were confirmed in units of C8, C10, C12, C14, and C16.
[0011] A method to produce PHA containing units of 3-hydroxyoctenoic acid and 3-hydroxyhexenoic acid is disclosed in Int. J. Biol. Macromol. Vol,12 p. 85-91 (1989), where Pseudomonas oleovorans ATCC 29347 is grown using 3-hydroxy-6-octenoic acid or 3-hydroxy-7-octenoic acid as a substrate.
[0012] A method to produce PHA containing units of 3-hydroxydecenoic acid and 3-hydroxytetradecenoic acid is disclosed in Appl. Environ. Microbiol. (1992) Vol. 58(2) p. 536-544, where Pseudomonas putida KT2442 is grown using glucose, fructose and glycerol as substrates.
[0013] A method to produce PHA containing units of 3-hydroxyoctenoic acid and 3-hydroxyhexenoic acid is disclosed in Polymer, Vol 35(10) (1994) p. 2090-2097, where Pseudomonas oleovorans ATCC 29347 is grown using n-octane and 1-octene as substrates.
[0014] A method to produce PHA containing units of 3-hydroxydecenoic acid and 3-hydroxytetradecenoic acid is disclosed in Int. J. Biol. Macromol. 23 (1994) p. 61-72 where Pseudomonas resinovorans NRRL B-2649 is grown using tallow as a substrate.
[0015] Although various methods have been studied to produce PHA having carbon-carbon double bonds in their side chains using microorganisms as described above, the inventors have come to think that more variety of the culture conditions and substrates are required for practical use. At present, studies on the use of organic substrate materials derived from relatively inexpensive minerals such as petroleum are not at least sufficient.
SUMMARY OF THE INVENTION
[0016] According to one embodiment of the present invention, there is provided a method for producing microbial polyester which comprises a step of growing a microorganism capable of producing a polyester in a medium containing 1-hexene as a sole carbon source.
[0017] Preferably, at least one monomer unit constituting the polyester is a hydroxyfatty acid having a carbon double bond, more preferably, at least one of 3-hydroxyhexenoic acid and 3-hydroxyocteinoic acid.
[0018] Preferably, the microorganism is a bacterium of genus Pseudomonas, more preferably, Pseudomonas cichorii YN2 (FERM BP-7375).
[0019] The method of the present invention further comprises a step of recovering the polyester product from the microorganism in the culture medium.
[0020] The method of the present invention enables the production of poly hydroxyalkanoate containing 3-hydroxyfatty acid having a double bond in the side chain by using 1-hexene as a sole carbon source.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is an 1 H-NMR chart of PHA.
[0022] [0022]FIG. 2 is a 13 C-NMR chart of PHA.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The present invention provides a method for producing a PHA containing a monomer unit having a carbon-carbon double bond in the side chain, by growing a microorganism in a medium containing 1-hexene as a sole carbon source.
[0024] Preferably, the microorganism is a bacterium of genus Pseudomonas, more preferably, Pseudomonas cichorii YN2 (FERM BP-7375).
[0025] Taxonomical characteristics of Pseudomonas cichorii YN2 are as follows:
[0026] Growth temperature: 30° C.
[0027] Morphology: rod (0.8×1.5 to 2.0 μm)
[0028] Gram staining: gram-negative
[0029] Spore formation: negative
[0030] Motility: positive
[0031] Colony morphology: circular, entire, convex, smooth, glossy, translucent
[0032] Catalase: positive
[0033] Oxidase: positive
[0034] O/F test: non-fermentive
[0035] Nitric acid reduction: negative
[0036] Indole production: positive
[0037] Glucose acidification: negative
[0038] Arginine dehydrolase: negative
[0039] Urease: negative
[0040] Esculin hydrolysis (β-glucosidase): negative
[0041] Gelatin hydrolysis (protease): negative
[0042] β-galactosidase: negative
[0043] Assimilation of compounds:
[0044] glucose: positive
[0045] L-arabinose: positive
[0046] D-mannose: negative
[0047] D-mannitol: negative
[0048] N-acetyl-D-glucosamine: negative
[0049] maltose: negative
[0050] potassium gluconate: positive
[0051] n-capric acid: positive
[0052] adipic acid: negative
[0053] dl-malic acid: positive
[0054] sodium citrate: positive
[0055] phenyl acetate: positive
[0056] Production of fluorescent pigment on King's B agar:
[0057] positive
[0058] Growth in 4% NaCl: positive (weak)
[0059] Accumulation of poly-β-hydroxybutyrate: negative*
[0060] Tween 80 degradation: positive
[0061] (* by staining of colonies on the nutrient agar with Sudan Black)
[0062] With the above characteristics, the bacterium was determined to be a strain of Pseudomonas cichorii according to Bergey's Manual of Determinative Bacteriology, 9th Edition. Further, the PHA production behavior of this strain indicates this being a novel strain, so that it has been deposited in National Institute of Bioscience and Human Technology, Agency of Industrial Science and Technology, as FERM BP-7375.
[0063] The culture medium used in the present invention may be any mineral salts medium containing phosphate and a nitrogen source such as ammonium salt or nitrate. By controlling the nitrogen concentration can be enhanced the PHA productivity. 1-hexene to be added in the culture medium is volatile, and poorly soluble in water, so that the culture vessel must be tightly closed after securing the required oxygen.
[0064] An example of the mineral salt medium composition is shown below.
[0065] M9 medium
Na 2 HPO 4 6.3 g/l KH 2 PO 4 3.0 g/l NaCl 0.5 g/l NH 4 Cl 1.0 g/l pH 7.0
[0066] 1/10 M9 medium
Na 2 HPO 4 6.3 g/l KH 2 PO 4 3.0 g/l NaCl 0.5 g/l NH 4 Cl 0.1 g/l pH 7.0
[0067] For better growth and PHA production, the following trace element solution must be added to the above inorganic salt medium to 0.3% (v/v).
[0068] Trace Element Solution (g/L)
nitrilotriacetic acid 1.5 MgSO 4 3.0 MnSO 4 0.5 NaCl 1.0 FeSO 4 0.1 CaCl 2 0.1 ZnSO 4 0.1 CuSO 4 0.1 AlK(SO 4 ) 2 0.1 H 3 BO 3 0.1 Na 2 MoO 4 0.1 NiCl 2 0.1
[0069] The culture temperature may be any temperature so long as the above strain can grow well, e.g., 15 to 40° C., preferably about 20 to 30° C.
[0070] Any culture method can be used in the present invention so long as the above strain can grow and produce PHA, for example, such as liquid culture, solid culture, batch culture, fedbatch culture, semi-continuous culture, and continuous culture.
[0071] As for PHA recovery from the cells in the present invention, ordinary chloroform extraction is most convenient. However, where the organic solvent is difficult to use, PHA can be recovered by removing the cell components other than PHA by treating with surfactants such as SDS, enzymes such as lysozyme, agents such as EDTA, sodium hypochlorite and ammonia.
[0072] Now the present invention will be described with reference to the following Example, however it is our intention that the scope of the invention be not limited by any of the details of the description.
EXAMPLE
PHA Production by Culturing Strain YN2 with 1-Hexene Carbon Source
[0073] Strain YN2 was grown on an M9 agar medium containing 0.1% yeast extract, and a colony was taken and suspended in a sterilized physiological saline to prepare a cell suspension of OD 600 1.0.
[0074] The suspension was spread on 20 plates of 1/10N-M9 agar not containing a carbon source, and the plates were incubated at 30° C. under 1-hexene atmosphere.
[0075] After 4 days incubation, cells were collected, washed with methanol, and the collected cells by centrifugation was dried under a reduced pressure. The dry weight of the cells was 150 mg.
[0076] To the dried cells, 50 ml of chloroform was added and stirred at 50° C. for 24 hrs to extract PHA. The chloroform layer was filtrated, concentrated by an evaporator. Cold methanol was added to remove the precipitate, which was then dried under a reduced pressure. Thus, 68 mg of dried PHA was obtained. The PHA weighed to about 45% of the dried cell weight.
[0077] The composition of the obtained polymer was determined as follows: 10 mg of the polymer was put into a 25 ml egg-plant type flask and dissolved by adding 2 ml chloroform, to which 2 ml of a methanol solution containing 3% sulfuric acid was added, and reacted at 100° C. under reflux for 3.5 hrs.
[0078] After the completion of the reaction, 2 ml water was added to the flask, and the flask was shaken vigorously for 10 min, and left stand for phase separation. The lower chloroform layer was removed and dried over magnesium sulfate. This was then subjected to gas-mass chromatography to identify each methyl hydroxyalkanoate peak by using a gas chromatograph-mass spectrograph (GC-MS; Shimadzu QP-5050, DB-WAX capillary column (J&W). The result is shown in Table 1.
TABLE 1 Unit C4 C6 C6: C8 C8: C10 C12 C12 C14 C14: Area % 0.5 27.2 8.0 11.9 0.5 25.7 10.3 10.9 2.5 0.6
[0079] In Table 1, each value represents the peak area (%) in the GC-MS TIC chromatogram.
[0080] C4 :3-hydroxybutyric acid
[0081] C6 :3-hydroxyhexanoic acid
[0082] C6: :3-hydroxyhexenoic acid
[0083] C8 :3-hydroxyoctanoic acid
[0084] C8: :3-hydroxyoctenoic acid
[0085] C10 :3-hydroxydecanoic acid
[0086] C11 :3-hydroxyundecanoic acid
[0087] C12′:3-HA unit having a double bond or a branch, not identified
[0088] C14 :3-hydroxytetradecanoic acid
[0089] C14: :presumably 3-hydroxytetradecenoic acid, not identified
[0090] The obtained polymer was further analyzed by NMR (FT-NMR:Bruker DPX400, subject nuclides: 1 H, 13 C, solvent:D-chloroform with TMS).
[0091] [0091]FIGS. 1 and 2 show the 1 H-NMR and 13 C-NMR charts. Table 2 shows the peak assignment in 1 H-NMR.
TABLE 2 resonant frequency: 400 MHz δ (ppm) Assignment 0.88 m; 2H, f 1.27 m; 4H, e 1.58 m; 2H, d 2.03 m; 0.3H, g 2.37 m; 0.7H, j 2.60 m; 1.6H, a 5.09 s; α 5.13 d; β 5.18 m; b 5.28 m; i 5.52 m; 0.068H, h 5.73 m; 0.143H, γ
[0092] m:multiplet, d:doublet, s:singlet
[0093] As shown above, PHA containing at least 3-hydroxyhexenoic acid units and 3-hydroxyoctenoic acid units is synthesized in Pseudomonas cichorii YN2 (FERM BP-7375) by culturing the strain in the presence of 1-hexene.
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A method for producing a microbial polyester by culturing a microorganism being capable of producing a poly hydroxyalkanoate polyester in a culture medium containing 1-hexene as a sole carbon source.
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This is a division of application Ser. No. 09/205,202, filed Dec. 4, 1998, now U.S. Pat. No. 6,188,386.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data conversion apparatus for converting index data to real data and to an image generation apparatus for converting, for example, index texture data to real texture data by the data conversion to make it possible to suitably carry out texture mapping.
2. Description of the Related Art
When storing a large amount of data such as, for example, image data in a computer or other processing apparatus, to make effective use of the limited storage region of the apparatus, it is preferable to reduce the amount of data stored. As a general method for reducing the amount of data for this purpose, there is the method of using index data.
In this method, actual data (hereinafter referred to as “actual data” or “real data”) is given a number expressed by a smaller bit width than the data bit width. By storing data by such numbers, it is possible to store the data by a smaller amount of data than that by directly storing the actual data. The numbers given to the actual data are referred to as “indexes”, and the data converted to a format referred to by indexes is referred to as “index data”.
When using index data, it is necessary to store both a list establishing correspondence between the index data and the real data, that is, an index table and the data expressed by the index data in the processing apparatus. However, usually the decrease of the amount of data caused due to the use of the index data is overwhelmingly larger than the increase of the amount of data caused due to the storage of the index table, therefore the amount of data can be greatly reduced as a whole.
When the method of storage using index data is applied to image data, the image data is stored in the form of index data inside the processing apparatus. When displaying the image data on a display or otherwise outputting the image data to the outside, the index data is converted to real data for output. The conversion of the index data to the real data must be carried out at a high speed in accordance with, for example, the speed of display of the display device. Therefore, usually this data conversion processing is frequently carried out by data conversion apparatus constituted by hardware.
Specifically, the data conversion apparatus is constituted by using, for example, a memory. When the index is input as an address, the converted real data is output as the output data.
An example of such a data conversion apparatus constituted by a memory is shown in FIGS. 1A and 1B.
FIG. 1A is a view of a data conversion apparatus constituted by a memory for converting 3-bit index data to 32-bit real data. The content of the index data stored in this memory is shown in FIG. 1 B.
In a field of computer graphics, color image data consisting of a very large amount of data is processed, therefore processing by “index color” expressing color data using indexes is frequently utilized.
“Processing by index color” means processing which defines index color data of for example 4 bits, 8 bits, and 16 bits for real color data of 24 bits comprised by for example 8 bits each of R, G and B by the number of required specified colors, maintains an index table corresponding to the index color data, and converts index color data to real color data.
For processing using computer graphics, there are many applications where there are no problems in actual use even if used while limiting the number of colors. In such a case, processing by index color is being used even more.
A data conversion apparatus for converting this index color data to real color data at a high speed is referred to as a “color look-up table” since it converts color data.
When using such index data, the types of usable data are limited by the number of entries of the index table. However, in some applications, there are cases where it is desired to use a larger amount of data than the number of entries of the index table. Therefore, in such a case, the methods of rewriting the index table for use or providing a plurality of index tables and using the same by switching in accordance with the situation are usually used. The method of rewriting of the index table, however, causes a reduction in the processing speed by an amount corresponding to the rewriting time. Therefore, in general the method of providing many index tables within a range allowed by the storage region of the memory of the data conversion apparatus is adopted.
Even if a plurality of index tables are provided due to such a method, there is no change in the fact that the types of data which can be used at each point of time are limited by the number of entries of the selected index table, but by providing many index tables and using them by appropriately switching in a series of continuous processing, substantially a large amount of data is used when seen from the standpoint of the application.
In this way, in processing by index data, provision of many index tables is becoming one of the most important factors in actual use.
Further, when using such index data, the bit width of the data output from the index table, that is, the precision of the index table, is also becoming important.
The requests on the data precision of an index table differ according to application. There are a variety of requests. For example, some require data precision, while others do not. When taking as an example the field of computer graphics, in CADs for graphic design, for example, the ability to display fine differences in the tone of colors is very important for designers and a high precision is required for the data of the index table. In the case of CADs for mechanical design, however, it is sufficient so far as parts can be discriminated by color and fine differences of colors of individual parts are not so important.
In this way, in processing using index data, the number of entries and the precision of the index table are very important items.
In the data conversion apparatuses heretofore, however, there has been a one-to-one correspondence between entries and addresses of the memory. The precision of the index table has corresponded to the data bit width of the memory and has been substantially fixed, so could not be adjusted corresponding to the application etc.
For this reason, there are many cases where the precision of the index table is set in advance so as to become a precision that can be also applied to applications for which a relatively high precision is required. Namely, in many cases each data has a certain longer bit width. As a result, even in a case of use with an application where not that high a precision is required, the processing is carried out with an index table having a precision of more than required.
Further, the number of entries is preferably made as large as possible, but an increase of the number of entries leads to an increase of the capacity of the memory which ends up being used. Therefore usually it cannot be sufficiently increased in many cases.
Namely, in the data conversion apparatuses heretofore, there tended to be the disadvantage that the number of entries was not sufficient despite the unnecessarily high precision etc., so there was a disadvantage in that it was difficult to effectively use the memory and carry out the processing using suitable indexes for the application.
As a result, in various processing apparatuses to which such a data conversion apparatus is applied, there has been a disadvantage in that suitable processing could not be carried out.
For example, when this data conversion apparatus is applied to processing for generating an image etc., the disadvantages having arisen that the number of usable colors has not been sufficient and therefore discrimination by color could not be suitably achieved and that the display of fine tones of color was not possible and therefore the desired image could not be displayed.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a data conversion apparatus that can suitably change the precision of the index table with respect to an entry and the number of entries according to need and that can suitably carry out the conversion from index data to real data in a desired format suited to the application.
Further, another object of the present invention is to provide an image generation apparatus which can suitably change the precision of the index table with respect to an entry and the number of entries in accordance with the type of the image data to be processed etc., which can thereby convert from index color to real color in the desired format suited to the application, and which can suitably generate the intended image.
So as to achieve the objects, the present invention provides a data conversion apparatus comprising a first memory and a second memory each for storing data having a n bit width and in which any data is stored, an address detecting means for detecting addresses of the first memory and the second memory based on input data at which data corresponding to the input data are stored, a data reading means for reading data stored at the detected addresses of the first memory and the second memory, a first data selecting means for selecting either of the data read from the first memory or the data read from the second memory based on the input data, a data extending means for extending the selected data to data having a 2×n bits width, and a second data selecting means for selecting either of the first data formed by connecting the data output from the first memory and the data output from the second memory or the second data of the extended data based on an input selection signal and outputting data selected by the second data selecting means with respect to the input of the data.
Preferably, the address detecting means adds the input data and a predetermined base address to detect the address at which the corresponding data is stored.
Specifically, the first memory and the second memory store real color data, the address detecting means is input index color data given corresponding to real color data to be read, and the index color data is converted to real color data.
Further specifically, said real color data is data having red luminance data, green luminance data, blue luminance data, and transparency data.
Further specifically, the first memory and the second memory are memories each storing data having a 16 bits width, the real color data is 32 bits width data having 8 bits each of red luminance data, green luminance data, blue luminance data, and transparency data or 16 bits width data of 5 bits, 5 bits, 5 bits, and 1 bit, the data extending means extends the selected data to 32 bits width real color data when the read data is the 16 bits width real color data, and the second data selecting means selects the 32 bits width real color data formed by connecting the data output from the first memory and the data output from the second memory when the read data is 32 bits width real color data and selects the extended 32 bits width real color data when the read data is 16 bits width real color data.
Preferably, a data width of the input data is smaller than n bits.
Further preferably, the first memory, the second memory, the address detecting means, the data reading means, the first data selecting means, the data extending means, and the second data selecting means are comprised in an integrated circuit.
Further, so as to achieve the objects, the present invention provides an image generation apparatus comprising a coordinate transforming means for carrying out a predetermined coordinate transformation with respect to vertexes of basic polygons of three-dimensional image data by which any three-dimensional cubic model may be shown as a set of basic polygons indicated by vertexes having at least three-dimensional position information, a pixel data generating means for generating pixel data of the basic polygons based on the data of vertexes of the basic polygons, a data conversion apparatus which converts texture index data to real texture data for carrying out texture mapping with respect to the generated each pixel data, a texture mapping means for generating display use three-dimensional image data by carrying out texture mapping with respect to the generated pixel data by using the converted real texture data, an image memory for storing the generated three-dimensional image data as display use image data, and an outputting means for reading data of a desired region from among the stored display use image data and outputting the same as display use screen data, the data conversion apparatus comprising a first memory and a second memory each for storing data having n bits width and in which real texture data is stored, an address detecting means for detecting addresses of the first memory and the second memory based on input index texture data at which real texture data corresponding to the input index texture data are stored, a data reading means for reading real texture data stored at the detected addresses of the first memory and the second memory, a first data selecting means for selecting either of the real texture data read from the first memory or the real texture data read from the second memory based on the input index texture data, a data extending means for extending the selected data to data having a 2×n bits width, and a second data selecting means for selecting either of the first data formed by connecting the real texture data output from the first memory and the real texture data output from the second memory or the second data of the extended data based on an input selection signal and outputting real texture data with respect to the input of index texture data.
Preferably, the address detecting means adds the input index texture data and a predetermined base address of the index table to detect the address at which the real texture data is stored.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will become clearer from the following description of the preferred embodiments given with reference to the attached drawings, in which:
FIGS. 1A and 1B are views of the data conversion apparatus constituted by a memory as an example of a data conversion apparatus of the related art;
FIG. 2 is a block diagram of the configuration of a three-dimensional computer graphic system of an embodiment of the present invention;
FIGS. 3A and 3B are views of formats of 16-bit and 32-bit real color data;
FIG. 4 is a block diagram for explaining the configuration of a color look-up table provided in a mapping unit of the three-dimensional computer graphic system shown in FIG. 2 :
FIG. 5 is a detailed block diagram of the color look-up table shown in FIG. 4; and
FIG. 6 is a view of the number of color look-up tables which can be set in a memory unit of the color data conversion apparatus shown in FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment according to the present invention will be explained below with reference to FIG. 2 to FIG. 6 .
In the present embodiment, an explanation will be made of a case where the data conversion apparatus of the present invention is applied to a three-dimensional computer graphic system for displaying a desired three-dimensional image for any three-dimensional object model, such as applied to a computer game machine, on a display device at a high speed.
First, an explanation will be made of a three-dimensional computer graphic system to which the memory apparatus of the present invention is applied by referring to FIG. 2 .
This three-dimensional computer graphic system is a system which carries out polygon rendering processing which expresses a cubic model as a combination of unit graphics, that is, triangles (polygons), draws the polygons, determines the color of each pixel of the displayed screen, and displays the same on a display.
Further, in the three-dimensional computer graphic system 1 , a three-dimensional object is expressed by using a z-coordinate expressing the depth in addition to the (x, y) coordinates expressing the plane. Any point in three-dimensional space is specified by these three x-, y-, and z-coordinates.
FIG. 2 is a block diagram of the configuration of the three-dimensional computer graphic system 1 .
The three-dimensional computer graphic system 1 has an input unit 2 , a three-dimensional image generation apparatus 3 , and a display device 4 .
Further, the three-dimensional image generation apparatus 3 has a geometric processing circuit 32 , a parameter calculating circuit 33 , a pixel generation circuit 34 , a mapping circuit 35 , a texture memory 36 , a memory control circuit 37 , an image memory 38 and a display control circuit 39 .
First, an explanation will be made of the structure and function of each unit.
The input unit 2 inputs the data of the cubic model to be displayed to the three-dimensional image generation apparatus 3 . In the present embodiment, the three-dimensional computer graphic system 1 is applied to a computer game machine, therefore the input unit 2 is connected to a main control device etc. for controlling the game per se of the computer game machine. The main control device determines the screen to be displayed based on the state of progress of the game etc., selects the cubic model necessary for the screen display, and generates the information of the display method. Accordingly, the input unit 2 receives this information from the main control device of the computer game machine, converts the same to a format suitable for input to the three-dimensional image generation apparatus 3 , and inputs this to the three-dimensional image generation apparatus 3 .
Specifically, the input unit 2 inputs the polygon data of the cubic model to be displayed as mentioned above to the geometric processing circuit 32 of the three-dimensional image generation apparatus 3 . Further, the polygon data input consists of x-, y-, and z-coordinate data of the vertexes and the color, transparency, texture, and other additional data.
The geometric processing circuit 32 arranges a polygon input from the input unit 2 at the desired position in the three-dimensional space and generates the polygon data at that position. Specifically, it carries out geometric transformation processing such as a parallel transference transformation, parallel transformation, and rotation conversion for every vertex (x, y, z) of a polygon. The polygon data subjected to the geometric transformation processing is output to the parameter calculating circuit 33 .
The parameter calculating circuit 33 finds the parameters necessary for generating the pixel data inside a polygon in the pixel generation circuit 34 based on the data of the polygon input from the geometric processing circuit 32 , that is, the data of each vertex of the polygon, and outputs the same to the pixel generation circuit 34 . Specifically, it finds for example the information of the color, depth, and inclination of the texture.
The pixel generation circuit 34 carries out linear interpolation between vertexes of the polygon based on the polygon data subjected to the geometric transformation processing at the geometric processing circuit 32 and the parameters found at the parameter calculating circuit 33 and generates the pixel data of the internal portion of the polygon and an edge part. Further, the pixel generation circuit 34 generates an address on a predetermined two-dimensional plane corresponding to the display of the pixel data. The generated pixel data and addresses are sequentially input to the mapping circuit 35 .
The mapping circuit 35 reads the pixel data and address generated at the pixel generation circuit 34 and carries out texture mapping processing with respect to the pixel data by using the texture data stored in the texture memory 36 . The pixel data and addresses subjected to the texture mapping processing are output to the memory control circuit 37 .
The texture memory 36 is a memory for storing a texture pattern used when carrying out the texture mapping at the mapping circuit 35 . In the present embodiment, in this texture memory 36 , the texture data is stored in the form of index data.
The memory control circuit 37 generates new pixel data based on the pixel data and address input from the mapping circuit 35 and the corresponding pixel data already stored in the image memory 38 and stores the same in the image memory 38 . Namely, the memory control circuit 37 reads the pixel data corresponding to the address input from the mapping circuit 35 from the image memory 38 , carries out the desired pixel operation processing by using this pixel data and the pixel data input from the mapping circuit 35 , and writes the obtained pixel data into the image memory 38 .
Further, the memory control circuit 37 reads the pixel data of the display region from the image memory 38 when the display region is designated from the display control circuit 39 and outputs the same to the display control circuit 39 .
The image memory 38 is a memory for recording the image data for display and has two memory buffers which can be simultaneously accessed, i.e., a frame buffer and a Z-buffer. The frame buffer stores the color information of the pixels, that is, the frame data. Further, the Z-buffer stores the depth information (Z values) of the pixels, that is, the Z-data.
The display control circuit 39 converts the pixel data of the display region read from the image memory 38 via the memory control circuit 37 to for example predetermined analog signals which can be displayed by the display device 4 , and outputs the same to the display device 4 . Note that, preceding this, the display control circuit 39 requests the pixel data of the display region to be displayed to the memory control circuit 37 .
The display device 4 is a television receiver having a video input terminal and so forth usually used in homes. From the display control circuit 39 of the three-dimensional image generation apparatus 3 , an analog video signal is input via a video signal input terminal. A three-dimensional picture is displayed on the screen based on the signal.
Next, an explanation will be made of the operation of this three-dimensional computer graphic system 1 .
First, in the main control device and so forth for controlling the game per se of the computer game machine, if the three-dimensional image to be displayed is determined, the information of the cubic model required for the screen display thereof is input to the input unit 2 . The input unit 2 inputs the polygon data of the cubic model for displaying the image to the three-dimensional image generation apparatus 3 based on this information.
Each polygon data input to the three-dimensional image generation apparatus 3 is first subjected to geometric transformation processing such as parallel transference transformation, parallel transformation, and rotation transformation in the geometric processing circuit 32 so as to be arranged at a desired position in the three-dimensional space for the screen display.
Next, the parameters necessary for generating the pixel data inside the polygon are found in the parameter calculating circuit 33 with respect to the polygon data transformed in coordinates. The pixel generation circuit 34 carries out linear interpolation between vertexes of the polygon and generates the pixel data of the internal portion of the polygon and the edge part.
The generated pixel data is sequentially input to the mapping circuit 35 . The mapping circuit 35 converts the index data recorded in the texture memory 36 , that is, the texture pattern data, to the real color data, carries out texture mapping processing by using this, and stores the generated pixel data in the image memory 38 via the memory control circuit 37 .
The pixel data stored in the image memory 38 is suitably subjected to the desired processing based on other pixel data input by a similar route or any control data.
Due to this, the newest image data is always stored in the image memory 38 and supplied to the screen display. Namely, the request for output of the data of a predetermined region for display on the display device 4 is made from the display control circuit 39 to the memory control circuit 37 . The pixel data of the region is suitably read from the image memory 38 , converted to the predetermined signal for the screen display in the display control circuit 39 , and output to the display device 4 .
By this, the desired image is displayed on the screen of the display device 4 .
Next, an explanation will be made of the color data conversion apparatus 100 according to the present invention by referring to FIG. 3A to FIG. 5 .
The color data conversion apparatus 100 is accommodated in the mapping circuit 35 for the texture mapping processing of the three-dimensional image generation apparatus 3 of the three-dimensional computer graphic system 1 mentioned above. The mapping circuit 35 reads the texture data from the texture memory 36 and maps this to the pixel data input by the pixel generation circuit 34 . As explained above, the texture data read from the texture memory 36 is stored as index color. Accordingly, the color data conversion apparatus 100 is provided for converting this index color to the real color and applying the same to the processing of the texture mapping.
First, the function of the color data conversion apparatus 100 will be explained in brief.
As explained above, the color data conversion apparatus 100 is an apparatus for converting index color data to real color data by referring to the index table (hereinafter referred to as a color look-up table).
As the index color data, use can be made of 2-bit, 4-bit, and 8-bit data.
A plurality of color look-up tables can be provided, and the table designated by indicating the base address.
As the real color data managed by the color look-up table, two index data having different precisions, that is, 16-bit data and 32-bit data, can be handled. The precision of the index data is selected by the mode signal “mode” of the precision of the index table.
Note that the data output from the color data conversion apparatus 100 is the 32-bit real color data.
The formats of the 16-bit and 32-bit real color data are shown in FIGS. 3A and 3B.
As shown in FIG. 3A, the 16-bit real color data is structured, from the LSB side, of 5 bits of red luminance data R, 5 bits of green luminance data G, 5 bits of blue luminance data B, and one bit of transparency data A.
Further, as shown in FIG. 3B, the 32-bit real color data is structured of 8 bits each of red luminance data R, green luminance data G, blue luminance data B, and transparency data A arranged from the LSB side.
Next, an explanation will be made of the concrete structure of the color data conversion apparatus 100 by referring to FIG. 4 and FIG. 5 .
First, the structure of the color data conversion apparatus 100 will be briefly explained by referring to FIG. 4 .
As shown in FIG. 4, the color data conversion apparatus 100 has an input interface unit 110 , a memory unit 120 , and a data extension unit 130 as fundamental structural units.
The input interface unit 110 picks out the required field from among the data read and input from the texture memory 36 , extracts the index color data, and inputs the same to the memory unit 120 .
The memory unit 120 accommodates the index table and converts the input index color to real color.
The data extension unit 130 extends the real color data read from the memory unit 120 to 32-bit full color data when it is 16-bit data and outputs the same.
Next, the structure of each unit of the color data conversion apparatus 100 will be explained in detail by referring to FIG. 5 .
As shown in FIG. 5, the color data conversion apparatus 100 has a selector (SEL) 111 and an adder (ADD) 112 as the input interface unit 110 , a first memory (MEM 1 ) 121 and a second memory (MEM 2 ) 122 as the memory unit 120 , a first multiplexer (MUX 1 ) 131 , a data extender (EXT) 132 , and a second multiplexer (MUX 2 ) 133 as the data extension unit 130 .
The selector 111 selects a valid part in 32 bits of data “mdata” read from the texture memory 36 based on the mode signal “mode” of the precision of the index table and the lower significant 4 bits “maddr” [3:0] of the data read from the texture memory 36 , extends 0 to the upper significant bits according to need, generates the 8-bit index data “index”, and outputs the same to the adder 112 .
The adder 112 adds the base address “base” of the index table used and the value of the index data index input from the selector 111 to generate the 9-bit memory address “addr” [8:0] for designating the intended entry. The lower 8 bits “addr” [7:0] of the generated memory address are supplied to the first memory 121 and the second memory 122 . The most significant data “addr” [8] is output to the first multiplexer 131 as the selection signal.
The first memory 121 and the second memory 122 are each 256 address×16-bit data SRAMs in which the color look-up tables are actually stored.
The first memory 121 and the second memory 122 store the color look-up tables via the 32-bit, thereby total 64-bit, input data lines WD.
Further, the data read from the first memory 121 and the second memory 122 are output to the first multiplexer 131 and the second multiplexer 133 .
Note that when the mode of precision of the index table is the 16-bit mode, the storage regions of these first memory 121 and second memory 122 are allocated to different address spaces. The entire memory unit 120 becomes a storage unit having 512 address×16-bit structure. Accordingly, the number of index entries at this time becomes 512 entries.
Further, when the mode of precision of the index table is the 32-bit mode, the storage regions of the first memory 121 and the second memory 122 are allocated to the region of the upper significant 16 bits and the region of the lower significant 16 bits of the same address space, and the entire memory unit 120 becomes a storage unit having a 256 address×32-bit structure. Accordingly, the number of index entries at this time becomes 256 entries.
The first multiplexer 131 selects either of the 16-bit data input from the first memory 121 or the 16-bit data input from the second memory 122 based on the signal “addr” [8] of bit 8 of the memory address generated at the adder 112 and outputs the same to the data extender 132 .
The data extender 132 extends the 16-bit data input from the first multiplexer 131 to 32-bit data and outputs the same to the second multiplexer 133 .
The 16-bit real color data is comprised, as shown in FIG. 3A, of 5 bits of red luminance data R, 5 bits of green luminance data G, 5 bits of blue luminance data B, and one bit of transparency data A. The data extender 132 prepares 8-bit data for the luminance data R, G, and B by adding the data “d” [4:2] of the upper significant 3 bits to the LSB side of “d” to the 5-bit data “d” [4:0]. Further, for the transparency data A, it prepares 8-bit data with respect to the transparency data A=0 and 8-bit data with respect to the transparency data A=1 in advance and prepares the 8-bit data by replacing this by the 8-bit data based on the value of the transparency data A.
As a result, the 32-bit real color data of the format as shown in FIG. 3 B.
The second multiplexer 133 selects either of the 32-bit data input from the data extender 132 or the 32-bit data consisting of the 16-bit data output from each of the first memory 121 and the second memory 122 based on the mode signal “mode” of precision of the index table and outputs the same as the output data from the color data conversion apparatus 100 , that is, 32-bit real color data.
The second multiplexer 133 selects the output of the data extender 132 when the mode of precision of the index table is the 16-bit mode, while selects the outputs of the first memory 121 and the second memory 122 when it is the 32-bit mode.
The output data is input to the calculating circuit for carrying out the texture mapping of the mapping circuit 35 .
Next, an explanation will be made of the operation of the color data conversion apparatus 100 .
First, in the color data conversion apparatus 100 , as the initial setup, the writing of the color look-up table to the first memory 121 and the second memory 122 is carried out.
The color look-up table is written by inputting the addresses via the selector 111 , supplying the write data to the 64-bit input data line WD, switching the read/write control signal “r/w” to “write”, and enabling the chip enable signal “ce”.
When carrying out the data conversion, the read/write control signal “r/w” is set at “read”, the mode “mode” of precision of the index table and the base address “base” of the index table to be used are designated, and then the lower significant bits of the data and the address read from the texture memory 36 are input to the selector 111 .
Based on these input data and address, the index data “index” is generated at the selector 111 and added to the base address base at the adder 112 , whereby the memory address “addr” is generated.
The lower 8 bits “addr” [7:0] of the generated address “ddr” are applied to the first memory 121 and the second memory 122 , and the real data is read from the first memory 121 and the second memory 122 .
When the mode of precision of the index table is the 32-bit mode, 32-bit real color data is output from the first memory 121 and the second memory 122 , therefore they are output to the texture mapping processing circuit of the mapping circuit 35 as they are via the second multiplexer 133 .
Further, when the mode of precision of the index table is the 16-bit mode, the data read from the first memory 121 and the second memory 122 are 16-bit real color data different from each other. Accordingly, either of the data output from the first memory 121 or the data output from the second memory 122 is selected at the first multiplexer 131 based on the most significant bit “addr” [8] of the address signal output from the adder 112 and is output to the data extender 132 .
The 16-bit real color data input to the data extender 132 is extended to the 32-bit real color data by the method as mentioned above and output to the texture mapping processing circuit of the mapping circuit 35 via the second multiplexer 133 .
Note that the number of entries of one color look-up table is determined by how many number of bits the index color data has. When 2-bit index colors are used, there are four index color values, i.e., 0, 1, 2, and 3, and there are four entries corresponding to this. Similarly, when 4-bit index colors are used, there are 16 entries in the color look-up table is 16, while when 8-bit index colors are used, there are 256 entries.
As the entire color data conversion apparatus 100 , the memory unit 120 is constituted by two memories each consisting of 16 bits×256 addresses, therefore when the mode of precision of the index table to be used is the 16-bit mode, there are 512 entries, while when it is the 32-bit mode, there are 256 entries.
The number of color look-up tables which can be set in the memory unit 120 in accordance with the number of bits of the index color data and the mode of precision of the index table is shown in FIG. 6 .
In this way, in the color data conversion apparatus 100 of the present embodiment, the number of bits of the index color data, that is, the precision of one color look-up table, and the number of entries can be selected according to necessity. Accordingly, the color look-up input can be constituted with the required precision and required number of entries in accordance with the type etc. of application, and suitable color data in accordance with the application can be generated.
Further, in the three-dimensional computer graphic system 1 of the present embodiment, at the time of texture mapping, the precision of the index table and the number of entries thereof can be suitably adjusted in accordance with the application. Accordingly, the desired color image can be obtained in accordance with the application, and the effective use of the memory and the enhancement of performances of the system by this become possible.
Note that the present invention is not limited to the present embodiment. Various modifications are possible.
For example, the data extension method in the data extender 132 of the data extension unit 130 can be any method. For example, a method of extension by entering a specific pattern such as 000 or 111 on the LSB side of each data can also be adopted.
Further, if the content of the color look-up table is fixed, it is also possible to constitute the first memory 121 and the second memory 122 of the memory unit 120 by ROMs. If they are constituted by ROMS, the color data conversion apparatus 100 can be made smaller in size.
Further, by entering various operation results in the memory unit 120 , it is also possible to constitute a general purpose processor.
As explained above, if the data conversion apparatus of the present invention is used, the precision of the index table with respect to one entry and the number of entries may be appropriately changed according to need and the conversion from index data to real data can be suitably carried out in the desired format adapted to the application.
Further, according to the image generation apparatus of the present invention, in accordance with the type of the image data to be processed, etc., the precision of the index table with respect to one entry and the number of entries can be appropriately changed. Due to this, the conversion from index color to real color can be suitably carried out in the desired format adapted to the application, and the desired image can be suitably generated.
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A data conversion apparatus for converting index data to real data and an image generation apparatus for converting index texture data to real texture data by the data conversion to make it possible to suitably carry out texture mapping. A data conversion apparatus comprises a first memory and a second memory each for storing data having a n bit width and in which any data is stored, an address detecting means for detecting addresses of the first memory and the second memory based on input data, a data reading means for reading data stored at the detected addresses of the first memory and the second memory, a first data selecting means for selecting either of the data read from the first memory or the data read from the second memory, a data extending means for extending the selected data to data having a 2×n bits width, and a second data selecting means for selecting either of the first data formed by connecting the data output from the first memory and the data output from the second memory or the second data of the extended data.
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BACKGROUND OF THE INVENTION
The present invention relates to an image scanning apparatus for obtaining an image from an object (e.g., a sheet of paper bearing an image) by separating a light signal consisting of a plurality of color components which are incident to and reflected from the object into respective color signals through a plurality of color filters corresponding to the respective color components.
In order to realize color reproduction suitable for the human visual system in an image processing apparatus, it is important to match the color signal in the range of visible light to human visual system. The typical response characteristic of the human visual system with respect to the wavelengths of red (R), green (G) and blue (B) has been outlined by the Commission International de I'Eclairage (CIE) as CIE-RGB chromacity diagram. Based on such chromacity diagram, a color image processor controls the spectral properties of three primary color signals R, G and B.
An image scanning apparatus (e.g., a scanner) obtains the image information of an object by separating the color image information thereof into color information consisting of three wavelength bands (red, green and blue) and quantifying the respective color information by means of an image sensor. This is commonly known as "color separation."
Generally speaking, color separation adopts two conventional methods which are largely classified into (1) a method which combines a black-and-white image sensor and a set of color filters whose bandpass characteristics correspond to the R, G and B wavelengths, and (2) a method using a color image sensor. The former method can minimize the cost for the embodiment of the apparatus but is difficult to realize technically. The latter method easily realize the constitution of the apparatus but bears an excessive cost and has certain limitations with regard to improvements in spectral characteristic.
Currently, the above former method is generally adopted and can be further subdivided into three separate methods. These are (1) a lamp switching method which uses one image sensor and separates colors by means of a plurality of light sources having different luminous spectral characteristics, (2) a filter switching method which uses one image sensor and one light source and separates colors by means of a color filter having bandpass characteristics corresponding to the R, G and B wavelengths, and (3) an optical path separation or prism mirror method which uses one light source, redirects the R, G and B optical paths by arranging an element (e.g., a prism) on an optical path having various refractive indices and separates colors by means of three image sensors.
Among the above three subdivided methods, the second (the filter switching method) is the best in terms of speed and cost. The filter switching method is again divided into a rotary filtering method which switches the filters by a rotating movement and a plate filtering method which switches the filters by a linear movement.
FIGS. 1A to 1D show embodiments of a color separating filter according to a conventional rotary filtering method, wherein arrows indicate the direction of movement of the rotary filters.
Rotary filter shown in FIG. 1A is disclosed in Japanese laid-open patent publication No. sho 61-294963. Here, a rotary filter is shown, wherein a set of red, green and blue color filters are installed on a rotary circular plate. In the case of a color image, the image information of the R, G and B wavelengths is obtained by rotating the rotary filter. For monochromatic images, the rotary filter is fixed and a single color filter is used to obtain image information.
Rotary filter shown in FIG. 1B is disclosed in Japanese laid-open patent publication No. sho 62-102690. Here, a rotary circular plate is installed in front of an image input apparatus. Then, a color filter for separating the three primary colors is attached to the rotary circular plate.
Rotary filter shown in FIG. 1C is disclosed in Japanese laid-open patent publication No. hei 2-89463 and is similar to that of FIG. 1A. Here, however, each color filter occupies a different sized area in order to maintain color balance.
Rotary filter shown in FIG. 1D is disclosed in U.S. Pat. No. 4,841,358 and shows a flat plate filter for switching filters by a rectilinear reciprocation.
However, none of these disclosures propose a specific device for calibrating a shading error due to the luminous characteristic of a light source and the vignetting characteristic of a lens. In general, a shading calibration is performed by an electrical circuit which can accomplish such calibration for shading errors of about 30% but no more. Moreover, even if the shading error is less than 30%, deterioration of the picture quality due to the calibration cannot be avoided.
FIG. 2 is a configurational diagram of the image scanning apparatus adopting a conventional rotary filter.
In the apparatus shown in FIG. 2, a light signal containing plural color components generated in a fluorescent lamp 20 is irradiated onto an image-bearing object 22 placed on a stand 21. The light signal reflected from image-bearing object 22 is incident to a line sensor 25 via a reflecting mirror 23 and a lens 24. The line sensor 25 generates an electrical signal proportional to the intensity of the incident light signal. A rotary filter 26 having a color filter 27 is installed between reflecting mirror 23 and lens 24. When rotary filter 26 is rotated by a driving motor 28, the respectively installed color filters 27a, 27b and 27c (FIG. 3) are sequentially interjected into the light path.
When an image is input by means of a line sensor, as in FIG. 2, one line of RGB information is input for every revolution of rotary filter 26. In the case of the image of an A4-sized sheet of paper (as prescribed by the International Organization for Standardization) being input with a resolution of 300 lines per inch, a rotation speed of 3,300 revolutions per minute is necessary to scan the sheet in one minute. To scan at higher speeds, rotary filter 26 should be rotated more rapidly. However, increasing the rotation speed results in a geometrical positioning error due to air friction of the filter and the unavoidable vibration of the rotating axis, and necessitates a cost increase for the pursuit of a high-quality driving motor.
FIG. 3 shows the relative position of a line sensor 25 with respect to the color filters 27a, 27b and 27c disposed on the rotary filter 26 of FIG. 2.
In the apparatus of FIG. 3, to input a subsequent line of image information after one line of image information is input, the sensor or the object to be scanned should be transported by one line interval. Given that color filters 27a, 27b and 27c are arranged equidistantly with respect to one another, since the transfer time of each filter cannot be established individually, the filter rotation is performed in conjunction with filter switching. As a result, a color registration error, whereby a pixel of a given point on the object cannot be matched with a pixel value of the corresponding location of R, G and B image information, is generated, thereby resulting in a geometrical distortion in the reproduced image. In particular, when an image consisting of a series of achromatic colors is input, the sharpness of the image contours is reduced, thereby resulting in a serious deterioration of picture quality.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an image scanning apparatus which can attain an effect of a geometrical shading calibration.
Another object of the invention is to provide an image scanning apparatus which can easily improve resolution without increasing the rotation speed of a color separating filter.
Still another object of the invention is to provide an image scanning apparatus which can reduce a color registration error due to the transfer of an object to be scanned.
To accomplish the objects of the present invention, there is provided an apparatus for inputting a color image, which comprises a light source having a rod-like shape for generating a light signal having plural color components R, G and B and irradiating the light signal onto the surface of an object; an object transfer apparatus for controlling the relative motion of the light source with respect to the object; a color separating filter for separating the light signal reflected and transmitted from the object surface into plural color signals, by arranging a set of color filters corresponding to the respective color components in a predetermined pattern; a line sensor for receiving the separated light signal through one of the color filters and outputting an electrical signal corresponding to the intensity of the separated light signal; and driving means for adjusting a relative location between the color separating filter and the line sensor and combining the color separating filter and the line sensor in a predetermined order, and wherein the width of a light receiving surface of each the color filter gradually increases from the central area thereof to the periphery and the longitudinal axis of the line sensor is disposed in parallel with that of the light receiving surface.
An image scanning apparatus according to the present invention performs a shading calibration of the light signal geometrically through a color filter, by forming the light receiving surface area of the color filter so as to have an inverse characteristic to the luminous characteristic of the light source.
Also, in an image scanning apparatus according to the present invention, an exact synchronization of a filter movement with respect to a scanned object transfer is achieved by forming a time clearance equal to the period necessary for transferring the scanned object when a set of color filters is formed.
Moreover, an image scanning apparatus according to the present invention reduces a light signal refraction effect due to a base plate, by cutting away the portion of the base plate in which the color filter is to be placed and inserting the color filter therein, without attaching the color filter to the base plate, thereby reducing the color registration error.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and other advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
FIGS. 1A to 1D show conventional rotary filters.
FIG. 2 is a configurational diagram of the image scanning apparatus adopting a conventional rotary filter.
FIG. 3 shows an arrangement of a rotary filter and a line sensor in a conventional image scanning apparatus shown in FIG. 2.
FIG. 4 shows a structure of the image scanning apparatus according to a preferred embodiment of the present invention.
FIG. 5 is a detailed diagram of essential parts of the apparatus shown in FIG. 4.
FIG. 6 is a timing chart showing the image scanning operation of the apparatus shown in FIG. 5.
FIG. 7 shows an arrangement of the rotary filter and the line sensor shown in FIG. 5.
FIG. 8 shows another embodiment of the rotary filter shown in FIG. 5.
FIG. 9A shows the structure of the photosensor means shown in FIG. 5.
FIGS. 9B, 9C and 9D illustrate the operation of the photosensor means according to the rotation of the rotary filter.
FIG. 10 shows an exterior structure of the rotary filter shown in FIG. 5.
FIGS. 11A to 11C show in detail the structure of the rotary filter shown in FIG. 10.
FIGS. 12A to 12C show the influence of the rotary filter on a tilt error.
FIGS. 13A to 13D are characteristic diagrams showing a shading distortion phenomenon occurring in a line sensor.
FIGS. 14A and 14B show an embodiment of a flat plate filter.
FIG. 15 is a block diagram showing the circuitry of the apparatus shown in FIG. 4.
FIG. 16 is a block diagram showing a detailed configuration of the synchronizing signal generator shown in FIG. 15.
FIG. 17 is a timing diagram showing a timing relationship between a filter groove location detecting signal and various other signals.
FIG. 18 is a block diagram showing a detailed configuration of the analog processor shown in FIG. 15.
FIG. 19 is a block diagram showing a detailed configuration of the preprocessor shown in FIG. 15.
FIG. 20 is a characteristic diagram showing tone calibrating characteristics.
FIGS. 21A and 21B show structures of a tone calibrating circuit and a tone calibrating look-up table.
FIG. 22 is a flow chart showing the processing of a tone and color calibration.
FIG. 23 is a timing chart of the operation of a tone and color calibration.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of the present invention will be given hereinafter with reference to the accompanying drawings.
FIG. 4 shows a preferred embodiment of the image scanning apparatus according to the present invention. In the apparatus of FIG. 4, when an image-bearing object 42 is transferred via a paper feed 41 by rotating a transfer motor 48, a light signal irradiated from a fluorescent lamp 40 is reflected from the object surface and transmitted to line sensor 45 via three reflecting mirrors 43a, 43b and 43c, a rotary filter 46 in which color filters (not shown) are separately installed, and a light condensing lens 44. A reference numeral 49 is a transfer motor driver for driving transfer motor 48, 50 is a lamp driver which drives fluorescent lamp 40, 51 is a driver for line sensor such as a charge-coupled device which drives line sensor 45, 52 is an image processor which performs a color balance calibration, shading calibration and tone calibration with respect to the image information generated from line sensor 45, and 53 is an interfacing unit for interfacing with an external system.
It is necessary to set an appropriate timing relationship between the rotation of transfer motor 48 and that of rotary filter 46. In FIG. 4, while transfer motor 48 is stopped, the color filters are switched by rotating rotary filter 46 so that the R, G and B spectral information can be obtained. In this way, a subsequent line of image information is scanned by moving transfer motor 48 by one step after scanning one line of the image information. By repeating such an operation by a number corresponding to the size of the object to be scanned, all the image information of image-bearing object 42 is supplied to image processor 52.
A timing relationship between filter switching and object transfer is shown in FIG. 6 with regard to the aforementioned operation. In FIG. 6, the ordinate axis indicates the amount (distance) of object transfer by transfer motor 48 and the horizontal axis indicates time. The amount of transfer corresponding to one step of transfer motor 48 is indicated by a reference letter L and the time necessary for one line of transfer is indicated by a reference letter T. Time T is divided into the object's transfer time and that for scanning the spectral information of three wavelengths (R, G and B) through three filters (red, green and blue).
FIG. 5 shows essential pans of the apparatus shown in FIG. 4 in more detail. In FIG. 5, when a groove (see FIG. 7) on rotary filter 46, which is for detecting a reference location, coincides with the position of photosensor 54, the photosensor outputs a signal F-PHOTO. The F-PHOTO signal is used as a reference signal for color synchronization according to the rotation of rotary filter 46 and for control of line sensor 45 and florescent lamp 40. Also, the F-PHOTO signal is input to a phase-locked loop (PLL) controlling circuit 55 to be used in controlling a constant speed of filter driving motor 56.
In order to drive rotary filter 46 for color separation, it is necessary to know through which color filter the light signal currently being received by sensor 45 is passing. To this end, the structures of FIGS. 7 and 8 are proposed in the present invention.
In FIG. 7, a filter location detecting groove 47d for passing the light signal is positioned at the edge of red filter 47a, with blue filter 47b and green filter 47c being located at intervals with respect thereto. Therefore, line sensor 45 receives the light signal through green filter 47c at the time of groove detection by photosensor 54.
In contrast to FIG. 7, FIG. 8 shows two sets of color filters and scanning speed is directly related to the rotation speed of the rotary filter, in order to improve the resolution of the scanned image or improve scanning speed, the rotation speed of rotary filter should be increased. As shown in FIG. 8, with two sets of color filters being installed, the scanning speed is twice that of the case where only one set of filters is installed as in FIG. 7, and is accomplished without increasing rotation speed. Therefore, the increased generation of noise and vibration and the greater air friction of the rotary filter, which arise due to the increase of the rotation speed of the rotary filter, can be avoided. Here, the limit of additional filter sets which can be installed is determined by the desired resolution, the reduction rate of a lens and other factors. In general, the higher the lens reduction rate, the more filter combinations are permitted. It should be noted that if the light signal is received by line sensor 45 through more than one color filter at a time due an interval between the respective color filters which is too narrow, color interference may occur, which lowers the discrimination of color separation.
FIG. 9A shows the structure of the photosensor shown in FIG. 5. Transistor TR outputs the groove detection signal F-PHOTO when the filter location detecting groove is located between light emitting diode D1 and light receiving diode D2.
Referring to FIGS. 9B, 9C and 9D. the image scanning apparatus of the present invention employs two photosensors, with only one being used in a color mode wherein a color image is input and both (PS1 and PS2) being used in a black-and-white mode wherein a black-and-white image is input. Here, using photosensor means that the output signal F-PHOTO1 or F-PHOTO2 of the corresponding photosensor is used as a valid signal. The portion indicating the groove of the filter is transparent, the width of which may be the same as or slightly wider than the installation interval of the two photosensors.
In the black-and-white mode, to fix the rotary filter, filter driving motor 56 is controlled so that both output signals F-PHOTO1 and F-PHOTO2 from photosensor means 54 maintain a logic state of "1" (FIG. 9C). If the state of FIG. 9B is detected, that is, photosensor PSI outputs a logic "0" and photosensor PS2 outputs a logic "1," rotary filter 46 should be moved slightly forward and if the state of FIG. 9D is detected, that is, photosensor PS1 outputs a logic "1" and photosensor PS2 outputs a logic "0," rotary filter 46 should be moved in a reverse direction so that the state of FIG. 9C is maintained.
It is important to install the respective color filters 47a, 47b and 47c on rotary filter 46 at appropriate intervals. FIG. 10 shows an arrangement of color filters 47a, 47b and 47c such that when one line of the object to be scanned is transferred, the color information is scanned in the order of green, then blue and then red. Then, the thus-scanned object is transferred to the subsequent line, as represented in the timing diagram of FIG. 6.
Referring to FIG. 10, it is assumed that the angle from the starting point of red filter 47a to that of blue filter 47b or from the starting point of blue filter 47b to that of green filter 47c is θ, and the angle from the starting point of green filter 47c to that of red filter 47a is 2θ. Here, θ is the filter angle. The adopted filter angle provides important technical information in the present invention. When rotary filter 46 is rotated at a constant angular speed, photosensor means 54 of FIG. 5 generates the F-PHOTO signal for every revolution of rotary filter 46, with the period of this output signal becoming the scanning period for one line of information, which is shown as "T" in FIG. 6. Therefore, if filter angle θ is 360°/4, that is, 90°, the time allotted to each filter is T/4, and accordingly, the light exposing time of line sensor 45 becomes T/4.
Meanwhile, the relationship between the driving frequency and the light exposing time of line sensor 45 is as follows. ##EQU1##
Here, Nd is a number of dummy pixels of the line sensor, Ne is a number of valid pixels of the line sensor and F is the driving frequency of the line sensor.
Also, the relationship between the rotational period T of rotary filter 46 and the time for scanning one page of the manuscript is as follows.
Tscan=L×R×T (2)
Here, Tscan is the time necessary for scanning the entire object (e.g., one sheet of paper), L is the length of manuscript in the direction of subscanning and R is the scanning density per line.
Accordingly, when an image scanning apparatus is designed, if the parameters Tscan and R are set, the rotational speed of rotary filter 46 is determined. Accordingly the light exposing time of the respective colors according to three wavelengths is also determined. Moreover, the driving wavelength is determined by the pixel number of the line sensor.
The filter angle θ can be expressed as follows. ##EQU2##
Here, M is the number of combinations (sets) of color filters installed on the rotary filter, N is the number of the color filters included in each set of color filter combinations, and X is the number of invalid intervals included in one set of color filters and is secured for a transfer operation to a subsequent line. Thus, in the case of FIG. 7 where N=3, M=1 and X=1, filter angle θ is 90°, and in the case of FIG. 8 where N =3, M=2 and X=1, filter angle θ is 45°.
Meanwhile, in FIG. 10, the valid angle, that is, the filter angle within which a filter is actually formed, of the red filter is indicated as θr. Similarly, the valid angles for the blue and green filters are θb and θg, respectively. The respective valid angles are related to the sensitivity characteristics of the wavelength bands corresponding to the spectral optical system. In general, variations in spectral sensitivity characteristics result from a combination of such factors as the spectral characteristics of the illuminating light sources, the transmission factor of the color filters, the chromatic aberration of the lens and spectral sensitivity characteristics of the line sensor. If the above factors are not ideal, the color balance is disturbed and thus color balance calibration should be performed. One method of color balance calibration is to adjust the valid angle and another is to control the gain of color signal output from the line sensor. The former method can be easily embodied geometrically but, in doing so, color balance cannot be kept completely. Thus, it is desirable to adopt a combination of the two methods as in Japanese laid-open publication No. hei 2-89463.
The allotment of the valid angles can be expressed as follows. ##EQU3##
Here, Rr, Rb and Rg are the sensitivity characteristics for red, green and blue in the dimension of the overall system, and Rc is one of Rr, Rb and Rg and a symbol MAX is a maximum value operation.
The difference angle between θ and θc is a division angle θdr, θdb or θdg of the respective color filters 47a, 47b and 47c. That is to say, the separation angle θd is expressed as follows.
θd=θ=θc (5)
The separation angles of the color filters prevent color interference. Here, larger separation angles are more advantageous for color interference prevention. However, since this separation angle is closely related to the valid angle and the reduction rate of lens 44, the proper setting of the separation angle is important. Since the input line sensor 45 should be blocked during the time corresponding to the separation angle, the portion corresponding to a separation angle on rotary filter 46 should be opaque. An achromatic color of 0% (black) in the transmission factor is most preferable.
FIGS. 11A to 11C show a detailed configuration of rotary filter 46 shown in FIG. 10. FIG. 11A shows the plate on which the color filters are to be placed, FIG. 11B shows a film-like color filter and FIG. 11C shows the allotment of valid filter angles of color filters. The rotary filter of FIG. 10 is formed by attaching the filter of FIG. 11B onto the plate shown in FIG. 11A according to a filter angle shown in FIG. 11C.
The thickness of a filter directly influences a color registration error. In order to minimize such an influence in the proposed embodiment, the portion of transparent rotary filter plate 46a where filter groove 47d is to be positioned is cut away. Here, the plate is made of a plastic material of highly polymerized compounds. However, if the color filters are formed by dyes deposited on a glass plate, the thickness of the plate should be minimized.
Also, rotary filter 46 and line sensor 45 should be kept parallel. Conventionally, when the plane of rotary filter 46 is perpendicular to the rotational axis, a constant distance between the rotary filter and the line sensor is maintained, irrespective of the rotation of rotary filter 46. Otherwise, a tilt error is generated, as will be described with reference to FIGS. 12A, 12B and 12C.
FIG. 12A shows the case that rotary filter 46 is not perpendicular to the rotational axis. Here, the degree of deviation from the right angle is indicated as an error angle θe. In case the rotary filter has a set of the color filters and scans one line of the manuscript per one rotation of the rotary filter, assuming that the error angle becomes +θe at a certain position, and the error angle becomes -θe when the rotary filter rotates 180°, as in FIG. 7. Accordingly, the error angle in the same line becomes 2θe.
In FIG. 12B, showing the optical path for an error angle of 0°, the light reflected from the scanned surface has an incident angle of 0°. Therefore, the reflected light is perpendicularly incident to line sensor 45, through air layer having a refractive index n1, color filter layer having a refractive index n2 and the filter plate layer having a refractive index n3.
FIG. 12C shows the case where the optical path includes an error angle e. Here, in contrast with FIG. 12B, the reflected light incident to the color filter has an incident angle of θe,. Accordingly, the light is refracted according to the refractive indices of the color filter layer and filter plate layer and then is incident to line sensor 45 with a deviation from the original location by a registration error Ed.
As stated above, since the error angle produced per one rotation of the rotary circular plate is θe, the actual deviation is 2Ed, which is a color registration error and is equal to the sum of the error h2 due to refraction of the color filter layer and the error h3 due to refraction of the filter plate layer. The registration error Ed can be expressed as follows.
Ed=d2(tan θ2)+d3(tan θ3) (6)
Here, θ2 and θ3 are the refractive angles of the color filter and the filter plate, respectively, and d2 and d3 are the thicknesses of the color filter and the filter plate, respectively.
Meanwhile, the refractive angle is a function of the refractive indices of the respective media. If the refractive indices of the color filter and filter plate layers are both one, like that of air, the reflected light from the scanned object progresses along a straight line and only a slight deviation is produced. However, such media is impossible to manufacture, of course. Therefore, it is most important to design a medium so that a tilt error may not be produced. In addition, it is a secondly important requirement to minimize the thickness of the respective media. As mentioned above, since the tilt error of the rotary filter is produced in both sides, a registration error of 2Ed per rotation of the rotary filter, given that one set of rotary filters is used (as in FIG. 7). Essentially, the registration error occurs when the landing locations of R, G and B color image information in the line sensor are different for the same scanning location, which reduces resolution as they do not land in the same location of a reproduced image. Moreover, the registration error becomes greater as resolution is enhanced.
Assuming a resolution of 300 lines per inch, in which the distance between the respective lines is about 83 μm, if Ed is larger than 41.5 μm, the locations of the R, G and B color information corresponding to one scanned location will deviate one line or more on the reproduced image. If Ed is larger than 70 μm, the reproduced image becomes unpleasant to the eye. Moreover, if the reproduced image is enlarged, its appearance worsens fatally. Since the thickness of the color filter is thin enough to be negligible compared to that of the plate, the plate thickness becomes fundamentally important and should be as thin as possible. In the embodiment of the present invention, as shown in FIG. 11A, corresponding portions of transparent rotary filter plate 46a are cut away so that color filters 47a, 47b and 47c may be inserted therein in order to reduce the color registration error. Here, the characteristics of the color filter material are such that unnecessary ultraviolet rays and infrared rays are eliminated and the amount of transmitted light is regulated.
Meanwhile, it is important to maintain the weight balance of the rotary filter, with respect to both vertical and horizontal weight distribution. Otherwise, it is difficult to maintain a constant speed of the rotary filter. Also, since air resistance is increased in high speed rotation due to the concavo-convex portions of the plate wherein no filter is inserted, the rotation speed may become unstable. In such an event, the concavo-convex portions of the plate are covered with a transparent film exhibiting a transmission factor of nearly 100% across the entire visible light spectrum.
In rotary filter 46 shown in FIGS. 7, 8 and 10, the starting portions of respective color filters 47a, 47b and 47c are linear and the ending portions thereof are curved. However, in the present invention, the diverse shapes of the starting and ending portions of the rotary filters bear no consequence in practice, and this example of curved ending portions is only for the convenience of explanation. Here, the concavo lens shape of one side of the respective rotary filters 47a, 47b and 47c is chosen so that the valid filter angle is smaller in the central area and larger in the outer areas. This reason will be explained with reference to FIGS. 13A to 13D.
FIG. 13A shows the arrangement of lamp, lens and line sensor. A hot-cathode tube or cold-cathode tube is adopted as the light source for image scanning apparatus. Such a light source has luminous characteristics such that the ends thereof emit the least light while its central area emits the most light, as illustrated in FIG. 13B. Also, an optical system producing reduced sized image using a condensing lens is generally adopted as the optical system of an image scanning apparatus because the cost for a line sensor and self-focus lens combination is excessive for optical systems producing equal sized image. A conventional condensing lens has the highest light transmission factor at the central point of the lens and which tapers off towards its periphery (called a vignetting characteristic), as illustrated in FIG. 13C. Here, the image becomes distorted due to a difference in the transmitted light intensity (luminosity), according to incident location and for a given amount of incident light. This phenomenon is called shading distortion (Refer to FIG. 13D).
In the present invention, to calibrate shading distortion optically, a curved concavo lens is used on each side of color filters 47a, 47b and 47c, which increases the actual light exposing time of the filter periphery by gradually enlarging the valid filter angle from the interior edge to the periphery of each color filter, since line sensor 45 is radially arranged toward the rotation axis of rotary filter 46 radiately, as shown in FIG. 7 in detail. Here, it is desirable for the locus of the curve, by which the valid filter angles of color filters 47a, 47b and 47c are regulated, to correspond to the shading distortion characteristic shown in FIG. 13D. However, for the sake of convenience, the curve may be divided into plural sections, and then the divided plural sections may be made linearly so that the curve becomes a poly-line. This is because it is almost impossible to calibrate a shading phenomenon completely using optical means only, due to the varying characteristics of each light source and lens. Also, it is technically easier to perform shading calibration via hardware using a shading calibration circuit.
Nevertheless, optical calibration is generally carried out in conjunction with shading calibration via hardware, and the reason for doing so is as follows.
First, the principle of the calibration by hardware will be explained. Assuming that for a location x along the main scanning direction of the line sensor, the scanned value for the color sample segment of the reference color (white) is expressed as Iwx and the scanned value for the object to be scanned (original) is expressed Iox and quantized into eight bits, that is, 256 steps. Accordingly, the calibrated value Ix can be shown as follows. ##EQU4##
Meanwhile, a shading error rate Es, expressed as a percentage, is calculated thus: where Iwx(min) is the minimum value of the reference color and Iwx(max) is its ##EQU5## maximum value.
In general, the calibrating level by the shading calibrating circuit is less than or equal to 30%. If the shading error rate is higher than this level, the calibration effect is reduced. Also, although the shading error rate is about 30% practically, the deterioration of the reproduced image following the calibration cannot be avoided. For example, assuming that the scanned value for the color sample segment of a reference white color is 180 at a random location of a main scanning direction when each color signal is quantized into eight bits, that is, 256 steps, the tone reproduction step at this location is only 181 steps. Further, since the scanned value for the color sample segment of the reference color is 180, the scanned value for an image to be scanned practically must be less than 180. Thus, although the absolute size of the tone value can be calibrated to some extent via shading calibration, the tone reproduction steps do not number more than 181 steps. To solve such a problem, it is desirable that, initially, 10˜20% of the calibration is carried out optically and then calibration using a shading calibrating circuit is performed secondly.
FIGS. 14A and 14B show flat plate filters which switch the color filters by a reciprocation. The difference between a flat plate filter and the aforementioned rotary filter result from the fact that rotary motion of a rotary filter is replaced with rectilinear reciprocation of the flat plate filters. If the rotation speed, filter angle θ of the rotary filter and valid filter angle θc (θr, θg or θb) are replaced with the speed of the linear movement and filter interval Lb of the flat plate filter, and valid filter height Lc (Lr, Lg or Lb), respectively, the operation can be understood by applying the same principles.
To move a flat plate filter linearly, we may use a cam, a linear motor, a piezoelectric phenomenon, etc. Such methods bear no differences in their operations, except that the power sources necessary for moving a flat plate filter are different, and although the rotary filter has only to rotate in one direction continuously during the scanning operation, the flat plate filter has to be reciprocated. In FIGS. 14A and 14B, the reference location detecting groove is installed at the location of a green filter, for convenience. Also, it is assumed that the line sensor is receiving the light signal through the green filter at the time of groove detection by photosensor means 54.
Here, if the flat plate filter is moved by one step in a positive direction (downward in FIG. 14A or to the left in FIG. 14B), then, the light signal is received by the line sensor through a red filter. If the flat plate filter is moved by one step in a negative direction (upward in FIG. 14A or to the right in FIG. 14B), the light signal is received by the line sensor through a blue filter.
In the case of a black-and-white image input mode, the flat plate filter is controlled so that the green-filtered light signal is received by the line sensor. For a color image input mode, the initial state is set so that the red filtered light signal is received by the line sensor, and then the flat plate filter is moved by one step in the negative direction to receive the green-filtered light signal and finally moved by another step in the same direction to receive the blue-filtered light signal. In this way, after scanning the spectral information of all three colors, the direction is switched to move the flat plate by two steps in the positive direction and thus be returned to the initial state, and simultaneously, transfer the object to be scanned by one line. Here, the operation of returning the filter to the initial state after one line of image information is input may reduce the scanning speed, but does not present such a critical problem in practice because the reciprocation period of the flat plate filter corresponds to the rotation period of the rotary filter if the transfer operation is performed in synchronization with the filter returning time. In the case of a flat plate filter, since the groove detection by photosensor means 54 happens twice per reciprocation, it is necessary to divide the F-PHOTO signal by two. Also, the color filters of the flat plate type are formed such that the light receiving width thereof is smaller in the central area and wider at the edges, as in the above-described rotary filter.
FIG. 15 is a block diagram showing a circuitry of the apparatus shown in FIG. 4. In FIG. 15, microprocessor 60 which performs the overall control operation of the image scanning apparatus by performing the incorporated programs for scanning, pre-processing, tone calibration, color calibration, etc. synchronously, according to the movement status of color filters 47a, 47b and 47c, and outputs the processed image signal to the outside of the apparatus through an interfacing unit 72.
Synchronizing signal generator 64 receives a groove detecting signal F-PHOTO generated in the photosensor means 54 of FIG. 5, generates a light exposing control signal φSH determining the light exposing period of the line sensor, a driving signal STEP for transfer motor 48, and color information signals RGB-A, RGB-B, GS, BS and RS for a currently scanned object, and finally transfers these to the respective circuits. Line sensor driver 65 receives a light exposing control signal φSH from synchronizing signal generator 64 and generates the signals φSH, φRS, φ1 and φ2 necessary for driving line sensor 45 and a clock signal SCLK. Since the operation of line sensor driving is generally known, the explanation thereof is omitted here.
Analog processor 66 not only regulates the amplitude, current and voltage of the signals so that the output signal of the line sensor can be processed in the pre-processor 67 but also calibrates a color unbalance generated due to the difference in the irradiating intensities of the light sources, the difference in the transmission ratio of the color filters, the chromatic aberration of the lens, and the difference of sensitivities of the line sensor according to wavelengths. Pre-processor 67 calibrates shading error, as mentioned above, and shown in FIGS. 13A through 13D via hardware and, at the same time, performs analog-to-digital conversion of the image signal and transfer the result to the tone calibrator 68 and color calibrator 69.
Since the driving control of the color filters in the embodiment of the present invention is a phase-locked loop control by conventional pulse width modulation and since lamp driver 50, motor driver 49, photo sensor 54 and interfacing unit 72 are generally known, the detailed explanation of circuitry and operational thereof will be omitted.
The present invention relates to an apparatus which synchronizes the scanning order according to the filter location detecting signal, maintains the color balance of the scanned image signals of the respective wavelength bands through a common amplifier, performs analog-to-digital conversion and the shading calibration through a common pre-processor, performs the tone calibration and color calibration in synchronization with the color filter location, and transfers the image-bearing object to the next scanning location. Thus, synchronizing signal generator 64 has a great significance, and the detailed configuration thereof is shown in FIG. 16 and, the operation of various signals according to the operation of color separation filter shown in FIG. 17 using various output signals thereof.
In FIG. 17, a reference letter T is the time necessary for scanning one line of color images and T/4 is the time for scanning the respective colors. Also, it is assumed that the rotary filter shown in FIGS. 7 and 10 is adopted. Since the movement locus of the color filter are the same as that of the line sensor on the time axis, the detailed explanation for the flat plate filter can be substituted by that for the rotary filter provided hereinbelow.
While the groove position of the filter passes through the photosensor, according to one rotation of the rotary filter, the photosensor generates an F-PHOTO signal. In the rotary filter shown in FIG. 10, when a green filter comes to the location of the line sensor, an F-PHOTO signal is generated. Delay time Twait between the φSH signal and F-PHOTO signal shown in FIG. 17, which is varied according to the arrangement of a color separating filter, photosensor and line sensor, is controlled according to the time for the color filter of a subsequent color to be positioned exactly on the line sensor, after the groove is detected by the photosensor. Such a time control is performed by a first timer 162 shown in FIG. 16. First timer 162 starts its operation if the F-PHOTO signal is applied through flip-flop 161, and automatically stops its operation after a duration Twait and waits for a subsequent F-PHOTO signal to be applied. Second timer 164 operates in a period T/4 as the F-PHOTO signal is applied and the output signal of the first timer 162 is applied after the Twait period through flip-flop 163. The output signal of second timer 164 is provided as a control signal 4, SH which controls the light exposing time of the line sensor 45 through logic circuits 165 and 170 and provided to third timer 167 through flip-flop 166. Second timer 164 starts to operate by the output signal of first timer 162, generates the output signal four times and is reset by the F-PHOTO signal. At this time, if one rotation period of the rotary filter is different from the period for generating outputs of the second timer four limes, a rotation speed deviation of the rotary filter is generated, and accordingly, the former should not differ from the latter.
The sensor output enabling signal SOE shown in FIG. 17 is a signal for identifying the block in which the valid pixel value of the line sensor is generated. The practical line sensor has an internal delay factor according to its configurational characteristics. This delay is generally called an initial dummy pixel. Since the amount of the initial dummy pixels is different according to line sensor type, it can be properly regulated in application. Third timer 167 shown in FIG. 16 is devised to control the amount of initial dummy pixels. After the initial dummy pixels are eliminated during the operation of a period T/4, it detects Tpixel of output period of the valid pixels to generate a SOE signal through flip-flop 168, invertor 174 and buffer 175. Buffer 175 controls the output of SOE signal by RGB-A and RGB-B provided through AND gate 173. The output block of the valid pixels is identified by a fourth timer 169 shown in FIG. 16. Accordingly, the time difference Tdummny between T/4 and Tpixel is automatically treated as the dummy pixel period. Meanwhile, since the SOE signal is released during the null interval, that is, the period allotted for transferring the object to be scanned, the subsequent operation is not processed.
In FIG. 17, the RGB-A and RGB-B signals are count outputs of a divide-by-four frequency divider 171 shown in FIG. 16, which is initialized by the F-PHOTO signal as the color filter identifying signal and receives the φSH signal as a clock input for counting the output of second timer 164. In other words, if the RGB-A and RGB-B values are "11," a null interval (that is, an interval in which valid image data is not generated by the line sensor) is generated and green, blue and red image information is generated by the line sensor when the RGB-A and RGB-B values are "00," "01" or "10," respectively. Accordingly, a decoder 172 generates the information on the colors being scanned as a GS, BS and RS in the case of green, blue and red color information, respectively, and generates a STEP signal for shifting the object to be scanned to the next line, after red-image-scanning is completed. Meanwhile, the TONEC-END and COLORC-START signals which are generated in the microprocessor 60 of FIG. 15 are signals indicating the completion of the tone calibration which is performed simultaneously with scanning the respective colors of R, G and B, and controlling the start of the color calibration after completing the scanning of one line of the R, G and B color image and the tone calibration.
In FIG. 18 which is a detailed circuit diagram showing the analog processor shown in FIG. 15, the color balance processing mentioned above is performed. The technical point herein is to control the difference in outputs of the line sensors according to the colors by the shift of a color separating filter and the gain of the respective colors is controlled by using an operational amplifier. It is constructed so that the gain values for the respective colors, that is, gain factors of the operational amplifier are multiplexed using the output signals GS, BS and RS of the decoder 172 shown in FIG. 15.
FIG. 19 is a circuit diagram showing the detailed configuration of the pre-processor shown in FIG. 15. A shading calibrater and analog-to-digital converter shown within the dotted line in FIG. 19 are proposed for a monochromatic color mode, but have limitations when applied to color images. The simplest method is to provide the respective shading calibrators and analog-to-digital converters for the three wavelength bands of R, G and B colors, which increases cost without improving performance if not processed in parallel. Among pre-processing functions, the since analog-to-digital conversion is the same as that of the conventional method, the explanation thereof will be omitted, and only a shading calibration function will be explained. The shading calibration is to perform such an operation as exemplified by Equation 7, by scanning a color sample segment of a reference color. Here, the value of the color sample segment is the data used for performing shading calibration. If the color balance of red, green and blue is identical to the gamma characteristic, the shading calibration data is commonly applicable for the R, G and B image information, but, this being unrealistic, the shading calibration data should be separately applied for each color signal. The application of Equation 7 to a color mode is as follows. ##EQU6##
Here, Y represents one color among red, green and blue. In practice, the principle of shading calibration is not necessarily different for each color, and the only problem lies in the application of shading calibration data for each color. In the present invention, the data for calibrating the respective colors of R, G and B is stored in the shading calibrating memory, and the RGB-A and RGB-B signals generated through frequency divider-by-four 171 of FIG. 16 are used as the extension bits of address for controlling the shading calibrating memory.
FIG. 20 is a characteristic graph showing the output values of the line sensor for density values and the tone calibrating characteristics, and FIGS. 21A and 21B show the tone calibrator 68 of FIG. 15 and the look-up tables for performing red, green and blue tone calibration. In tone calibration, the gamma characteristics of the respective R, G and B colors are regulated. Here, for the density value which means an optical density, the line sensor has an exponential relation therewith, while human visual sensitivity characteristics have a linear relation therewith. An image scanning apparatus which quantifies a reflected light after a predetermined quantity of light is incident to a scanned object, consequently quantizes the reflecting characteristics of the scanned object according to the locations. In other words, the line sensor in the image scanning apparatus has a linear relation with a reflective index R expressed as: where IREFLECTED is the intensity of the reflected light and IINCIDENT is the ##EQU7## intensity of the incident light.
The reflective index (R) and optical density Do have the following relationship.
D.sub.o =-log.sup.R (11)
Accordingly, a reflective index of 100% translates into an optical density of 0.0 while a reflective index of 0.01% translates into an optical density of 2.0. The horizontal axis of FIG. 20 indicates the scanned values in case a tone calibration has not been performed. Here, it is understood that the characteristics of the line sensor has an exponential relation with an optical density. Meanwhile, since human visual characteristics have a linear relation with the optical density, it is the principle of tone calibration to correspond to the form represented in the dotted line in FIG. 20. The horizontal direction indicates the optical densities of the color sample segments of a used achromatic color. As a result, if the tone reproductive fields to be reproduced on the basis of optical density, are set for optical densities of 0.0 to 2.0, the conversion of the optical densities into the values corresponding to the input values will do. That is to say, in the case of 8-bit quantization, the output value "0" corresponds to an optical density of 0.0, 255 corresponds to an optical density of 2.0, and the intermediate values are merely interpolated.
Color calibrator 69 shown in FIG. 15 matches the spectrum characteristics of three wavelength bands of the image scanning apparatus with those of an image output system or human vision. Limiting the spectrum characteristics to color matching to a specific system is called a device-dependent color calibration and matching the spectrum characteristics to the color coordinating system stipulated by the CIE is called a device-independent color calibration, which are influenced by the determining basis of color calibration coefficients rather than the difference in the embodiments of the practical systems.
Color calibration methods include 3×3 linear masking or 3×9 nonlinear masking as well as three dimensional UT methods. The present invention adopts a 3×3 linear masking method.
The 3×3 linear masking method is defined as the following relationship. Here, a subscript letter c indicates the calibrated value and r indicates the input row data.
R.sub.c =a.sub.11 R.sub.r +a.sub.12 G.sub.r +a.sub.13 B.sub.r
G.sub.c =a.sub.21 R.sub.r +a.sub.22 G.sub.r +a.sub.23 B.sub.r
B.sub.c =a.sub.31 R.sub.r +a.sub.32 G.sub.r +a.sub.33 B.sub.r
Here, a 11 , a 12 , . . . a 32 , a 33 are color calibration coefficients which are determined by the spectrum characteristics of the designed image scanning apparatus and the referenced color coordinating system. Accordingly, color calibrator 68 shown in FIG. 15 performs a 3×3 matrix operation and functions as a controlling device of scanning and writing the image data memory. FIG. 22 is a flow chart of tone and color calibrations and FIG. 23 is the operational waveforms thereof. The tone calibration is performed independently on the three wavelengths of the respective colors. However, in the color calibration, the respective colors at a specific pixel point in a specific line should be considered simultaneously.
In FIG. 23, signal CO/BW denotes mode of color/black-white, VIDO denotes the output of valid image data, and REQ denotes request for the outputting valid image data to external device.
In the present invention, since three wavelength information scanning is performed in a line sequential method, after scanning all of three wavelength information of a specific scanning line, the color calibration is performed in the null interval to shift the manuscript to the subsequent location.
Although it is possible to switch filters by a plane sequential method, it is uneconomical because a memory enabling to store the image information of one page portion is necessary to calibrate the color. The present invention concretely proposes a method considering such characteristics. Also, the present invention is devised so that the color information of the scanned image and the respective processing within the allotted time during one line scanning period are completely synchronized according to the movements of filters, thereby preventing the deterioration of a picture quality and processing an input efficiently.
As described above, the image scanning apparatus according to the present invention attains simply an effect of a shading calibration by arranging color filters and a line sensor so that a shading distortion can be calibrated geometrically.
Also, the image scanning apparatus according to the present invention has an advantage in that a resolution can be increased by installing a plurality of combinations of three color filters to a color separating filter such as a rotary filter or flat plate filter, without increasing the movement speed of a color separating filter.
Moreover, the image scanning apparatus according to the present invention can reduce a color registration error due to a manuscript transfer by reducing the refractive index of a color separating filter by inserting the color filter in the area which a part of the color separating filter such as a rotary filter or flat plate filter is removed.
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An image scanning apparatus which can reduce a shading distortion generated by luminous characteristics of a light source, vignetting of a lens, etc. adopts color filters having a geometrical structure which enables to counterbalance a shading distortion and is characterized in that a line sensor is vertically arranged for the radial direction of the rotary filter. The image scanning apparatus can accomplish a simple shading calibration by arranging color filters and the line sensor so that a shading distortion is calibrated geometrically.
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BACKGROUND OF THE INVENTION
This invention is concerned with flooding of underground formations, such as oil-bearing strata and the like, and is more particularly concerned with an improved pump installation for pumping sub-surface water to an oil-bearing formation, and with improved control valve apparatus.
In the secondary recovery of fluid hydrocarbons, such as oil, it is common practice to flood the hydrocarbon-bearing formation with water pumped through a bore hole, thereby applying fluid pressure which increases the yield of the desired hydrocarbon from its underground formation. Both surface water and sub-surface water have been employed for this purpose. In the employment of sub-surface water, two schemes have been utilized -- (1) pumping the water upwardly to the surface through a first bore hole, then downwardly to the hydrocarbon-bearing formation through a second bore hole, and (2) pumping the water through a single bore hole communicating with both the water-bearing zone and the hydrocarbon-bearing zone. As will appear more fully hereinafter, the present invention is principally concerned with the second technique.
The following patents are typical of the prior art dealing with flooding oil-bearing strata and the like: Krueger; U.S. Pat. No. 2,808,111 Van Den Beemt; U.S. Pat. No. 2,706,526 Gray et al; U.S. Pat. No. 2,551,434 Heath; U.S. Pat. No. 2,347,779 Arutunoff; U.S. Pat. No. 3,170,520 Engle; U.S. Pat. No. 3,354,952 Hassler; U.S. Pat. No. 2,352,834 Chenoweth; U.S. Pat. No. 3,455,382.
Krueger, Van Den Beemt, and Gray et al pump water downwardly through a bore hole and through a packer to flood an oil-bearing zone communicating with the bore hole at a lower level. Heath employs a similar technique, but in which the water pressure is high enough to avoid the need for a pump. The flow rate is regulated by a mechanically adjusted valve. Arutunoff and Engle pump upwardly through a bore hole for flooding. Hassler and Chenoweth are broadly concerned with regulation of the flow of the flooding medium.
As will appear more fully hereinafter, underlying the present invention is the discovery of the need for a critical type of flow control, by means of a special flow control valve in conjunction with a submergible pump. Valves of various types in wells and/or in conjunction with pumps have of course been known for many years. See, for example, the following prior patents: O'Rourke, U.S. Pat. No. 3,807,894; Miller, U.S. Pat. No. 3,084,898; Page, U.S. Pat. No. 3,477,507; Baker, U.S. Pat. No. 1,631,509; Garrett, U.S. Pat. No. 3,698,411; Litchfield et al, U.S. Pat. No. 3,698,426; Vincent, U.S. Pat. No. 3,294,174; Pistole et al, U.S. Pat. No. 3,007,524; Bows, U.S. Pat. No. 3,747,618; Verheul, U.S. Pat. No. 3,640,303; Reaves, U.S. Pat. No. 3,610,569; Kruse et al, U.S. Pat. No. 1,829,704; Natho, U.S. Pat. Re. No. 25,109; and Canadian Pat. No. 749,740. However, the prior art is devoid of a teaching of the type of pump discharge flow control in flooding or the type of flow control valve required by the invention.
SUMMARY OF THE INVENTION
It is accordingly a principal object of the invention to provide improved secondary recovery apparatus and methods, improved apparatus and methods for flooding, improved pump installations, and improved control valves.
Briefly stated, in a preferred embodiment of the invention sub-surface water is pumped downwardly through a bore hole to an oil-bearing formation by a pump installation in the bore hole including a submergible pump and an adjustable control valve at the discharge side of the pump. The control valve closes automatically when the pump is not operating and is controlled hydraulically from the surface of the earth to vary the flow to the oil-bearing formation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further described in conjunction with the accompanying drawings, which illustrate preferred and exemplary embodiments, and wherein:
FIG. 1 is a truncated vertical sectional view illustrating a flooding installation in accordance with the invention; and
FIG. 2 is a truncated vertical sectional view illustrating the preferred control valve of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawings, in accordance with the illustrated application of the invention it is desired to flood an oil-bearing zone 10 with sub-surface water pumped from a water-bearing zone 12, which, in the example shown, is at a higher sub-surface level than the oil-bearing zone. Both zones communicate with a bore hole 13, which in the example shown, contains a casing 14.
To pump water from zone 12 to zone 10, a pump installation 16 is provided. As shown, the pump installation 16 may be suspended by tubing 18 from the well head 20 at the surface of the earth, successive colinear housing sections of the installation being bolted together. The down-hole end of the installation engages and traverses a conventional packer 22, which divides the casing 14 into an upper zone above the packer and a lower zone below the packer.
Water from the water-bearing zone at 12 enters casing 14 via perforations 24 and flows downwardly to the intake head 26 of a submergible pump 28, which may be of the centrifugal type having a tubular housing containing diffusers and a shaft carrying impellers. The pump is driven by an electric motor 30 energized by power supplied from the surface via cable 32. The electric motor is preferably of the oil-filled type, and the drive shaft of the motor extends through a combined protector and thrust section 34 to engage the impeller shaft of the pump 28. The thrust section 34 is also filled with oil in the manner of the protector described in Arutunoff U.S. Pat. No. 2,783,400, for example, and preferably contains a plurality of thrust bearings to accommodate both upward and downward thrust of the drive shaft. At its upper end the motor 30 may be provided with an expansion chamber 36 containing a flexible bag, one side of which is exposed to the ambient pressure in the bore hole via a vent 38, the other side of which is exposed to the oil pressure in the motor 30. By this arrangement the thrust section 34 may be kept completely isolated from the fluid in the bore hole and need not include the check valves that are conventionally employed in protectors.
The discharge end 40 of the submergible pump is coupled to a flow meter 42, such as the turbine type manufactured by the Halliburton Company, the flow meter being coupled in turn to pressure sensors 44, such as the type employed in the Lynes Sentry Systems manufactured by Baker Division of Baker Oil Tools Inc. The pressure sensors may measure the discharge pressure of the pump as well as the ambient bore hole pressure, if desired. Electrical output signals from the pressure sensors 44 and the flow meter 42 are transmitted to indicators (not shown) at the surface of the earth via cables 46 and 48.
Coupled in turn to the pressure sensors 44 is a flow control valve 50 in accordance with the invention. The discharge pipe 52 of the flow control valve extends through packer 22. As will be seen hereinafter, operation of the flow control valve requires a hydraulic fluid connection to the surface, and in the form shown this connection is provided by a conduit 53 connecting the flow control valve 50 to the tubing 18, by which the pump installation may be suspended. Tubing 18 and conduit 53 may be pressurized with hydraulic fluid supplied from the surface by a hand pump 54, and the pressure may be relieved by a valve indicated diagrammatically at 56. An indicator 58 shows the pressure in tubing 18.
FIG. 2 illustrates the structure of the control valve. The valve comprises a cylindrical housing 60, which in the form shown is constituted by several consecutive parts threaded together and provided with suitable O-rings 62 to prevent leakage. The housing contains a large-diameter longitudinal passageway 64, one end of which (the upper end in the form shown) is adapted to be closed by engagement of the head or plug 66 of a valve member with a seat 68. The valve head is preferably tapered and engages a seat of complementary taper, thereby isolating a first space above the valve head from a second space below the valve head. The valve head is supported at one end of a stem or shaft 70, which reciprocates in a bearing 72 supported by the center portion of an apertured disk or spider 74. The lower end of the valve stem carries a further apertured disk or spider 76 connected to one end of a plurality of circumferentially spaced rods 78 (only two of which are shown). At their opposite end the rods are connected to an annular piston 80 which reciprocates in an annular cylinder or chamber 82 formed in the wall of the valve housing and isolated from the main passage 64 of the valve by means of seals 84 and 86. Piston 80 may be provided with internal piston rings 88 and external piston rings 90. Coil compression springs 92 surrounding the rods 78 urge the piston 80 upwardly in the chamber 82 and hence tend to close the valve head 66 against the seat 68. The upper end of chamber 82 is vented to the exterior of the housing of the valve (to the ambient pressure in the bore hole) by means of a vent 94, while the lower end of chamber 82 is connected to conduit 53 for the supply of hydraulic fluid thereto from the surface, so that a pressure differential can be provided across the piston and so that an adjustable force can be selectively applied to the valve member.
When the pump is not operating, springs 92 have sufficient force to close the control valve 50. When it is desired to pump water from zone 12 to an oil-bearing zone 10 for flooding, the pump is energized with the valve closed, sufficient hydraulic pressure having been built up in the conduit 53 to maintain the valve closed even when the pump is started. This insures that the pump will start against adequate back pressure to prevent runaway and damage to the pump. As the pump discharge pressure builds up, indicated by the pressure sensors 44, the operator at the surface relieves the pressure in conduit 53, so that the pump discharge pressure gradually forces the valve head 66 away from the seat 68 against the force of springs 92. Water discharged from the pump then begins to flow through passage 64 of the valve, the flow being indicated by the output of the flow meter 42. The operator relieves the pressure in conduit 53 enough to provide the desired pressure and flow conditions for flooding. With the large diameter passage 64 through the valve, flow is minimally restricted by the valve per se when it is desired to provide maximum flow to the oil-bearing zone 10. The ambient pressure in the bore may vary considerably, particularly as the head of water drops, and the hydraulic pressure in conduit 53 can be reduced further to compensate for lower ambient pressures.
When the pump is de-energized, springs 92 will close the valve 50 automatically, since the discharge pressure on the valve head 66 will no longer tend to open the valve. Springs 92 may have sufficient force to maintain the valve closed against any column or water above the valve. Even if a substantial ambient pressure develops above the packer when the pump is not operating, the valve will remain closed if sufficient pressure is maintained in conduit 53, the ambient pressure being insufficient to overcome the combined force of the springs 92, the pressure in conduit 53, and the pressure exerted upon the underside of valve head 66. The valve configuration prevents reverse flow (upwardly) through the bore once the valve is closed, insuring against loss of flooding pressure, flow of oil through the flooding bore, and windmilling of the pump (free reverse rotation) which would prevent safe starting of the pump in the required rotational direction.
While a preferred embodiment of the invention has been shown and described, it will be apparent to those skilled in the art that changes can be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims.
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Sub-surface water is pumped through a bore hole to an oil-bearing formation by a pump installation in the bore hole including a submergible pump and an adjustable control valve at the discharge side of the pump. The control valve closes automatically when the pump is not operating to prevent reverse flow and loss of flooding pressure and to insure a back pressure on the pump during starting, and is controlled hydraulically from the surface of the earth to vary the flow to the oil-bearing formation. A novel control valve structure provides accurate and reliable control without unduly restricting the flow volume.
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FIELD OF THE INVENTION
[0001] The present invention relates to foam-based carbon foams and more particularly to activated such foams that provide porous, monolithic and structurally sound activated carbon materials for filtration applications.
BACKGROUND OF THE INVENTION
[0002] Activated carbon and filters made therewith are well known in the art. Such filters conventionally comprise masses of activated carbon particulate that is loaded into a permeable frame with the combination of the permeable frame and the contained activated carbon particulate serving as the filtering medium. Alternative similar structures using gell forms of activated carbon are also well known. While such arrangements are entirely satisfactory for many applications and provide entirely satisfactory filtering of fluids, especially gases, their use is often cumbersome or expensive due to the requirement that the activated carbon particulate must be loaded into some kind of permeable frame or container to obtain the desired filter element. Additionally, since carbon particles are, by their very physical nature, “dirty” and dusty, i.e. friable and not particularly durable, the handling thereof for purposes of loading the filter element is at best inconvenient and time consuming and at worst dangerous and costly. This is particularly true in the case of smaller filter elements that require changing of the filter medium only occasionally, such as in the case of furnace filters for the home and the like.
[0003] Thus, the availability of a monolithic activated carbon filter material that provides all of the advantages of an activated carbon particulate filter, but does not require the handling of particulate carbon to obtain these advantages would be highly desirable. Such an activated carbon material available as a monolithic pre-sized element that can easily inserted into a duct or other fluid conduit would be highly useful.
OBJECT OF THE INVENTION
[0004] It is therefore an object of the present invention to provide a monolithic, activated carbon foam that can replace prior art activated carbon particulate filters that require the handling of ablative carbon particulate or gels.
SUMMARY OF THE INVENTION
[0005] According to the present invention, there is provided an ablation resistant, monolithic, activated, carbon foam produced by the activation of a coal-based carbon foam through the action of carbon dioxide, ozone or some similar oxidative agent that pits and/or partially oxidizes the carbon foam skeleton, thereby significantly increasing its overall surface area and concurrently increasing its filtering ability. Such activated carbon foams are suitable for application in virtually all areas where particulate or gel form activated carbon materials have been used. Such an activated carbon foam can be fabricated, i.e. sawed, machined and otherwise shaped to fit virtually any required filtering location by simple insertion and without the need for handling the “dirty” and dusty particulate activated carbon foam materials of the prior art.
DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a graph showing the heat treatment temperatures for the various phases of the production process used in the fabrication of the activated carbon foam of the present invention.
DETAILED DESCRIPTION
[0007] U.S. patent application Ser. No. 09/453,729 filed Dec. 2, 1999 and entitled, “Coal-Based Carbon Foams”, which is incorporated herein by reference in its entirety, describes a family of carbon foams having a density of preferably between about 0.1 g/cm 3 and about 0.8 g/cm 3 that are produced by the controlled heating of coal particulate preferably up to ¼ inch in diameter in a “mold” and under a non-oxidizing atmosphere. The process described in this application comprises: 1) heating a coal particulate of preferably small i.e., less than about ¼ inch particle size in a “mold” and under a non-oxidizing atmosphere at a heat up rate of from about 1 to about 20° C. to a temperature of between about 300 and about 700° C.; 2) soaking at a temperature of between about 300 and 700° C. for from about 10 minutes up to about 12 hours to form a green foam; and 3) controllably cooling the green foam to a temperature below about 100° C. According to the method described in the aforementioned application, the porous foam product of this process is subsequently preferably carbonized by the application of known techniques, for example, soaking at a temperature of between about 800° C. and about 1200° C. for a period of from about 1 to about 3 hours. Although this is the preferred temperature range for carbonization, carbonization actually occurs at temperatures between about 600° C. and 1600° C.
[0008] Graphitization, commonly involves heating the green foam either before or after carbonization at a heat-up rate of less than about 10° C. per minute, preferably from about 1° C. to about 5° C. per minute, to a temperature of between about 1700° C. and about 3000° C. in an atmosphere of helium or argon and soaking for a period of less than about one hour. Again, the inert gas may be supplied at a pressure ranging from about 0 psi up to a few atmospheres.
[0009] While carbon foams prepared as just described are useful “as fabricated” for filtering applications, they are not particularly satisfactory in many of these application because of their relatively low overall surface area of from about 1.0 m 2 /g to about 2.0 m 2 /g. It has now been discovered that the filtering ability of such coal-based carbon foams can be increased, as measured by their overall surface area, by activation with, for example CO 2 or ozone. Such treatment apparently causes pitting of the carbon foam skeleton through oxidation thereof and increases the overall surface area of such materials to a level of between about 10 m 2 /g to about 25 m 2 /g, and preferably between about 15 m 2 /g to about 20 m 2 /g, depending upon the level, i.e. duration and intensity of the activation procedure. At these overall surface area levels, the carbon foams of the present invention provide excellent monolithic filtration media that exhibit all of the desirable strength, ablation resistance, and ease of fabrication benefits of the parent coal-based carbon foams.
[0010] The method of producing the activated carbon foams of the present invention comprises initially: 1) heating a coal particulate of preferably small, i.e. less than about ¼ inch particle size in a “mold” and under an inert or non-oxidizing atmosphere at a heat up rate of from about 1 to about 20° C. to a temperature of between about 300 and about 600° C.; 2) soaking at a temperature of between about 300 and 600° C. for from about 10 minutes up to about 12 hours to form a “green foam”; and 3) controllably cooling the “green foam” to a temperature below about 100° C. The green foam may be subsequently carbonized and/or graphitized as describe hereinafter in an inert or non-oxidizing atmosphere to produce a carbonized or graphitized foam. The inert or non-oxidizing atmosphere may be provided by the introduction of inert or non-oxidizing gas into the “mold” at a pressure of from about 0 psi, i.e., free flowing gas, up to about 500 psi. The inert gas used may be any of the commonly used inert or non-oxidizing gases such as nitrogen, helium, argon, CO 2 , etc.
[0011] It is generally not desirable that the reaction chamber or mold be vented or leak during this heating and soaking operation. The pressure of the mold or chamber and the increasing volatile content therein tends to retard further volatilization while the cellular product sinters at the indicated elevated temperatures. If the mold or chamber is vented or leaks during soaking, an insufficient amount of volatile matter may be present to permit inter-particle sintering of the coal particles thus resulting in the formation of a sintered powder as opposed to the desired cellular product. Thus, according to a preferred embodiment of the present process, venting or leakage of non-oxidizing gas and generated volatiles is inhibited consistent with the production of an acceptable cellular product.
[0012] Additional more conventional blowing agents may be added to the particulate prior to expansion to enhance or otherwise modify the pore-forming operation.
[0013] The term “mold”, as used herein is meant to define any mechanism for providing controlled dimensional forming of the expanding coal or carbon or containing the foaming operation. Thus, any chamber into which the coal particulate and carbide precursor blend is deposited prior to or during heating and which, upon the foam precursor attaining the appropriate expansion temperature, contains the expanding carbon to some predetermined configuration such as: a flat sheet; a curved sheet; a shaped object; a building block; a rod; tube or any other desired solid shape can be considered a “mold” for purposes of the instant invention. The term “mold” as used herein, is also meant to include any container, even an open topped container that “contains” the expanding mixture so long as such a device is contained in a pressurizable vessel that will permit controlled foaming as described herein. Clearly, a container that results in the production of some particular near net or net shape is particularly preferred.
[0014] As will be apparent to the skilled artisan familiar with pressurized gas release reactions, as the pressure in the reaction vessel, in this case the mold increases, from 0 psi to 500 psi, as imposed by the inert or non-oxidizing gas, the reaction time will increase and the density of the produced porous coal will increase as the size of the “bubbles” or pores produced in the expanded carbon decreases. Similarly, a low soak temperature at, for example about 400° C. will result in a larger pore or bubble size and consequently a less dense expanded coal than would be achieved with a soak temperature of about 600° C. Further, the heat-up rate will also affect pore size, a faster heat-up rate resulting in a smaller pore size and consequently a denser expanded coal product than a slow heat-up rate. These phenomenon are, of course, due to the kinetics of the volatile release reactions which are affected, as just described, by the ambient pressure and temperature and the rate at which that temperature is achieved. These process variables can be used to custom produce the expanded coals of the present invention in a wide variety of controlled densities, strengths etc.
[0015] Cooling of the “green foam” after soaking is not particularly critical except as it may result in cracking of thereof as the result of the development of undesirable thermal stresses. Cooling rates less than 10° C./min to a temperature of about 100° C. are typically used to prevent cracking due to thermal shock. Somewhat higher, but carefully controlled, cooling rates may however, be used to obtain a “sealed skin” on the open cell structure of the product as described below. The rate of cooling below 100° C. is in no way critical.
[0016] After expanding the carbon material as just described, the “green foam” is an open celled material. Several techniques have been developed for selectively “sealing” the surface of the open celled structure to improve its adhesive capabilities for further fabrication and assembly of a number of parts. For example, a layer of a commercially available graphitic adhesive (for example an epoxy-graphite adhesive) can be coated onto portions of the surface and cured at elevated temperature or allowed to cure at room temperature to provide an adherent skin.
[0017] After expanding, the “green foam” is readily machineable, sawable and otherwise readily fabricated using conventional fabrication techniques.
[0018] A variety of additives and structural reinforcers may be added to the carbon materials of the present invention either before or after expansion to enhance specific mechanical properties such as fracture strain, fracture toughness and impact resistance. For example, particles, whiskers, fibers, plates, etc. of appropriate carbonaceous or ceramic composition can be incorporated into the abrasive foam to enhance its mechanical properties.
[0019] The activated foams of the present invention can additionally be impregnated with; for example, petroleum pitch, epoxy resins or other polymers using a vacuum assisted resin transfer type of process. The incorporation of such additives provides load transfer advantages similar to those demonstrated in carbon composite materials. In effect a 3-D composite is produced that demonstrates enhanced impact resistance and load transfer properties.
[0020] The cooling step in the expansion process results in some relatively minimal shrinkage on the order of less than about 5% and generally in the range of from about 2% to about 3%. This shrinkage must be accounted for in the production of near net shape or final products of specific dimensions and is readily determinable through trial and error with the particular carbon starting material being used. The shrinkage may be further minimized by the addition of some inert solid material such as coke particles, ceramic particles, ground waste from the coal expansion process etc. is as common practice in ceramic fabrication.
[0021] According to the method of the present invention, subsequent to the production of the “green foam” as just described, the “green foam” may be subjected to carbonization and graphitization within the controlled conditions described below to obtain activated foams that exhibit specific thermal or electrical conductivity or insulating properties or strengths for specific applications.
[0022] Carbonization, sometimes referred to as calcining, is conventionally performed by heating the green foam under an appropriate inert gas at a heat-up rate of less than about 5° C. per minute to a temperature of between about 600° C. and about 1600° C. and preferably between about 800° C. and about 1200° C. and soaking for from about 1 hour to about three or more hours. Appropriate inert gases are those described about that are tolerant of these high temperatures. The inert atmosphere is supplied at a pressure of from about 0 psi up to a few atmospheres. The carbonization/calcination process serves to remove substantially all of the non-carbon elements present in the green foam such as sulfur, oxygen, hydrogen, etc.
[0023] Graphitization, commonly involves heating the carbon foam either before or after carbonization at heat-up rate of less than about 10° C. per minute, preferably from about 1° C. to about 5° C. per minute, to a temperature of between about 1700° C. and about 3000° C. in an atmosphere of helium or argon and soaking for a period of less than about one hour. Again, the inert gas may be supplied at a pressure ranging from about 0 psi up to a few atmospheres. According to a preferred embodiment of the process described herein, the activated foams of the present invention are produced by sequentially carbonizing and then graphitizing the green foam as described above.
[0024] Activation of the coal-based carbon foams prepared as described hereinabove is achieved by flowing carbon dioxide or ozone through the carbon foam, “green” foam, calcined foam or graphitized foam, at elevated temperature to partially oxidize and pit the carbon foam. The activation process involves placing the carbon foam into a heated container and flowing the oxidative gas, for example CO 2 or ozone through the carbon foam at elevated temperature for a period of time adequate to obtain the required oxidation/pitting. Specific operative processing conditions include but are not limited to gas flow rated on the order of from about 1 to about 10 cubic feet per minute for a period of from about 1 to about 12 hours at a temperature of between about 600° C. and about 1200° C. Depending upon the level of activation desired, these operating parameters can be varied broadly to obtain activated foams of varying levels of activation. As shown in example 1 below, specifically preferred operating ranges include gas flow rates on the order of 4 to 5 cubic feet per minute after an initional purge at a temperature of between about 800° C. and about 1200° C. for a period of between about 2 and about 6 hours. As will be apparent to the skilled artisan, the level of “activation” i.e. increase in overall surface area will be dependent upon the duration of the activation process as well as the temperature at which the activation is performed and the oxidative potential of the activating agent, CO 2 or ozone. It has generally been found that treatments that do not adversely affect the carbon foam or its structure yield activated foams demonstrating overall surface areas in the range of between about 10 m 2 /g and about 25 m 2 /g. A preferred overall surface area is between about 15 m 2 /g and about 20 m 2 /g.
[0025] The following example will serve to better illustrate the successful practice of the invention.
EXAMPLES
[0026] A laboratory scale activation cell was made from 3 inch inside diameter pipe, end caps and tube fittings (to provide gas access to the interior of the cell)—all fabricated from 304 stainless steel. The cell was situated vertically in a Harper SiC heating element furnace on a firebrick pedestal. Carbonized coal-based carbon foam samples 3.0 inches in diameter and 0.5 inches in thickness were loaded into the cell and separated by 304 stainless steel folded expanded metal standoffs. The foam samples were made from Powellton bituminous coal having a bulk density of about 30 pounds per cubic foot and had been prepared as described hereinabove and calcined at 1050° C. to remove volatile material therefrom. A plug of very fine (#00) steel wool was placed beneath the lower foam sample and above the upper foam sample to scavenge oxygen in the cell and to prevent over oxidation. The cell was sealed and the 304 stainless steel tubing fed through a sight port in the door of the furnace. A pair of ¼ inch stainless steel tubes were connected via compression fittings to: 1) additional tubing that connected to a type 320 carbon dioxide regulator atop a compressed carbon dioxide tank; and 2) an exhaust port to permit venting of gas from the cell. The tubing was connected so that gas entered the cell from the bottom and passed through the steel wool and carbon foam samples before exiting the top of the cell.
[0027] The following furnace profile was used:
[0028] Heat at 2° C. per minute from ambient up to 900° C.;
[0029] Hold at 900° C. for 2 and 6 hours for each of two experiments; and
[0030] Turn furnace power off and cool to ambient (controlled rate).
[0031] Carbon dioxide, after an initial 10 cubic feet per minute purge, was passed through the reactor at 4-5 cubic feet per minute for the duration of each experiment. In both experiments, two foam samples were loaded in the activation cell. In the two hour test, a “green” foam sample was included in place of a calcined sample. This sample was expected to lose about 15% of its mass during the process as it calcined, plus whatever activation losses occurred. Mass losses and dimensional changes are reported in Table 1 below.
TABLE 1 Time at Experiment 900° C. Initial Mass(g) Final Mass(g) MassLoss(%) 1, Calcined 2 hours 18.03 17.24 4.3 1, “Green” 6 hours 13.97 11.2 20.4 2, calcined 6 hours 21.18 18.17 14.2 2, calcined 6 hours 21.38 18.95 11.4
[0032] All samples had an initial overall surface area of between 1 m 2 /g and 2 m 2 /g and a final overall surface area of between 15 m 2 /g and 20 m 2 /g.
[0033] As will be apparent to the skilled artisan, either before or after activation as described herein, the carbon foam structures of the present invention may be fabricated into any appropriate shape for the production of carbon filter elements. The fabricability by sawing, machining or otherwise of the coal-based carbon foams from which the activated foam is produced allows the production of monolithic filter elements of virtually any desired shape.
[0034] As the invention has been described, it will be apparent to those skilled in the art that the same may be varied in many ways without departing from the spirit and scope of the invention. Any and all such modifications are intended to be included within the scope of the appended claims.
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An ablation resistant, monolithic, activated, carbon foam produced by the activation of a coal-based carbon foam through the action of carbon dioxide, ozone or some similar oxidative agent that pits and/or partially oxidizes the carbon foam skeleton, thereby significantly increasing its overall surface area and concurrently increasing its filtering ability. Such activated carbon foams are suitable for application in virtually all areas where particulate or gel form activated carbon materials have been used. Such an activated carbon foam can be fabricated, i.e. sawed, machined and otherwise shaped to fit virtually any required filtering location by simple insertion and without the need for handling the “dirty” and friable particulate activated carbon foam materials of the prior art.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 13/206,994 filed Aug. 10, 2011, which claims the benefit of U.S. Provisional Application No. 61/373,945 filed Aug. 16, 2010, both of which are herein incorporated by reference in their entirety.
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of coated filler particles. More particularly, it relates to treated inorganic filler particles for use with polymers and elastomers.
2. Description of the Related Art
Mesoporous inorganic filler particles consisting of aggregated primary particles having a very high hardness, such as fumed and precipitated silica, are widely employed in state-of-the-art elastomeric and polymeric compositions as agents that impart especially high durability. In these compositions, the very small size of the primary particles allows for good optical transparency when the aggregates are sufficiently well-dispersed. On the other hand, particles that are not well-dispersed but remain as aggregates are useful as agents for creating desirable surface textures for improving adhesion or repelling liquids.
The small size of the primary particles also results in a large specific surface area. As a result, the surface characteristics of these particles are paramount in controlling the properties of polymeric and elastomeric formulations into which the particles are incorporated. The surfaces of inorganic particles immediately after production typically contain chemical functionalities that impart undesirable properties to polymeric and elastomeric formulations. Fumed and precipitated silica, for instance, typically feature surfaces with a high concentration of chemically bound silanol groups, in addition to large quantities of physisorbed and chemisorbed water and weakly bound organic impurities. For non-polar polymers and elastomers, and particularly for highly fluorinated polymers and elastomers, the high polarity of such surfaces greatly inhibits the establishment of intimate contact between the inorganic and polymeric or elastomeric components, leading to poor dispersion, mechanical weakness, poor flow properties, and a lack of readily reproducible physical characteristics.
To overcome these limitations, numerous techniques for modifying the surfaces of inorganic particles have been described. For fluorinated polymers and elastomers, a typical approach involves the treatment of silica particles with fluoroalkyl-alkylsilanes. In some instances, a small amount, generally less than 15 parts by weight of fluoroalkyl-alkylsilane per 100 parts by weight of silica, is added. The silane becomes chemically attached to the silica particles, often through formation of a three-dimensional silicate network on the particle surface. These networks minimize the concentration of surface accessible silanols, while also binding fluoroalkyl functional groups to the silane surface, which increases the chemical compatibility of the filler with the fluoropolymer or fluoroelastomer. Although these methods produce inorganic particles that no longer inhibit intimate contact between the filler and the matrix, the limited amount of fluoroalkyl-alkylsilane employed, along with the disorganized nature of the three-dimensional network, results in a surface energy that is typically no lower than around 30 mJ per square meter. For optimal repellency of fats, oils, and greases, a surface energy of 5-30 mJ per square meter is required.
In many cases, fluoroalkyl-alkylsilane treatment of idealized or carefully prepared surfaces of low specific surface area, such as silicon wafers or plate glass, or of high specific surface area (but with a non-discrete aggregated structure), such as a sol-gel, have been utilized. These coated objects, however, cannot be readily deposited onto other substrates by simple techniques such as spraying and thus cannot impart a nanoscale to microscale texture to surfaces not already patterned. In other cases, non-porous silica particles coated with fluoroalkyl-alkylsilanes have been utilized. In these cases, the lack of mesoporosity, as quantified by specific surface area, limits the range of textures that may be imparted to a surface. In particular, textures that are useful for liquid repellency against fluids at pressures beyond a few kPa require roughness at length scales below 100 nm.
In yet other cases, large quantities of fluoroalkyl-alkylsilane have been reportedly mixed with a wide variety of silica particles by non-specific methods, saturating the surfaces with both bound and unbound fluoroalkyl functionality. A more recent approach involves the dispersion of unbound fluorinated organic/inorganic hybrid molecules directly into polymers and elastomers. In such cases, the lack of covalent chemical bonding between the filler and the fluorinated surface treatment causes the treatment to disappear over time due to abrasion or leaching by fluids in contact with the fluorinated polymers or elastomers.
There exists, therefore, a need for a treated filler particle having a well-defined monolayer-like arrangement of fluoroalkyl chains attached to its surface via covalent and thermally stable chemical bonds, such that the surface energy of the particle, for purposes of liquid repellency, is less than 30 mJ per square meter, and such that a formulation incorporating the particles can be coated onto a substrate, with the surface texture of the coating being controlled by conformality with the texture of the particle aggregates so as to further impart desirable liquid repellence characteristics.
SUMMARY OF THE INVENTION
The present invention provides a treated, mesoporous aggregate comprising a plurality of coated particles. The particles comprise an inorganic oxide substrate having the formula MO x , in which M is an oxide of at least one of Li, Be, B, Na, Mg, Al, K, Ca, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ga, Ge, Rb, Y, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Cd, In, Sn, Sb, Te, Cs, Ba, Ce, Hf, Ta, W, Re, Os, Ir, Pt, Pb, and Bi. The inorganic oxide substrate possesses a specific surface area of at least 50 square meters per gram. At least some of the inorganic oxide substrate comprises a molecular layer coating comprising an approximate monolayer of covalently bonded fluoroalkyl-alkyl fragments. The geometric shape of the treated aggregate is determined by the combination of the arrangement of the particles and the molecular layer coating, with the geometric shape being characterized by an occurrence of concave features of multiple sizes spanning a range from about 5 nm to about 0.001 mm. The molecular layer coating comprises a plurality of —CF 3 terminated molecular fragments that are covalently bound to the inorganic oxide substrate such that at least 15 parts by weight of fluorine in the form of —CF—, —CF 2 —, or —CF 3 fragments is covalently bound to 100 parts by weight of the inorganic oxide substrate.
In some embodiments, M is Na, K, Mg, Ca, Ba, Ti, Mn, Fe, Cu, Zn, Zr, Hf, B, and/or Al. In other embodiments, the inorganic oxide substrate further comprises at least one oxide of silicon. In yet other embodiments, the treated aggregate further comprises a surface energy of less than 30 mJ per square meter. In further embodiments, the aggregates are dispersed in a formulation containing a fluoropolymer or fluoroelastomer that may be applied to a substrate and impart a surface texture combining a low surface energy with a well-defined texture extending from nanometer to micrometer length scales.
The present invention further comprises a method for producing a treated aggregate comprising the steps of: a) removing a plurality of physically adsorbed water from the inorganic oxide substrate while leaving intact at least one surface hydroxyl group per square nanometer; b) exposing the inorganic oxide substrate to an atmosphere containing a concentration of alkylamine vapor for a length of time sufficient to cause adsorption onto the surface; c) dispersing the inorganic oxide substrate in a carrier solvent; d) introducing at least a four-fold molar excess of a fluorinated chlorosilane coupling agent; e) stirring the mixture, whereby a portion of the fluorinated chlorosilane coupling agent is covalently bound to the inorganic oxide substrate; f) removing the carrier solvent and excess reagents via centrifugation; g) removing substantially all non-covalently bound fluorinated chlorosilane coupling agent by continuous extraction in an extraction solvent with a neutral to acidic pH to form the treated aggregate; and h) drying the treated aggregate to remove the extraction solvent.
In some embodiments of the method, the fluorinated chlorosilane coupling agent may be heptadecafluoro-1,1,2,2-tetrahydrodecyl)dimethylchlorosilane, tridecafluoro-1,2,2,2-tetrahydrooctyl)dimethyl-chlorosilane, heptadecafluoro-1,1,2,2-tetrahydrodecyl)methyl-dichlorosilane, or mixtures thereof. In other embodiments, the alkylamine vapor is dimethylamine and the time of exposure to the alkylamine vapor is at least 17 hours. In other embodiments, the time utilized for stirring the inorganic oxide substrate and the fluorinated chlorosilane coupling agent in the carrier solvent is at least 72 hours. In further embodiments, the continuous extraction is performed for at least 72 hours.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a reaction between silica at the outermost surface layer of atoms of an inorganic oxide particle with a fluorinated chlorosilane according to an embodiment of the present invention.
FIGS. 2A-2C are scanning electron microscope (SEM) images of an exemplary superhydrophobic coating taken at three different magnifications.
FIG. 3 is a Fourier transform-infrared (FT-IR) of untreated and treated silica aggregates.
DETAILED DESCRIPTION OF THE INVENTION
The treated, mesoporous aggregate of the present invention comprises an inorganic oxide substrate having the formula MO x , where the identifier M represents a metal or metalloid or a combination of metal and/or metalloid atoms, and a molecular layer coating of —CF 3 terminated molecular fragments covalently bonded to the substrate. The substrate comprises a plurality of particles that possess a specific surface area of at least 50 square meters per gram, with at least one surface hydroxyl group per square nanometer prior to treatment. At least 15 parts by weight of the element fluorine (F), in the form of >CF—, —CF 2 —, or —CF 3 fragments in the coating, is covalently bound to 100 parts by weight of the substrate. The geometric shape of the treated aggregate is determined by the arrangement of the particles comprising the aggregate and the molecular coating and is further characterized by the occurrence of concave features of multiple sizes spanning a range from 5 nm to at least 0.001 mm, with the maximum distance between any two points in the aggregate not exceeding 0.02 mm. The covalent grafting of the fluorinated chlorosilanes onto the surface of the particles imparts hydrophobic and oleophobic properties to the aggregate.
With reference now to FIG. 1 , the particle may comprise an inorganic oxide substrate 10 generally comprises a material with a reactive surface group (e.g., a silanol). In particular, the substrate 10 may comprise a metal or metalloid that is capable of forming an oxide. Examples may include, but are not limited to, alkali and alkaline earth metals, transition metals, poor metals, lanthanides, and metalloids and other oxides of metals or metalloids or combinations thereof. In some embodiments, the substrate is an oxide of silicon. In other embodiments, the substrate 10 is selected from the group consisting of one or more oxides of Li, Be, B, Na, Mg, Al, K, Ca, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ga, Ge, Rb, Y, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Cd, In, Sn, Sb, Te, Cs, Ba, Ce, Hf, Ta, W, Re, Os, Ir, Pt, Pb, and Bi. In yet other embodiments, the substrate 10 comprises a combination of one or more oxides of Si and oxides of one or more of these metals or metalloids.
In some embodiments, the inorganic oxide particles 12 are about 7 nm in diameter and are composed of a plurality of silica at the outermost surface layer 14 of atoms with surfaces containing 4-5 silanol groups per square nanometer. The particles 12 may be aggregated in a hierarchical fashion and contain a polydispersity of aggregate sizes, with the majority of aggregates spanning no more than 20 micrometers in any direction. The limited overall dimensions of the aggregates are essential for compatibility for simple coating processes. The specific surface area is about 390 square meters per gram.
In further embodiments, the inorganic oxide particles are 22 nm in diameter and are composed of a plurality of silica at the outermost surface layer of atoms. The surfaces of these particles contain from 5 to 12 silanol groups per square nanometer. The particles are aggregated in a hierarchical fashion, with the majority of aggregates spanning no more than 20 microns in any direction. The specific surface area is about 120 square meters per gram. In some embodiments, the substrate closely resembles precipitated silica, such as Hi-Sil® 233 (differentiated only by the presence of less than 5% of other metal oxides or metalloid oxides), and the molecular coating consists of —Si(CH 3 ) m CH 2 CH 2 —(CF 2 ) n CF 3 , in which m=1 or 2 and n=5 or 7.
The present invention also includes a method of producing the treated aggregate, which is schematically illustrated in FIG. 1 . The method begins by removing substantially all physically adsorbed water from the high specific surface area inorganic oxide substrate, while leaving intact at least one surface hydroxyl group per square nanometer, followed by exposing the dried inorganic oxide substrate to an atmosphere containing a sufficient concentration of alkylamine vapor for a sufficient time to cause adsorption onto the inorganic oxide substrate surface. The inorganic oxide particles are then dispersed in a carrier solvent, and an excess of fluorinated chlorosilane coupling agent (illustrated as —Si(CH 3 ) m Cl n (RF) p CF 3 , wherein the subscript m ranges from 0 to 2, the subscript n ranges from 1 to 3, and the subscript p is greater than or equal to 1) (at least a four-fold molar excess) is introduced. In some embodiments, the carrier solvent is moisture free. In other embodiments, where moisture is present in the carrier solvent, it has a neutral to acidic pH. The mixture is stirred to allow a portion of the fluorinated chlorosilane coupling agent to covalently bind to the surface hydroxyl groups on the inorganic oxide particles. The hydroxyl groups on the surface of the metal or metalloid substrate react with the fluorinated chlorosilane coupling agent to form a covalent bond between the substrate and the fluorinated chlorosilane. The method continues with removal of the carrier solvent and excess reagents by centrifugation and removal of substantially all of the non-covalently bonded fluorinated chlorosilane coupling agent by continuous extraction for 1.0 to 1000 hours in an extraction solvent that is suitable for fluoroalkyl-silanes and possesses a neutral to acidic pH to form a treated aggregate according to the present invention. The treated aggregate is then dried to remove substantially all traces of the extraction solvent.
In some embodiments of the method, the inorganic oxide substrate is dried under vacuum sufficiently to remove all physisorbed water from their surface. The procedures for drying will be apparent to one skilled in the art and will vary according to the quantities dried in one batch. A typical drying procedure for 2.0 grams of the inorganic oxide substrate involves maintaining a pressure of no more than 0.001 atm at a temperature of 200° C. for 16 hours. Great care must be taken to avoid exposing the aggregates to any source of water once the removal process is accomplished. Precautions may include using column chromatography to remove all traces of water from any solvents employed subsequent to water removal. Note that in contrast to methods for preparing flat surfaces such as silicon wafers for treatment, no etching procedures are used because etching will severely alter and potentially destroy the inorganic oxide particles of the aggregate.
In other embodiments, the dried aggregates are transferred to a container containing dimethylamine gas at 1.0 atm pressure and allowed to equilibrate for at least 24 hours, followed by suspension in moisture-free chloroform. In one embodiment, (heptadecafluoro-1,1,2,2-tetrahydrodecyl)dimethylchlorosilane (“FDec-MCS”), as obtained from the manufacturer, is introduced to the suspension in a four-fold molar excess compared to silanol, based on the previously determined specific surface area and hydroxyl density of the aggregates. The suspension is then stirred for at least 72 hours in an inert atmosphere.
In other embodiments, a silane having a shorter fluoroalkyl-alkyl chain length than FDec-MCS is used in place of at least some of the FDec-MCS. An example of such a silane is (tridecafluoro-1,1,2,2-tetrahydrooctyl)dimethylchlorosilane (“FOct-MCS”). In yet other embodiments, (heptadecafluoro-1,1,2,2-tetrahydrodecyl)methyldichlorosilane (“FDec-DCS”) is used to replace at least some of the FDec-MCS. The fluoroalkyl-alkyl silane selected, however, must contain a sufficient number of —CF 2 — and —CF 3 fragments near its non-bonded terminus to ensure that substances in contact with the treated aggregates encounter a surface with sufficiently low energy. As apparent to one skilled in the art, mixtures of silanes meeting these compositional requirements may also be used in place of the FDec-MCS. For example, a variety of other suitable fluoroalkylsilanes with 3 to 30 carbons may be used. Suitable fluoroalkylsilanes have at least one trifluoromethyl group at its terminus/termini, or having branched chains with trifluoromethyl, pentafluoroethyl, heptafluoropropyl, pentafluorophenyl, or heptafluorotolyl on the terminal groups of branches. In place of the dimethylamine gas, other monoalkylamines, dialkylamines, or trialkylamines, having up to 30 carbon atoms, may also be used.
In further embodiments of the method, the removal of all non-covalently bound species is accomplished by filtration and centrifugation of the aggregates and extraction in a Soxhlet apparatus in dry chloroform, followed by collection and drying. Additional carrier and/or extraction solvent(s) may be selected from, dichloromethane, carbon tetrachloride, other halogenated or non-halogenated hydrocarbons, aliphatic or aromatic ketones, ethers, and nitriles, or any other solvents of sufficient dryness and inertness to avoid interference with the reaction and extraction steps, and to dissolve the reactants and impurities as needed, which may be determined by one skilled in the art. The procedures for the centrifugation, extraction, and drying vary with the size of the aggregate batches being processed and are able to be determined by one skilled in the art. A typical procedure for 2.0 gram batches of aggregates involves centrifugation for 60 minutes, extraction for 72 hours, and drying at 100° C. for 24 hours under no more than 0.001 atm of inert gas.
The following examples and methods are presented as illustrative of the present invention or methods of carrying out the invention, and are not restrictive or limiting of the scope of the invention in any manner.
Example 1: Chlorosilane Selection
Among silane coupling agents, multiple chemical forms are known, including mono-, di-, and tri-chlorosilanes as well as mono-, di-, and tri-alkoxysilanes. It is widely understood that alkoxysilanes should be hydrolyzed (often in-situ) in order to become properly activated for attachment to silica surfaces. It is also understood that the attachment reaction generates water as a byproduct. Because the presently disclosed invention involves methods that are effective only when the concentration of water is minimized (as apparent to one skilled in the art), the surface treatment agent was selected only from among the chlorosilanes. Others have shown that the choice of chlorosilane will impact the final properties of the treated surface; however, based only on these previous findings, the impact of the choice of chlorosilane, particularly as it relates to the need for minimal surface energy, is not obvious. In particular, whereas silanes of higher functionality may attach fluorine-containing chemical functionality at a higher concentration, they may also reduce the homogeneity of the modified surface layer. The relative importance of these factors in controlling the contact angle dynamics on highly textured surfaces in fluoroelastomer composites, for instance, has not been quantitatively determined.
To determine the best choice of chlorosilane, precipitated silica (Hi-Sil® 233, 22 nm diameter, 135 m 2 /g specific surface area) was purchased from PPG Industries. Fluorinated silane reagents: FDec-MCS, FDec-DCS, and (heptadecafluoro-1,1,2,2-tetrahydrodecyl)trichlorosilane (“FDec-TCS”) were purchased from Gelest™, Inc. Anhydrous dimethylamine was purchased from Aldrich®. The preceding materials were all used as received from the manufacturer. Reagent grade chloroform was purchased from Aldrich® and passed through an activated alumina column prior to use.
The surface functionalization of silica particles was performed using Schlenk line techniques, taking great care to minimize moisture exposure. Silica particles (2.0 g), in a 250 mL round-bottom flask, were initially dried by heating overnight at 200° C. under dynamic vacuum. The dried silica was allowed to cool to room temperature under vacuum, then stirred under one atmosphere of dimethylamine for 17 hours. The silica particles were then suspended in 80 mL of dry chloroform. A four-fold excess of fluoroalkyl-substituted chlorosilane reagent (e.g. 7.0 g FDec-MCS), assuming a maximum grafting density of 4 μmol per square meter, was then added via syringe. The reaction mixture was allowed to stir for three days in a dry nitrogen environment before the fluoroalkyl-functionalized silica particles were recovered by centrifuge and purified by exhaustive Soxhlet extraction in chloroform. The extraction was allowed to proceed for three days in a nitrogen environment to ensure the removal of any non-covalently bound chlorosilane-derived species or other surface contaminants. After the extraction process, the particles were dried in a stream of nitrogen, transferred to vials, and dried at 100° C. under dynamic vacuum for approximately one hour. A typical yield was 2.0-2.5 g of modified silica.
Fluorine elemental analyses were performed by Atlantic Microlab Inc. Nitrogen adsorption-desorption isotherm experiments were conducted at 77 K using a Micromeritics® ASAP® 2020 Accelerated Surface Area and Porosimetry system. Samples were initially degassed at 110° C. for 8 hours under dynamic vacuum. Surface areas were calculated by Brunauer-Emmet-Teller (BET) equation analysis using a nitrogen cross-sectional area of 16.2 square Angstroms. Water uptake of functionalized silica particles was determined by exposing particles to 25° C./90% R.H. in a Tenney® ETCU series environmental chamber for 24 hours, then measuring the weight loss due to water evaporation/desorption using thermogravimetric analysis (TA Instruments® Q5000 IR TGA system). The “wet” samples were heated in a nitrogen environment from room temperature to 100° C. at 10° C./min, held isothermally for 1 hour, and then ramped to 1000° C. at 10° C./min. Weight loss due to heating from room temperature to 100° C. was used for water uptake values, while the weight loss from heating up to 1000° C. was used to determine the thermal stability of the grafted layer and to estimate the graft density. The approximate errors in the measurement techniques were 0.5 wt % for fluorine elemental analysis, 0.5 wt % for thermogravimetric analyses, 1 square meter per gram for BET surface area, 1 (dimensionless) for the BET C constant, and 0.2% for water uptake.
As is evident from Table 1, the choice of chlorosilane did have a significant impact on the performance of the invention. The BET C constant has been recognized as being a good proxy for surface energy, with a roughly linear relationship in which the surface energy in mJ per square meter is equal to the C constant value plus approximately 5, based on measurements of fluorinated compounds with a known surface energy, and in agreement with previously reported work on silicone-treated silica particles. The BET C constant was lowest, by a significant amount, for the FDec-MCS. The FDec-MCS also provided the greatest amount of attached fluorine, which was present in the form of the needed —CF 2 — and —CF 3 molecular fragments, and the least amount of water uptake, thereby allowing the best compatibility with fluoropolymers or fluoroelastomers
TABLE 1
Effect of Chlorosilane Choice on Key Properties of Treated Silica Particles
BET
% Wt. Loss
% Wt. Loss
Surface
Water
Wt. %
(23-
(200-
Area
BET C
Uptake
Sample*
F
200° C.)
1000° C.)
(m 2 /g)
Constant
(wt. %)
Prec-Blank
0.4
4.8
5.0
123
127
3.7
Prec-FDec-TCS
6.6
4.3
16.1
128
30
3.2
Prec-FDec-DCS
9.0
3.5
21.2
94
23
3.0
Prec-FDec-MCS
9.9
3.8
20.1
92
21
2.8
*Prec = Precipitated
The BET data also indicated that the particles retained their high specific surface area, thus they retained a complex geometry with roughness at multiple length scales (as confirmed by SEM observation), allowing them to impart a complex nanoscale to microscale texture when included in coating formulations. Because it is known that silane coupling reactions to substrates comprising a combination of a plurality of silica and one or more non-silica metal and/or metalloid oxides form monolayers essentially similar to silica, the trends evident for surfaces containing only silica will also be observed for surfaces containing a plurality of silica in combination with other metal and/or metalloid oxides. In addition, these trends should further extend to substrates consisting only of non-silica materials with properties that are similar to fumed and precipitated silica e.g. a similar hydroxyl density.
Example 2: Comparison of Silane Tail Group Length
In addition to silane head-group functionality, another choice in selecting the appropriate surface treatment was the length of the silane tail group. As mentioned previously, the treated aggregates must possess enough —CF 2 — and —CF 3 molecular fragments to provide good compatibility with fluoropolymers or fluoroelastomers. However, if the size of the silane molecule used in the surface treatment was too large, the geometrical constraints inherent in mesoporous silica may have prevented a high density of grafting, making the choice not obvious based on the prior art. To determine the proper tail length, the same techniques for analysis described in Example 1 were utilized for precipitated silica. In addition, fumed silica (7 nm diameter, 390±40 m 2 /g specific surface area), as purchased from Sigma-Aldrich®, was treated in separate batches along with the precipitated silica described in Example 1. The silanes used were FDec-MCS, FOct-MCS, and (3,3,3-trifluoropropyl)dimethylchlorosilane (“FPro-MCS”).
According to Table 2, the FDec-MCS provided the highest level of fluorine, and the least water uptake (though in fumed silica, the water uptake was not significantly different for FDec-MCS and FOct-MCS), maximizing compatibility with fluoropolymers and fluoroelastomers. FDec-MCS also provided the lowest BET C constant by a significant margin for precipitated silica, while providing the lowest BET C constant, though not significantly different from FOct-MCS, for fumed silica. These results indicated that FDec-MCS provided the lowest surface energy (as explained in Example 1). Despite their large size, the longer tails resulted in only a modest decrease in BET surface area, indicating that the treated aggregates retained a complex nanoscale to microscale texture and thus the ability to impart said texture to surfaces formed by facile methods of coating substrates. Although fumed silica provided slightly higher BET C constants (in a dry state) than precipitated silica, fumed silica resulted in much lower water uptake, thus in the presence of moisture, fumed silica would be expected to retain its low surface energy to a much greater extent. Because the trends seen in Table 2 depend on the geometry of the substrate and the molecular geometry of the silane and because the chemical attachment levels for substrate surfaces containing a plurality of silica among other metal oxides and/or metalloid oxides are known to be similar to those for substrates comprised only of pure silica, the results seen in Table 2 should also apply to substrate surfaces with similar hydroxyl density to fumed and precipitated silica, including substrates comprising a combination of one or more silica materials and one or more non-silica materials, as well as substrates comprising non-silica materials with similar properties.
TABLE 2
Effect of Chlorosilane Tail Length on Key Properties of Treated Silica Particles
BET
% Wt. Loss
% Wt. Loss
Surface
Water
Wt. %
(23-
(200-
Area
BET C
Uptake
Sample*
F
200° C.)
1000° C.)
(m 2 /g)
Constant
(wt. %)
Prec-Blank
0.4
4.8
5.0
123
127
3.7
Prec-FPro-MCS
2.1
4.4
8.2
106
29
3.4
Prec-FOct-MCS
7.4
4.3
16.2
101
24
3.4
Prec-FDec-MCS
9.9
3.8
20.1
92
21
2.8
Fum-Blank
0.0
3.9
2.6
250
111
2.9
Fum-FPro-MCS
4.7
1.5
9.4
256
29
0.7
Fum-FOct-MCS
13.4
1.0
21.3
187
26
0.4
Fum-FDec-MCS
17.5
1.6
26.9
184
25
0.6
*Prec = Precipitated;
Fum = Fumed
Example 3: Fabrication of Fluoroelastomer-Coated Particles
In order to demonstrate that the presently disclosed invention allowed for the creation of coating formulations with a fluoroelastomer that subsequently imparted a complex surface texture and outstanding liquid repellence characteristics to a substrate via a simple coating process, elastomeric composites were produced by dispersing 5 mg/mL of a blend consisting of 50 wt % functionalized fumed silica particles (treated with FDec-MCS as described in Examples 1 and 2) and 50 wt % Viton® Extreme™ ETP-600S fluoroelastomer (a copolymer of ethylene, tetrafluoroethylene, perfluoro(methylvinyl) ether, and bromotetrafluorobutene obtained from DuPont™) into a 5 mg/mL solution of 1,3-dichloro-1,2,2,3,3-pentafluoropropane (AK- 225 G) solvent. This mixture was then spin-coated onto silicon wafers at 900 rpm for 30 seconds.
Dynamic contact angles for the coatings were measured using a DataPhysics Instruments OCA20 goniometer equipped with a TBU90 tilting stage. Deionized water that was further purified using a Millipore® system was used as a probing liquid for contact angle measurements. Advancing contact angles were measured by dispensing a 4 μL droplet onto a test substrate, then slowly adding water to the droplet through a syringe needle at a rate of 0.2 μL/sec until the droplet advanced on the substrate past 5 μL. This was immediately followed by removing liquid at the same rate until the droplet receded in order to measure the receding contact angle value. The advancing and receding contact angles were measured with an elliptical fit using DataPhysics Instruments droplet fitting software. Three to five experiments were conducted on different areas of each sample with contact angles typically varying by ±2.5°. Roll-off angles were measured by placing a 10 μL droplet onto the test substrate and then slowly tilting the base unit.
The advancing contact angle of the coating was, on average 160.5° with a standard deviation of 3.5°, while the receding angle was, on average, 160.0° with a standard deviation of 3.4°. These very high contact angles, with a minimal difference between the average advancing and receding angles, are characteristic of superhydrophobicity, a technologically important liquid repellence phenomenon that generally requires both a specific range of surface energy and a specific surface texture to realize in practice. SEM micrographs of this superhydrophobic coating containing the treated fumed silica at magnifications of 400× ( FIG. 2A ), 12,000× ( FIG. 2B ), and 24,000× ( FIG. 2C ) revealed a surface with regularly dispersed sub-micron features that appear to range from 50-500 nm, with occasional aggregates ranging from 2-10 microns. Atomic force microscopy analysis provided additional evidence that the majority of the surface consisted of tightly packed sub-micron features (not shown).
Example 4: FT-IR Analysis of Treated Vs. Untreated Aggregates
An important distinguishing characteristic of the presently disclosed invention is the covalent chemical attachment of a large majority of the fluorinated chemical fragments to the substrate surface. This covalent attachment prevents the slow washing away of the beneficial chemical functionality on periods of extended contact with liquids. To demonstrate covalent bonding, the Diffuse Reflectance Infrared Fourier Transform (DRIFT) spectra of untreated, “as received,” silica and FDec-MCS treated silica samples (as described in Examples 1 and 2) was obtained. FIG. 3 shows FT-IR of the untreated and treated aggregates: (a) untreated fumed silica; (b) fumed silica treated with FDec-MCS; (c) untreated precipitated silica; and (d) precipitated silica treated with FDec-MCS. The inset in FIG. 3 is a magnification of the FT-IR data in the range of 3000-3500 cm −1 to illustrate the small peaks occurring in this range. The labels (x4, x1, etc.) indicate the factor by which the absorbance scale is magnified in the inset.
The strong narrow band at 3747 cm −1 in the spectrum for “as received” fumed silica (a) was indicative of isolated silanols on the outer silica surface. This narrow band was significantly weaker in the precipitated silica spectrum (c), consistent with a heavily hydroxylated silica surface with a large population of vicinal and geminal silanols. Broad overlapping peaks from 3000-3700 cm −1 were attributed to these silanol types, both interior and on the surface, as well as surface adsorbed water. Once silanols were substituted with fluoroalkyl substituents, the isolated silanol band was almost completely absent from spectra for both surface types as seen in spectra (b) and (d), indicative of covalent attachment. The formation of siloxane bonds, indicated by the spectral features from 1100-1250 cm −1 , as well as fine stretches in the fingerprint region, also suggested covalent attachment.
Although specific exemplary embodiments have been described in detail in the foregoing description and illustrated in the drawings, various other embodiments, changes, and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the spirit and scope of the appended claims.
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Treated, mesoporous aggregates comprising a plurality of coated particles that comprise an inorganic oxide core having a surface area of about 50 to about 500 square meters per gram and a shell or coating consisting of an array of fluoroalkyl molecular chains covalently bonded to the core at a density of at least one chain per square nanometer. The aggregates are formed by the chemical attachment of fluoroalkyl-alkylsilanes after exposure to an alkylamine and followed by an extraction to remove any unbound organic material. The dense packing of molecular chains in the fluoroalkyl shell combined with a mesoporous structure imparts a very low surface energy, a very high specific surface area, and surface texture over a wide range of length scales. Such features are highly desirable for the creation of, for example, superhydrophobic and superoleophobic surfaces, separation media, and release films.
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BACKGROUND
[0001] The invention relates to a method and a pump arrangement for evacuating a chamber. The pump arrangement, which is connected to the chamber, comprises a booster pump and a downstream forepump.
[0002] In many technical applications, it is nowadays required for a chamber to be evacuated to a predefined vacuum within a short time. One example is lock chambers through which products are introduced into a vacuum chamber. The products may be, for example, mass-produced articles such as solar cells, displays etc. for which individual manufacturing steps are carried out in the vacuum chamber. It is sought for such products to be introduced into the vacuum chamber with ever shorter cycle times. It is not uncommon for lock chambers with a volume of a few hundred liters to have to be evacuated to a pressure of less than 10 −2 mbar in considerably less than 10 seconds.
[0003] For the evacuation of such lock chambers, use is normally made of pump arrangements composed of two series-connected pumps, wherein the first pump is normally referred to as booster pump, and the downstream pump is normally referred to as forepump. The series connection of two pumps is expedient because, according to the ideal gas law (pressure*volume=constant; assuming constant temperature), the forepump can be designed for a significantly smaller volume flow than the booster pump.
[0004] If, however, a lock chamber is to be evacuated proceeding from atmospheric pressure within a very short time, the booster pump initially delivers a large volume flow at high pressure, with the result that a large volume flow arrives at the outlet of the booster pump. Forepumps that can handle such a large volume flow are cumbersome and expensive.
SUMMARY
[0005] The invention is based on the object of providing a method and a pump arrangement which permit the fast evacuation of a chamber with reduced outlay in terms of apparatus. Taking the stated prior art as a starting point, the object is achieved by means of the features of the independent claims. The subclaims relate to advantageous embodiments.
[0006] In the method according to the invention, the booster pump is initially accelerated. Gas from the chamber to be evacuated is then introduced into the booster pump, such that from the booster pump there is temporarily extracted an excess power which exceeds the power provided by the drive of the booster pump. The gas that is delivered to the outlet of the booster pump is discharged through a bypass valve for as long as the outlet pressure in the booster pump lies above a predefined threshold value. The gas is conducted onward to the forepump when the outlet pressure of the booster pump has fallen below the threshold value. The gas supplied by the booster pump is compressed by means of the forepump.
[0007] A few expressions will firstly be explained. The expressions “booster pump” and “forepump” illustrate the sequence of the pumps in the pump arrangement. Said expressions do not yield a limitation with regard to the configuration of the pump.
[0008] The invention has recognized that, as a result of the acceleration of the booster pump and the subsequent extraction of the excess power, it is possible for the gas from the chamber to be delivered to the outlet of the booster pump at such a high pressure that the gas can be discharged directly, bypassing the forepump. Only when the evacuation process has progressed to such an extent that the booster pump is no longer capable of compressing the gas to the corresponding pressure is the forepump additionally used for the further compression. By means of the invention, it is possible for the forepump to be designed not only for a smaller volume flow but also for a small mass flow than the booster pump.
[0009] In general, atmospheric pressure prevails at the outlet of the bypass valve. In this case, the threshold value corresponds to the atmospheric rusher. The gas thus emerges through the bypass valve for as long as the outlet pressure of the booster pump lies above atmospheric pressure. At its peak, the outlet pressure of the booster pump may be at least 1 bar, preferably at least 2 bar, more preferably at least 3 bar above atmospheric pressure. The gas compressed by means of the forepump may likewise be discharged at atmospheric pressure to the environment.
[0010] At the start of the evacuation process, atmospheric pressure generally prevails in the chamber, such that the evacuation process begins at atmospheric pressure. Before the beginning of the evacuation process, the inlet of the booster pump may be closed, such that no gas from the chamber can enter into the booster pump. The evacuation process then begins at the time at which gas is introduced into the booster pump.
[0011] In order to be able, at the beginning of the evacuation process, to deliver a large volume flow at high pressure (for example atmospheric pressure), the booster pump must provide a high compression power. The high compression power is provided by virtue of the fact that, during the evacuation process, there is temporarily extracted from the booster pump more compression power than is provided by the drive of the booster pump. The excess power that exceeds the drive power is extracted from the kinetic energy of the booster pump. The booster pump is thus braked, and the rotational speed of the pump decreases.
[0012] Within the context of the invention, the power extracted in the booster pump may be considerably higher than the drive power. It is for example possible that, at its peak, the excess power is more than 50%, preferably more than 100%, more preferably more than 200%, of the drive power. In the case of an excess power of 100%, the compression power is twice as great as the drive power.
[0013] It may also be provided that the excess power is extracted not only instantaneously but rather over a certain time period. If the evacuation process begins at the time at which the pressure in the chamber falls below the outlet pressure, and ends at the time at which the final pressure in the chamber is reached, the time period during which excess power is extracted may extend for example over 10%, preferably over 20%, more preferably over 50% of the evacuation process. The rotational speed of the booster pump may, as a result of the extraction of the excess power, be reduced by at least 5%, preferably at least 10%, more preferably at least 25%.
[0014] In order that it is possible for excess power to be extracted from the pump to such an extent, the pump must, before the beginning of the evacuation process, be placed into a state in which a correspondingly large amount of kinetic energy is available. The pump is thus accelerated before the beginning of the evacuation process.
[0015] To be able to provide adequate kinetic energy, the rotational speed of the booster pump at the start of the evacuation process is preferably higher than 8000 rpm, more preferably higher than 10,000 rpm, more preferably higher than 12,000 rpm. The diameter of the parts that are in rotation is preferably greater than 5 cm, more preferably greater than 10 cm, more preferably greater than 20 cm.
[0016] If the gas from the chamber is introduced into the booster pump at substantially atmospheric pressure, the booster pump is subjected to an abrupt load. Some pump types which have hitherto been used as booster pumps, such as for example Roots pumps, are generally less suitable for accommodating such abrupt loads. In one advantageous embodiment, as a booster pump, use is made of a screw-type pump, the preferred configuration of which is explained in more detail below. The forepump may for example be a conventional liquid-ring vacuum pump.
[0017] With the method according to the invention, it is possible for a chamber with the volume of more than 100 L to be evacuated from atmospheric pressure to a pressure of less than 10 −2 mbar in less than five seconds. This possibility is of particular interest within the context of lock applications where a lock chamber of said order of magnitude must be repeatedly evacuated with a short cycle time. Atmospheric pressure prevails at the inlet of the lock chamber, which means that atmospheric pressure is also assumed in the lock chamber when the inlet is opened in order to introduce a component into the lock chamber. The outlet of the lock chamber is adjoined by a vacuum chamber in which the pressure is for example 10 −2 mbar. The lock chamber must thus be evacuated to said pressure before the outlet can be opened in order to transfer the component into the vacuum chamber.
[0018] If the cycle time of the lock is for example 10 seconds, then the time period in which excess power is extracted from the booster pump may be for example one second, while the rest of the cycle time is utilized to accelerate the booster pump to the starting rotational speed again. In more general terms, the time period of the extraction of excess power is preferably at least 5%, more preferably at least 10% of the cycle time. During at least 30%, preferably at least 50%, more preferably at least 70% of the cycle time, the power extracted from the booster pump is lower than the drive power, such that the booster pump is accelerated.
[0019] The invention also relates to a pump arrangement. The pump arrangement comprises a booster pump and a forepump, wherein the outlet of the booster pump is connected to the inlet of the forepump. Between the booster pump and the forepump, there is arranged a bypass valve by means of which gas delivered by means of the booster pump can be discharged while bypassing the forepump. The pump arrangement also comprises a control unit which is configured so as to output a control signal if the rotational speed of the booster pump lies above a predefined rotational speed threshold value. The rotational speed threshold value is such that, after the respective rotational speed is exceeded, the booster pump is ready for the extraction of excess power. Such a pump arrangement is suitable for evacuating a chamber in a short time in accordance with the method according to the invention.
[0020] The control signal may be transmitted to a controller of the chamber to be evacuated, in order to indicate that the booster pump is ready for the next evacuation process. The controller of the chamber may thereupon open the inlet of the booster pump via which the booster pump is connected to the chamber. The gas from the chamber then enters into the booster pump, and the chamber is quickly evacuated. As the gas enters the booster pump, the load increases abruptly, such that the rotational speed of the booster pump decreases.
[0021] The control unit of the booster pump may furthermore be configured to accelerate the booster pump before the beginning of the evacuation process such that the rotational speed threshold value is exceeded. To provide an adequate amount of kinetic energy for the extraction of the excess power, the rotational speed threshold value preferably lies above the delivery rotational speed of the booster pump. The delivery rotational speed denotes the rotational speed which is assumed as a steady state when the induction pressure is 100 mbar. The drive power corresponds, at the delivery rotational speed, to the pump power, which means that the rotational speed of the booster pump remains constant. The rotational speed threshold value may be higher, by 10%, preferably by 30%, more preferably by 50%, than the delivery rotational speed. In absolute numbers, the rotational speed threshold value may for example be at least 8000 rpm, preferably at least 10,000 rpm, more preferably at least 12,000 rpm. Normally, booster pumps used for an application within the context of the invention are operated at considerably lower rotational speeds. A rotational speed of 6000 rpm is generally not exceeded during the operation of such booster pumps. In the case of the method according to the invention, too, the booster pump can be accelerated beyond the delivery rotational speed.
[0022] The arrangement according to the invention may furthermore encompass the chamber to be evacuated. The control unit of the arrangement may for this purpose be designed to open the inlet of the pump, via which the booster pump is connected to the chamber, after the rotational speed threshold value has been exceeded. Furthermore, the control unit may be configured to keep the inlet closed while the booster pump is accelerated.
[0023] In one advantageous embodiment, as a booster pump, use is made of a screw-type pump in which the screws of two threads engage with one another in such a way that the gas is conveyed from a suction side to a pressure side between the thread turns. To be able to withstand the stated high rotational speeds, the screws preferably have in each case two threads, such that the forces that arise in the longitudinal direction of the screws cancel one another out. The threads of the screws are preferably of double-start configuration. Here, in a radial direction, point-symmetry of the screws may exist such that the screws are imaged into themselves by a rotation of 180° about the longitudinal axis. The diameter of the screws is preferably greater than 10 cm, more preferably greater than 15 cm, more preferably greater than 20 cm, such that the screws, as a whole, have approximately the above-stated dimensions.
[0024] In order that the screw-type pump can accommodate the large volume flow required in the case of booster pumps, the inlet opening is preferably larger than 60%, more preferably larger than 80%, more preferably larger than 100% of the cross-sectional area of a screw. To keep leakage losses low, it is provided that, close to the pressure side, the radial spacing between the housing of the pump and the thread of the screw is as small as possible (radial minimum spacing), for example less than 0.2 mm, preferably less than 0.1 mm.
[0025] In the inlet region, that is to say in particular in that housing portion in which the inlet opening is formed, a suction gap may exist between the thread of the screw and the housing in order to permit a large volume flow into the working chambers of the pumps. The radial diameter of the suction gap is larger, preferably by a factor of 50, more preferably by a factor of 100, more preferably by a factor of 200, than the radial minimum spacing. The suction gap may extend for example of a circumferential angle of at least 15°, preferably at least 30° of the housing. In the longitudinal direction, the suction may extend over at least 20%, preferably at least 30%, more preferably at least 40% of the length of a thread of the screw. The length of the suction gap preferably corresponds to the length of a 360° turn of the thread in said region. The thread thus has a very large pitch in the inlet region. The first 360° turn may extend for example over at least 20%, preferably at least 30%, more preferably at least 40% of the length of the thread. Overall, each thread turn of the double-start thread preferably comprises at least three, more preferably at least four complete 360° turns.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The invention will be described by way of example below with reference to the appended drawings on the basis of advantageous embodiments. In the drawings:
[0027] FIG. 1 shows a pump arrangement according to the invention which is connected to a lock chamber;
[0028] FIG. 2 shows a perspective, partially cut-away illustration of a screw-type pump suitable for the arrangement according to the invention;
[0029] FIG. 3 shows a detail of the pump from FIG. 1 in an enlarged illustration;
[0030] FIG. 4 shows the view from FIG. 3 in another state of the pump;
[0031] FIG. 5 shows a schematic cross-sectional view of a screw-type pump suitable for the arrangement according to the invention, along an axis of a screw; and
[0032] FIGS. 6A and 6B show sections along the lines A-A and B-B in FIG. 5 .
DETAILED DESCRIPTION
[0033] In a vacuum chamber 40 shown in FIG. 1 , certain method steps are performed on a product 41 . The product 41 , which is illustrated in simplified block form, may be for example a multiplicity of semiconductor components such as for example solar cells or displays. The method step may be a coating process. For the method step, it is necessary for the pressure in the vacuum chamber 40 to be below 0.5 mbar. To keep the vacuum chamber at said pressure, a vacuum pump (not illustrated in FIG. 1 ) is connected to the vacuum chamber 40 .
[0034] The vacuum chamber 40 is adjoined by a lock with a lock chamber 42 through which the product 41 is introduced into the vacuum chamber. The lock chamber 42 has an inlet opening and an outlet opening which are provided with sliding doors 43 , 44 . The sliding doors 43 , 44 are controlled by a controller 50 such that they are not both simultaneously open at any time. When the sliding door 43 is open, atmospheric pressure prevails in the lock chamber 42 . The lock has a volume of for example 200 l.
[0035] When the sliding door 43 is open, the product 41 can be introduced into the lock chamber 42 by means of conveyor belts 45 . After the sliding door 43 has subsequently been closed again, the lock chamber 42 is evacuated by means of a pump arrangement connected to the lock chamber 42 , such that the pressure in the lock chamber 42 corresponds to the pressure of less than 0.5 mbar prevailing in the vacuum chamber 40 . After the completion of the evacuation process, the sliding door 44 is opened, and the product 41 is introduced into the vacuum chamber 40 by means of the conveyor belts 45 . The sliding door 44 is subsequently closed again, the lock chamber 42 is brought to atmospheric pressure, and the sliding door 43 is opened. A cycle in the lock is thus completed. The cycle time of the cycle is approximately 10 seconds.
[0036] For the evacuation process itself, by means of which the pressure in the lock chamber is reduced from atmospheric pressure to a final pressure of less than 0.5 mbar, a time period is available which is considerably shorter than the cycle time. The evacuation process may extend for example over a time period of five seconds.
[0037] To be able to evacuate a lock of this volume in such a short time, a powerful pump arrangement is required which in particular has a high suction capacity across the entire pressure range between atmospheric pressure and final pressure. This is provided by the pump arrangement according to the invention, in which, as per FIG. 1 , a screw-type pump as a booster pump 46 and a liquid-ring vacuum pump as a forepump 47 are connected in series. The liquid-ring vacuum pump is of conventional configuration, such that a detailed description is not necessary.
[0038] To start the evacuation process, the booster pump 46 is initially accelerated to a rotational speed considerably higher than the delivery rotational speed. A valve 48 arranged between the booster pump 46 and the lock chamber 42 is closed, such that no gas from the lock chamber 42 can enter into the inlet of the booster pump 46 . The booster pump 46 is thus not under load, such that a relatively low drive power is sufficient to accelerate the booster pump 46 .
[0039] When the booster pump 46 has been accelerated to such an extent that a predefined rotational speed threshold value is exceeded, a control unit 16 of the booster pump 46 transmits a control signal to the controller 50 of the lock chamber. The controller 50 is thus provided with the information that the booster pump 46 is ready for the next evacuation process. When the lock chamber 42 is also ready for the next evacuation process, the controller 50 can open the valve 48 such that the booster pump 46 can induct air from the lock chamber 42 . The air is delivered, and in the process compressed, by the booster pump 46 such that a pressure considerably higher than atmospheric pressure prevails at the outlet of the booster pump 46 . At its peak, a pressure of 3 bar above atmospheric pressure may for example prevail at the outlet of the booster pump 46 .
[0040] Between the forepump 47 and the booster pump 46 there is arranged a bypass valve 49 , at the outlet of which atmospheric pressure prevails. The bypass valve 49 is configured as an overpressure valve, such that the compressed gas from the outlet of the booster pump 46 automatically exits via the bypass valve 49 for as long as the pressure at the outlet of the booster pump 46 lies above atmospheric pressure. If the pressure at the outlet of the booster pump 46 falls below atmospheric pressure, the bypass valve 49 closes. The gas is then taken on by the forepump 47 and compressed further such that said gas can be discharged at atmospheric pressure to the environment.
[0041] The closer the pressure in the lock chamber 42 comes to the final pressure, the lower the pressure between the booster pump 46 and the forepump 47 also becomes. The forepump 47 is configured such that it can compress the gas from said pressure to atmospheric pressure.
[0042] During such an evacuation process, the booster pump 46 is subjected to particularly high loads. When the valve 48 is opened, the air flow entering the booster pump 46 generates an abrupt load. Furthermore, as a result of the entry of a large volume flow at atmospheric pressure, a high compression power is demanded of the booster pump 46 . Said compression power exceeds the drive power of the booster pump 46 , which means that an excess power is extracted from the booster pump 46 . The excess power is gained from the kinetic rotational energy of the booster pump 46 , which means that the rotational speed of the booster pump 46 decreases in said phase.
[0043] To be able to provide adequate kinetic rotational energy, the booster pump 46 is accelerated to a high rotational speed of higher than 10,000 rpm before the beginning of the evacuation process. As a result of the extraction of the excess power, the rotational speed decreases within one second to 9000 rpm. The remaining cycle time is utilized to accelerate the booster pump 46 to the original rotational speed again. In this phase, the drive power is consequently higher than the compression power extracted from the booster pump 46 .
[0044] The booster pump 46 which firstly withstands the loads at the beginning of the evacuation process and which secondly has the required suction capability across the entire pressure range is described below.
[0045] The screw-type pump which is suitable as a booster pump comprises, as per FIG. 2 , two screws 14 which are accommodated in a pump housing 15 . Owing to the pump housing 15 not being illustrated in its entirety, one of the screws 14 is visible over the entire length, whereas the other screw 14 is largely hidden by the pump housing 15 . The two screws 14 engage with one another, which means that the thread projections of one screw 14 engage into the depression between two thread projections of the other screw 14 .
[0046] The pump comprises a control and drive unit 16 in which, for each of the screws 14 , there is arranged an electronically controlled drive motor 17 . The electronic controller of the drive motors 17 is set up such that the two screws 14 run entirely synchronously with respect one another, without the thread projections of the screws 14 making contact. For additional security against damage to the screws 14 , the two screws 14 are in each case equipped with a gearwheel 18 . The gearwheels 18 mesh with one another and generate positive coupling of the two screws 14 in the event of failure of the electronic synchronization of the screws 14 .
[0047] Each screw 14 is equipped with two threads 19 , such that the pump has a total of four threads 19 . The threads 19 extend in each case from a suction side 20 in the centre of the screw 14 to a pressure side 21 at the outer ends of the screw 14 . The two threads of a screw 14 are oriented in opposite directions such that they work from the suction side 20 toward the pressure side 21 .
[0048] Each of the threads 19 comprises a first thread turn 22 and a second thread turn 23 . The threads 19 are thus of double-start form in the sense that the thread turns 22 , 23 are interlaced with one another such that they together form a double-helix-like form. The two thread turns 22 , 23 are formed such that the threads 19 are symmetrical in a radial direction. The screw 14 furthermore has symmetry in a longitudinal direction when the screw 14 is viewed from the pressure side of the first thread 19 to the pressure side of the second thread 19 .
[0049] The threads 19 are configured such that a larger volume is enclosed between two adjacent thread projections in the region of the suction side 20 than in the region of the pressure side 21 . The volume of the working chambers, which corresponds to the volume enclosed between the thread projections, thus decreases from the suction side to the pressure side, such that gas contained in the working chamber is compressed on the path from the suction side to the pressure side.
[0050] The housing 15 of the pump is provided with an inlet opening 24 which is arranged so as to provide access to the suction side 20 of all four threads 19 . To permit a large volume flow into the pump, the inlet opening 24 has a large cross section. In the exemplary embodiment, the cross-sectional area of the inlet opening 24 is larger than the circular contour spanned by a screw 14 .
[0051] To further improve the volume flow into the working chambers, there is formed on the housing 15 of the pump a suction gap 25 which adjoins the inlet opening 24 and which follows the contour of the screw 14 in the circumferential direction. In the longitudinal direction, the suction gap 25 extends over approximately half of the length of the thread 19 between the suction side 20 and the pressure side 21 . In the circumferential direction, the dimensioning of the suction gap 25 varies with the inlet opening; the further the inlet opening 24 extends to the side at the respective point, the shorter is the extent of the suction gap 25 in the circumferential direction at said point. At the widest point of the inlet opening 24 , the suction gap 25 extends over a circumferential angle of approximately 45°. In the region which the inlet opening 24 no longer covers the suction gap 25 , the suction gap 24 extends over a circumferential angle of approximately 120°. The dimension of the suction gap 25 in the radial direction corresponds to the spacing between the pump housing 15 and the contour of the screw 14 in said region. Said spacing lies in the range of approximately 10 mm.
[0052] As a result of the suction gap, the gas is no longer restricted to entering the working chambers in a radial direction, and instead the gas can also move into the working chamber across a thread projection and through the suction gap. The volume flow into the working chambers is further increased in this way.
[0053] A further contribution to the increase of the volume flow into the working chamber is achieved by virtue of the fact that there is a spacing between the suction side 20 of the first thread 19 of a screw 14 and the suction side 20 of the second thread 19 of the screw 14 . In this way, in the centre of the screw 14 , a space is left free through which the gas can also enter into the working chamber in a radial direction.
[0054] The region in which the suction gap 25 extends (=first housing portion 26 ) serves for the filling of the working chambers. In the adjoining second housing portion 27 , the spacing between the housing and the contour of the screw 14 is as small as is technically possible (radial minimum spacing). The compression takes place in the second housing portion, and a leakage flow from one working chamber into the next working chamber is undesirable.
[0055] A transition edge 28 is formed at the transition from the first housing portion 26 to the second housing portion 27 . The transition edge 28 extends in a circumferential direction over the entire section 25 and defines the transition from the suction gap 25 to the second housing portion 27 , in which the radial minimum spacing exists between the housing 15 and screw 14 .
[0056] The compression begins when the working chamber has passed into the second housing portion, that is to say when the thread projection which delimits the working chamber toward the suction side has formed a closure with the transition edge 28 . The transition edge 28 is arranged such that the formation of a closure between the thread projection and the transition edge 28 takes place at a time at which the working chamber still has its maximum volume.
[0057] As viewed in the circumferential direction, the transition edge 28 encloses with the transverse direction an angle smaller than the gradient of the thread projection which forms a closure with the transition edge 28 . It is achieved in this way that the formation of a closure between the thread projection and the transition edge 28 does not take place abruptly but rather extends over a short time period. The operating noise of the pump is reduced in this way.
[0058] The actual volume compression takes place in a short portion of the thread directly after the closure of the working chamber. The adjoining further turns of the thread served for sealing and also effect a thermodynamic compression.
[0059] On the pressure side 21 of the thread 19 , the gas is discharged from the working chamber. Through a bore 29 in the pump housing 15 , the compressed gas from the pressure sides 21 situated at the outside are brought together to a central outlet opening. The outlet opening (not visible in the figures) is arranged opposite the inlet opening 24 . As shown in FIGS. 2 , 3 and 5 , the bore 29 is integrated into the pump housing 15 and extends between the two screws 14 , wherein the line 29 is arranged partially within a tangential plane 35 resting on the two screws 14 .
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A method for evacuating a chamber employs a pump arrangement composed of a booster pump and of a downstream forepump is connected to the chamber. The booster pump is accelerated, gas from the chamber is introduced into the booster pump, such that from the booster pump there is temporarily extracted an excess power which exceeds the power provided by the drive of the booster pump. The gas is discharged through a bypass valve while the outlet pressure of the booster pump lies above a predefined threshold value, and the gas is directed to the forepump when the outlet pressure of the booster pump has fallen below the threshold value. The gas supplied by the booster pump is compressed by means of the forepump.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to surgical scissors instruments and, more particularly, to endoscopic scissor instruments having small-sized scissor blades.
[0003] 2. State of the Art
[0004] Endoscopy is a minimally invasive diagnostic medical procedure that is used to assess the interior of the human body using an endoscope. An endoscope generally consists of a rigid or flexible tube, an fiber optic illumination system to guide light provided by a light source through the tube of the endoscope in order to illuminate the organ or object under inspection, and a viewing system for collecting an image of the organ or object under inspection and for recording the image on an internal CCD device (video-endoscope) or for transmitting the image through the tube via a fiber optic bundle to an external video processor for viewing (fiber-endoscope). The endoscope can include one or more “operating” channels (typically 2-4 mm in diameter) that provide for passage of specialized medical instruments through the endoscope and into the field of view. Such specialized instruments (which can include biopsy forceps, brushes, needles, snares, scissors, graspers, cutters, clip appliers, etc.) can be used to take biopsies and retrieve organs (or pieces thereof) and/or foreign objects from the inside of the body. In some instruments (especially those with lateral-viewing optics), the distal tip of the operating channel incorporates a small deflectable elevator or bridge, which permits some directional control over the instrument exiting therefrom. These general principles apply to most endoscopes, but specific instruments differ in length, size, stiffness, as well as other characteristics as the instruments are typically designed for a particular application. Endoscopy can involve, for example, the gastrointestinal tract such as the esophagus, stomach and duodenum, small intestine, and colon. It can also involve the respiratory tract, the urinary tract, the female reproductive system, and the organs of the chest. It can also involve the interior of a joint (arthroscopy). Many endoscopic procedures are considered to be relatively painless and, at worst, associated with moderate discomfort.
[0005] Laparoscopy is a minimally invasive surgical technique in which operations in the abdomen or thorax are performed through small incisions (usually 0.5-1.5 cm) via a laparoscope. There are generally two types of laparoscopes, including a telescopic rod lens system that is usually connected to a video camera (single chip or three chip) and a digital laparoscope where the camera is placed at the end of the laparoscope, thus eliminating the rod lens system. A fiber optic cable system connected to a light source (halogen or xenon is inserted through a surgical port to illuminate the operative field for viewing. The abdomen is usually insufflated with carbon dioxide gas to create a working and viewing space. Specialized surgical instruments can be introduced into the abdomen or thorax through a surgical port in order to take biopsies and retrieve organs (or pieces thereof) and/or foreign objects from the inside of the body.
[0006] The specialized surgical instruments used for endoscopy, laparoscopy or arthroscopy generally include end effector means (e.g., graspers, cutters, forceps, scissors, clip appliers, etc.) mounted adjacent the distal end of a tube or coil. Handles (or other actuation control means) are mounted to the proximal end of the tube or coil and move an actuator axially through the tube or coil. The distal end of the actuator is mechanically coupled to the end effector means in a manner that transforms the axial movement of the actuator into the desired movement of the end effector means. Such specialized endoscopic, laparoscopic or arthroscopic surgical instruments are collectively referred to herein as endoscopic surgical instruments or endoscopic instruments. These general principles apply to most endoscopic instruments, but specific endoscopic instruments differ in length, size, stiffness, as well as other characteristics as the instruments are typically designed for a particular application as such instruments can be used for a wide variety of minimally invasive surgical procedures, including the endoscopic, laparoscopic and arthroscopic applications summarized above.
[0007] Endoscopic surgical scissors instruments generally include a pair of scissor blades pivotably mounted adjacent the distal end of a tube or coil. The scissor blades have sharpened edges that effect cutting of tissue during pivotal movement of the scissor blades relative to one another. Handles (or other actuation control means) are mounted to the proximal end of the tube or coil and move an actuator axially through the tube or coil. The distal end of the actuator is mechanically coupled to the scissor blades in a manner that transforms the axial movement of the actuator into pivoting movement of the scissor blades.
[0008] Endoscopic scissors instruments may be generally classified as either “single acting” or “double acting.” In a single acting instrument, a stationary scissor blade is supported adjacent the distal end of the tube or coil and a movable scissor blade is coupled to the distal end of the actuator and is supported adjacent the distal end of the tube or coil for rotation relative to the stationary scissor blade in accordance with actuation transmitted by the actuator. In double acting instruments, two scissor blades are coupled to the distal end of the actuator and supported adjacent the distal end of the tube or coil for rotation relative to one another in accordance with actuation transmitted by the actuator.
[0009] The construction of the scissor blades theoretically supplies a moving contact point between the opposing cutting edges as the scissor blades are closed by their pivotable movement. In order to effect a smooth cutting action, the engaging cutting edges must be kept in a moving contact point throughout the closing of the scissor blades. Typical scissor designs usually accomplish this by the use of any of the following methods: firstly, via a mechanism or feature separated from the blades that biases the scissor blades together as the scissor blades are closed; secondly, by dimensioning the blades with a longitudinally bowed profile that forces the opposed scissor blades against each other as the scissor blades are closed and lastly by a very accurately constructed assembly with no mechanical slop in the dimensions of, or the positioning of, the scissors' blades or related components
[0010] The biasing means of the first example typically is accomplished by tightening the scissors' pivot nut to remove all dimensional slop in the assembly or with a cammed surface behind the pivot area that effects biasing of the scissor blades closer together as they close over each other. In the second method, which is used most commonly for larger or longer scissor blades, such as those in a standard full-sized scissor as used in regular “open” surgery, a bowed-profile that runs along the longitudinal axis of the scissor blade forces the cutting edges together. This method gives a mostly adequate cutting performance for open style surgical scissors. However for smaller scissor blades such as those used in endoscopic devices, the total loss of resiliency, due to the stiffness of small blades, means that a bowed profile in the scissor blade will not work and will only result in the contacting cutting edges gouging each other or quickly wearing away. Therefore in the currently available endoscopic scissor devices such small non-resilient and rigid blades must be designed to maintain the edge to edge contact through the use of components with very stringent dimensional accuracies, tight tolerances and tight fits. This last design method involves difficult and costly assembly and manufacturing processes. In addition, the effects of using cams or similar features in the design of small endoscopic scissors is limited by the remoteness of the cam surface from the cutting edges and because of persistent assembly “slop” offers little improvement to the problem of maintaining edge to edge contact. These design schemes have historically failed to give small surgical scissor instruments the desired sensitive feel and cutting performance that surgeons require and are familiar with through their experience in open surgery using larger hand-held surgical scissors.
SUMMARY OF THE INVENTION
[0011] The invention provides an endoscopic scissors instrument with small-size scissor blades with improved cutting performance through an improved biasing means whereby features contained in and as part of the blade itself automatically provide a preload to its cutting edge as two scissor blades move past one another.
[0012] The invention also provides such an endoscopic scissors instrument that avoids inherently expensive components, assembly and manufacturing processes.
[0013] According to the invention, an endoscopic scissors instrument includes an elongate hollow member having a proximal end and a distal end, an actuator that moves axially through the hollow member, and first and second scissor blades with respective cutting edges. At least one of the first and second scissor blades are rotatably coupled to the hollow member adjacent its distal end. At least one of the first and second scissor blades includes a base supporting a resilient leaf-spring portion that defines a respective cutting edge. The resilient leaf-spring portion extends from the base in a cantilevered arrangement along the length of the base. The cantilevered arrangement and angling of the leaf-spring portion serves to generate a spring force acting on the respective cutting edge such that, when in a loaded state, there is an automatic preloading force imparted between the cutting edges of the scissors' blades that maintains a consistent and continuous mating force between the two opposed sharpened cutting edges, preferably over the complete range of rotational movement of the scissor.
[0014] It will be appreciated that the endoscopic scissor instrument of the present invention provides improved edge to edge preload of the opposed scissor blades and thus enables superior cutting quality and operator feel for endoscopic scissor instruments where historically it has not been available.
[0015] Additional advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a side view of an exemplary endoscopic scissors instrument that embodies the present invention.
[0017] FIG. 2 is an isometric view of the distal portion of the endoscopic scissors instrument of FIG. 1 in accordance with the present invention where the scissor blades of the instrument are positioned in an open configuration.
[0018] FIG. 3 is an isometric view of the distal portion of the endoscopic scissors instrument of FIG. 1 in accordance with the present invention where the scissor blades of the instrument are positioned in a closed configuration.
[0019] FIGS. 4A and 4B are schematic views of the scissor blades of the endoscopic scissors instrument of FIGS. 1-3 in accordance with the present invention.
[0020] FIG. 5A is a side view of one of the scissor blades of FIGS. 4A and 4B in accordance with the present invention.
[0021] FIG. 5B is a cross-sectional view of the scissor blade of FIG. 5A along the section labeled 5 B- 5 B in FIG. 5A .
[0022] FIG. 5C is a cross-sectional view of the scissor blade of FIGS. 5A and 5B along the section labeled 5 C- 5 C in FIG. 5B .
[0023] FIGS. 6A and 6B are front cross-sectional views of the respective scissor blades of the instrument of FIGS. 1-3 along section lines similar to 5 B- 5 B in FIG. 5A which illustrate the relief angles of the cutting features of the respective scissor blades relative to the corresponding blade supports in accordance with the present invention; the cross hatching of the section is omitted to more clearly show the relief angles depicted therein.
[0024] FIG. 6C is a cross-sectional view of the scissor blade of FIG. 6B along the section labeled 6 C- 6 C in FIG. 6B which illustrates the blade bias angle of the cutting feature of the respective scissor blade relative to its blade supports in accordance with the present invention; the cross hatching of the section is omitted to more clearly show the blade bias angle depicted therein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] For purposes herein, the “distal end” of a surgical instrument or any part thereof, is the end most distant from the surgeon and closest to the surgical site, while the “proximal end” of the instrument or any part thereof, is the end most proximate the surgeon and farthest from the surgical site.
[0026] Turning now to FIGS. 1 and 2 , an exemplary endoscopic scissors instrument 101 in accordance with the invention includes a housing 121 for supporting a handle assembly 123 . A hollow tubular member 125 is provided with a proximal end fixably coupled to the housing 121 and a distal end fixably coupled to a clevis 127 . The hollow tubular member 125 can be a coil to provide for bending and flexibility or can be a rigid or operator plastically deformable tube. A push rod actuator (not shown) extends through the hollow tubular member 125 to the clevis 127 . The push rod actuator is coupled to a pair of scissor blades 131 , 133 via linkages, cams or other suitable coupling features and the scissor blades 131 , 133 are rotatably mounted in the clevis 127 by a pivot post (not shown). In this configuration, axial movement of the push rod actuator within the hollow tubular member 125 causes the scissor blades 131 , 133 to rotate around the post and thus pivot relative to one another. Additional details of the hollow tubular member 125 , the clevis 127 , and the push rod actuator may be obtained by reference to U.S. Pat. No. 5,192,298 to Smith et al., herein incorporated by reference in its entirety. It will also be appreciated that other actuating mechanisms and other mechanisms for causing rotation of the scissor blades could be utilized for the endoscopic scissors instrument of the invention. Indeed, rather than using a clevis with a post around which the scissor blades rotate, the scissor blades could be provided with arcuate grooves as disclosed in U.S. Pat. No. 4,712,545 to Honkanen, herein incorporated by reference in its entirety. The invention applies to single acting and double acting endoscopic surgical scissors. It will be appreciated by those skilled in the art that other mechanisms for linking the actuation mechanism to the scissor blades 131 , 133 may be utilized, such as links and pins, or a pin riding in cammed slots, or other suitable actuating mechanism. Indeed, if desired, in a single acting instrument, the push rod or actuating wire could be directly connected to the scissor blade, and in double acting instruments, two connected push rods or actuating wires could be utilized for direct connection to the scissor blades.
[0027] In the illustrative embodiment, the handle assembly 123 includes a movable front handle 135 and a fixed rear handle 137 . The front handle 135 has an aperture 139 defined therethrough which enables a user to grasp and move the front handle 137 relative to the rear handle 137 . More particularly, front handle 135 is selectively moveable by the user from a first position offset from the rear handle 137 to a second position in closer proximity to the rear handle 137 . Such movement is transmitted to axial movement of the push rod actuator 50 extending through the hollow tubular member 125 in order to impart pivotal movement of the scissor blades 131 , 133 relative to one another. A control wheel 141 can be supported within the housing 121 and extend through sidewalls of the housing 121 to allow the user to rotate together the hollow tubular member 125 , the clevis 127 and the scissor blades 131 , 133 mounted thereto or to rotate the clevis 127 and the scissor blades 131 , 133 independently of and separately from, the hollow tubular member 125 .
[0028] As shown in FIGS. 2 and 3 , each of the scissor blades 131 , 133 is provided with an inside cutting edge 151 , 153 that contact one another as the scissor blades 131 , 133 pivotably rotate relative to one another during use. During such rotation, a point of contact of the cutting edges 151 , 153 moves along the cutting edges. In an open configuration, the point of contact is nearer to the pivot point or clevis ( FIG. 2 ). As the blades close, the point of contact moves further from the pivot point or clevis ( FIG. 3 ). In FIG. 2 , the scissor blades 131 , 133 are shown in an open configuration where the cutting edges 151 , 153 are in bearing contact near the pivot point at a point shown generally by the circled portion 155 .
[0029] FIGS. 4A and 4B show a schematic view of scissor blades 131 , 133 , each of are realized by two unitary parts 201 , 203 . The first part 201 , referred to herein as a “blade support”, is thicker and stiffer than the second part 203 , referred to herein as a “cutting feature.” The thin cutting feature 203 includes a sharpened cutting edge ( 151 , 153 ) that extends along the entire length of the top edge of the cutting feature 203 preferably with a tapered profile as shown. Other profiled designs, such as a stepped profile or other variable profile can be used.
[0030] As shown in FIG. 5A , the blade support 201 includes a thru-hole 205 that receives a pivot post (not shown) as well as a cam-slot 207 disposed proximal to the thru hole 205 that receives a cam pin (not shown) connecting to the distal end of the actuator rod of the instrument. This arrangement provides for pivotal movement of the scissor blades 131 , 133 relative to another in response to axial movement of the actuator rod as is well known.
[0031] As best shown in the cross-section of FIG. 5B , the thin cutting feature 203 of the scissor blades 131 , 133 realizes a cantilever spring arrangement by fixing its bottom portion 209 to the blade support 201 with its top portion 211 angled or otherwise arranged to hold a bias along the length of the respective sharpened cutting edge (labeled 151 in FIG. 5B ) that will ensure that the cutting edge intersects the opposing blade's cutting edge in a scissor assembly. In this cantilever spring arrangement, the thin cutting feature 203 acts as a resilient leaf-spring that allows for resilient deflection of the top portion 211 of the cutting feature 203 relative to its bottom portion 209 being rigidly held and positioned by the thick blade support 201 . This allows the sharpened cutting edge 204 to forcibly engage with the opposing blade's cutting edge in a resilient and deflective manner so no gouging or wear damages the cutting edges. Such resilient deflection is depicted by vector arrow 213 in FIG. 5B . The cantilever spring arrangement of the cutting feature 203 extends along the length of the cutting feature 203 such that the resilient deflection of the top portion 211 relative to its bottom portion 209 and the blade support 201 is provided along the entire length of the cutting feature 203 . The cantilever spring arrangement of the cutting feature 203 also provides a spring moment that is primarily directed across the cutting edge of the cutting feature 203 laterally outward away from the blade support 201 in the direction of vector arrow 215 as shown in FIG. 5B .
[0032] The cantilever spring arrangement and positional bias of the cutting features 203 ensure that the cutting edges 151 , 153 of the two blades 131 , 133 are in intersecting planes as the blades 131 , 133 are closed. In the preferred embodiment as illustrated in FIGS. 6A-6C , the opposed cutting features 203 extend from respective base supports 201 at a relief angle a relative to the rotational planes 205 of the respective scissor blades. Moreover, as best shown in FIG. 6C , the lengthwise profile of the respective cutting features 203 of the scissor blades are angled at a blade bias angle β relative to the rotational planes 205 of the scissor blades. The bias angle of the cutting features of the two blades point toward one another as is evident from FIGS. 6A and 6B . In an illustrative embodiment, the relief angle α of the cutting features is in the range between 3° and 7° (more preferably on the order of 5°) and the blade bias angle β of the cutting features is in the range between 0.5° and 3° (more preferably on the order of 1.5°). Importantly, the relief angle α and the blade bias angle β of the cutting features 203 are provided such that selectively only the cutting edges 151 , 153 of the two blades 131 , 133 are on intersecting planes and therefore edge to edge contact one another is insured as the blades 131 , 133 are closed. These design aspects of the leaf-spring provide a necessary blade-to-blade preload force as the blades 131 , 133 are closed, which maintains a consistent and continuous forceful contact of the two opposed cutting edges 151 , 153 over the complete range of rotational movement of the scissor blades 131 , 133 . Using this design strategy enables a small scissor to use components and manufacturing techniques with much lower quality standards without need of the high tolerance and ultra fine positioning that is presently required in surgical scissors while elevating the cutting ability and feel to a level beyond that of existing endoscopic and other small surgical scissors.
[0033] In the preferred embodiment, the blade support 201 of the respective blade has a thickness between 0.25 mm and 5 mm, while the cutting feature 203 of the respective blade has a thickness between 0.05 mm and 0.5 mm and a length less than 50 mm and preferably a the range between 5 mm and 20 mm. FIG. 5C illustrates an exemplary embodiment where the blade support 201 has a maximal thickness of 0.6 mm, and the cutting feature 203 has a thickness of 0.08 mm and a length of 7 mm. In the preferred embodiment, the scissor blades 131 , 135 (including the cutting features 203 of the respective blades) are realized from high tensile strength stainless steel such as high chrome alloys.
[0034] Advantageously, the endoscopic scissor instrument of the present invention provides an improved automatic edge to edge preload of the opposed scissor blades while avoiding the problems associated with a bowed blade profile and biasing cams used in the prior art, and thus enables superior cutting quality for endoscopic scissor instruments where historically it has not been available.
[0035] There have been described and illustrated herein scissors instruments with improved scissor blades. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while the surgical scissors instrument illustrated herein for exemplary purposes were double acting scissors where both blades pivot relative to each other, it will be recognized that the invention can be applied to a single acting scissors with one blade fixed and the other blade pivoting relative to the fixed blade. It may also be applied to a scissors where only one blade incorporates the present invention coupled with a standard rigid opposing blade. Also, while particular actuation mechanisms were described for causing the pivoting of the scissor blades, it will be appreciated that other mechanism could be utilized. Thus, for example, the instrument could be a flexible instrument with an outer tube formed from a coiled element which could be used through an endoscope channel or a rigid instrument with a relatively stiff outer tube of structural plastic or tubular metal which could be used through a laparoscope or arthroscope. In addition, while particular materials and dimensions have been disclosed for the scissor blades of the endoscopic scissors instruments, it will be understood that other materials and dimensions can be used. Moreover, while a particular unitary configuration of the respective scissor blades is shown, other non-unitary configurations can be used. For example, it is contemplated that the cutting features of the respective blades can be a separate and distinct part that is secured to the blade support of the scissor blade by welding (e.g., by laser welding, spot welding, resistance welding), one or more screws or rivets, or other suitable mechanical fixation means. In this configuration, the blade support can be realized from a wide range of materials, such as a stainless steel, plastics, ceramics, etc. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as so claimed.
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An endoscopic scissor instrument includes an elongate hollow member having a proximal end and a distal end, an actuator that moves axially through the hollow member, and first and second scissor blades with respective cutting surfaces. At least one of the first and second scissor blades are rotatably coupled to the hollow member adjacent its distal end. At least one of the first and second scissor blades includes a base supporting a resilient leaf-spring portion that includes a respective cutting edge. The resilient leaf-spring portion extends from the base in a cantilevered arrangement along the length of the leaf-spring portion. The cantilevered arrangement of said leaf-spring portion generates a spring force acting on said respective cutting edge such that in a loaded state there is an automatic preload force imparted between the cutting edges of the scissor blades to maintain a consistent and continuous mating force between the two opposed sharpened cutting edges preferably over the complete range of rotational movement of the scissor blades.
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BACKGROUND
The present invention relates to active geophysical exploration. It has long been known that there are substantial electromagnetic fields associated with the Earth. The origin of these electromagnetic fields is unclear: one theory holds that low-frequency electromagnetic fields are emitted from beneath the surface of the Earth and radiate outward, such that they can be measured by low frequency methods at the surface. Others postulate that currents are generated by oxidation-reduction type reactions taking place where water and hydrocarbons are present, and that the electromagnetic radiation is caused by interaction of these steady and unsteady currents with the Earth's magnetic field. Still others postulate that the radiation is reflected from outside the Earth's atmosphere.
Irrespective of the source, it is well-documented scientific theory that discontinuities in the subterranean structure of the Earth crust cause reflection and refraction of electromagnetic radiation at interfaces between electrically differing materials. Additionally, the distance a transverse electromagnetic wave travels in a material before being substantially absorbed, is a known function of the frequency of the wave (so-called “skin-depth” expression). Thus, it has been hypothesized that prospecting for hydrocarbons, such as oil, gas and coal, as well as precious metals, could be achieved by mapping the strength of electromagnetic waves at various frequencies which naturally emanate from the Earth providing a passive method of subterranean exploration and prospecting techniques.
Utilizing naturally occurring signals seems plausible, but has proven problematic. Because the emitted wave is so random and its exact source not known, obtaining meaningful signal is an extremely difficult task, if not impossible. In addition, since the source and strength is not known, calibration of instruments is a guess. One almost insurmountable problem with these signals is “noise.” That is, there is an extremely low signal-to-noise ratio associated with these low frequency signals, and this high level of noise typically causes interference in detecting those signals that are determinative of geologic formations. For example, even the cycling of the measurement equipment, such as cooling fans, disrupts the signal.
None-the-less, many different passive methods for picking up and determining low frequency electromagnetic waves emanating from the Earth have been proposed. By utilizing an antenna to pick up these naturally occurring frequencies emanating from the Earth's surface, theoretically one can filter, amplify, modify and otherwise process these signals to turn them into a readable signal. Various low pass and high pass filtering techniques have been proposed, and in some cases employed, after the initial amplification of the signal to improve the quality of the signal. This amplification and filtering is known as “conditioning” and/or “pre-conditioning” of the signal and is generally considered to be the most common technique for identifying naturally occurring electromagnetic signals emanating from the Earth.
Many attempts to electronically solve these problems have met with only limited success. For example, U.S. Pat. No. 6,414,492 discloses a system for passively determining physical characteristics of subterranean geological formation that includes an antenna for acquiring low frequency signals naturally emanating from the Earth which signals are first put through a low pass filter and buffer and then converted from analog to digital, stored in a memory buffer, converted to a frequency spectrum by a Fourier transform, and then further processed to display geophysical information versus the depth of such discontinuities.
Unfortunately, irrespective of the methods employed to improve the quality of the signals from passive systems, problems remain with the signal. Signal-to-noise ratios, as well as the randomness of the electromagnetic wave source remain problematic and impede, if not totally prohibit reproducibility. In order to overcome these problems, active methods have been suggested. Well known active methods for determining geologic subterranean surfaces involve seismic methods wherein pre-programmed charges are detonated, sending a mechanical wave through the area to be mapped. These seismic systems do not employ electromagnetic energy. The “mechanical” seismic waves are received with sensitive seismic meters to locate and identify subterranean geologic formations. This methodology employs the concept that discontinuities in subterranean structure reflect mechanical waves, and that different wave frequencies propagate differently in the Earth. The distinguishing features of the seismic method (as with all active methods) is that the original probing signal is generated, and therefore of a known intensity and characterization.
The seismic refraction method is based on the measurement of the travel time of seismic waves refracted at the interfaces between subsurface layers of different velocity. Seismic energy is provided by a source (“shot”) located on the surface. Energy radiates out from the shot point, either traveling directly through the upper layer (direct arrivals), or traveling down to and then laterally along higher velocity layers (refracted arrivals) before returning to the surface. This energy is detected on the surface using a linear array of geophones. Observation of the travel-times of the refracted signals provides information on the depth profile of the refractor.
Use of mechanical wave propagation in a solid media, however, leads to a whole different set of problems. The problem with seismic waves is their propagation patterns within the media-Earth. Being mechanical waves, they have two propagation modes—transversal and compressional. These modes can mix at the boundaries between media resulting in a shear wave making the interpretation of the resulting data extremely difficult. Electromagnetic waves do not have these two propagation modes and, therefore, the signal is “cleaner”. The meaningfulness of the detected seismic signal is reduced by seismic noise as the sound waves bounce around inside the Earth, some canceling and other amplifying.
It would, therefore, be advantageous to have an active electromagnetic wave system that could produce reliable, reproducible data. However, prior art systems have not, to-date, been effective in accomplishing this for a myriad of reasons. One set of methods as illustrated by U.S. Pat. No. 3,636,435 falls into the, so-called, “Induced Polarization” (IP) class of prospecting methods. In accordance with this method, a large transmitting “loop” conductor is laid directly on the ground and fixed in this position while data is being taken. An alternating current is induced in the loop to generate an electromagnetic field. The inductive fields generated induce eddy currents in the Earth and these eddy currents create secondary fields that radiate in all directions to interact with all profiled obstacles, as well as the Ionosphere, i.e. the field radiates up, down and all around. A detecting loop (or pair of loops, etc.) is moved around and/or multiple detecting loops are positioned and held fixed. In either case, changes in the inductive field intensity as a function of position (so-called “gradients”) are recorded. The “Polarization” in IP refers to spatial separation of charged particles in the environment, and not to the vector direction of the electromagnetic fields.
The inherent problems with the IP-class methods are numerous. As the generating loop is near the ground, it is well known that the interaction with the ground is primarily “magnetic induction” and not electromagnetic waves, creating a near field effect. The near field effect is characterized as a region of space close enough to a transmitting antenna so that the strength of the induction field is larger than strength of the radiation field. As is well known, the radiation fields are those electric and magnetic fields that decay as 1/r (where r is the distance from the geodetic center of the antenna) and that collectively carry energy away from the source; while, induction fields are those electric and magnetic fields that decay as 1/r 2 and that collectively carry no energy away from the source.
Also, the art generally requires the generating loop, the Earth, and the receiving loop (or loops) all to reach steady-state, meaning that a relatively long time elapses (˜10 seconds) before data is taken. This transmission/reception time allows the generated energy to interact with unintended and interfering objects, including the Ionosphere. The recorded data from these unintended objects is meaningless for the intended purpose and creates undistinguishable interfering signals, i.e. it is generated noise. First, as the Ionosphere is randomly and chaotically changing, this interaction “scrambles” the reflected data. Second, no precise orientation or shape of the generating or receiving loops is maintained. If the field strengths at multiple IP ground receiving loops are differenced, the resulting measurements are basically identical to those obtained via the so-called resistivity sounding prospecting methods.
Another set of active electromagnetic prospecting methods, as illustrated by U.S. Pat. No. 3,500,175, or U.S. Pat. No. 3,617,866, are referred to as Radio Frequency Surveys (RFS's). In these methods, a continuous-wave transmitter (either one actively constructed as part of the apparatus or a “convenient” radio frequency transmitter known to already be in the area) is activated. The transmitter “lights up” the Earth-Ionosphere waveguide. A receiving antenna is moved across the surface region of interest (by human, motor vehicle, or airplane) and the resulting field intensities are recorded as a function of position.
In some methods in this class, where the transmitter is under the control of the person versed in the art, the relative phase between transmitted and received field is also recorded. The data set of interest is the change in received information as a function of changes in the position of the receiving antenna. The precise orientation of the receiver and transmitter is not controlled (except to aid in gathering time-delay (phase) information). Practitioners of RFS typically claim the readings produced indicate something about subsurface conductivities and the method is disclosed and practiced as being at a single, convenient frequency. Again, the interference and uncertainty of the random reflective, verses the emitted signal without time delay, makes the gathered information suspect and impossible of accurate interpretation.
A third broad class of electromagnetic prospecting methods falls into the Ground Penetrating Radar (GPR) class of methods as illustrated by U.S. Pat. No. 5,339,080. As practiced and disclosed, GPR is typically a pulsed method, at a single frequency eliminating ionospheric interference. However, in order to eliminate interaction between the ground and the inductive fields, GPR operates in the meter to centimeter wave region of the electromagnetic spectrum (approximately 100 MHz to 500 MHz). At these wavelengths, the transmitter can be only a few feet above the ground, yet the ground can still be in the far-field. Unfortunately, at these wavelengths, GPR can only “see” into the ground about 10-30 meters at the most (penetration, or skin-depth is a function of frequency). Moreover, GPR, like virtually all radar systems, makes only a field intensity measurement and generally operates at normal incidence (angle of incidence is 90°) to the Earth surface; therefore, no information on the polarization of the fields is measured or can be meaningful. Most GPRs are designed to transmit and receive only at a single fixed frequency.
In both the IP class and the RFS class of methods, there has been recent attention paid to “pulsed” transmission as illustrated in U.S. Pat. Nos. 5,498,958 or 5,796,253. In exemplary disclosures of pulsed methods to-date, the pulsed nature of the transmission is to facilitate attempting to view the “decay” characteristics of the received field intensity. In accordance with this practice, purportedly, the decay characteristics contain intelligible information about the location of buried conductors. Again, the pulsing is not carried out in a way that will limit interaction with the Ionosphere which randomly scrambles the received signal and is interfering (noise.) None of these methods allow the reconstruction of strata thicknesses and composition to produce a three-dimensional display (topology) of the subterranean landscape.
It will be realized that the foregoing discussion and examples of the related art and the scope of the illustrations related thereto are set forth as background only. Their intent is to be exemplary and illustrative of problems related to the art, as well as prior attempts to address these problems, at least in part. They are not, nor are they intended to be exclusive or exhaustive. Nor are they intended, in any manner, to be read as a limitation of the instant disclosure or the appended claims.
SUMMARY
The following embodiments and aspects thereof are described and illustrated in conjunction with systems, devices and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
In accordance with the instant system and method, subsurface strata thicknesses and chemical compositions associated with changes in intensity and polarization of electromagnetic waves which are transmitted and received from an elevated, spatial antenna system, specifically oriented and positioned, relative to a specific point on the earth surface are mapped to yield a three-dimensional topology (stratigraphy) and geology (geological layer composition) of subterranean formations. Plane-polarized (“s” and “p”) electromagnetic waves of varying, specific frequencies, and in one embodiment, specific duration, to minimize ionospheric effects, are emitted by a movable transmitting antenna held substantially stationary at an Incidence Station during a Read Cycle.
The plane electromagnetic polarized waves of these varying frequencies are transmitted into the Earth's surface to a depth, dependent on the designated frequency, in a layered fashion. The transmitted, polarized electromagnetic waves, which interact with subterranean formations at a specific depth, that are not absorbed, return to the surface by reflection to be received by a separate stationary receive antenna positioned at the Incidence Station. The differences between the transmitted and received wave carry geological information which is manipulated to map subterranean topology and identify geologic composition of the layers.
The antenna system is, advantageously, a line antenna system comprising a transmit line antenna and a receive antenna, each separately suspended between two aerial platforms, which are movable, but capable of hovering for substantial periods. Thus, the platforms are mobile in three-dimension, but posses the ability to remain relatively motionless during a Read Cycle. The ionospheric effect is mitigated by regulating the transmit duration, and/or the receive duration and/or data manipulation as a function of a transmission timeline.
In operation, parametric information is identified which includes, for example, a set of prospecting frequencies, as well as angles of incidence or incremental variations of the angles of incidence which may include specific start and termination boundaries. The angles of reflection are set to automatically mirror the specified criteria for the angles of incidence. The angles of revolution are likewise specified around the Centerline. At a particular Incidence Station, the transmit antenna is rotated in a plane perpendicular to the transmit propagation line, which is a line connecting the geodetic center of the transmit antenna with the Prospecting Point, to effect “s” and “p” polarizations. In each configuration, n polarized pulses are transmitted (wherein n is equal to or greater than two).
The receive antenna is rotated in a plane perpendicular to the receive propagation line which is a line connecting the geodetic center of the transmit antenna with the Prospecting Point n times during a Read Cycle. Thus, for each transmitted sequence of n identical electromagnetic wave pulses, of specific far-field polarization, sent from the transmit antenna, the receive antenna is rotated within plane to a sufficient number of positions to ascertain the polarization state of the received signal. By revolving the transmitting and receiving antennas, in a given relationship to each other and the Prospecting Point, in increments, 360° about the Centerline as well as varying the angle of incidence, and thus reflection, and emitting and receiving over the range of prospecting frequencies for each Read Cycle, as the process is repeated, a three-dimensional map of the subterranean geology, including composition, can be generated.
In addition to the summary of exemplary aspects and embodiments described above, further aspects and embodiments will become apparent to the skilled artisan by reference to the drawings and by study of the following descriptions all of which are within, without limitation, the scope of the claims.
BRIEF DESCRIPTION OF THE FIGURES
Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative and exemplary only and not limiting. The features and advantages of the present invention, without limitation, are hereinafter described in the following detailed description of exemplary embodiments to be read in conjunction with the accompanying drawing figures and will be apparent to one skilled in the art that other embodiments are included, in view of the following, wherein like reference numerals are used to identify the same or similar parts in the similar views in which:
FIG. 1 depicts a plane wave behavior at boundary between two media;
FIG. 2 depicts a plane wave reflecting off of a subterranean interface;
FIG. 3 depicts plane wave interacting with two subterranean interfaces having a boundary;
FIG. 4 depicts plane waves of differing frequencies interacting with two subterranean interfaces having a boundary;
FIG. 5 depicts polarization states of a plane wave incident on a media boundary;
FIG. 6 depicts the resonant cavity formed by the earth and ionosphere;
FIG. 7 depicts an exemplary transmit aerial platform system;
FIG. 8 depict an exemplary overall transmit/receive aerial platform system.
FIG. 9 depicts Skin-Depth Uncertaintyfor Finite Duration Sinusoidal Pulse Probe Signal.
DISCUSSION OF THE SYSTEM NOMENCLATURE
As used herein, the following terms are meant to have the meanings hereinafter set forth.
Centerline shall mean a line emanating from the Prospecting Point orthogonal to the Earth's surface.
Incidence Station shall mean a configuration of the transmit antenna and receive antenna wherein the transmit antenna is in the far-field of the Prospecting Point, such that the angle of incidence and the angle of reflection are equal and held at a pre-specified value and the revolution angle about the Centerline is fixed.
Prospecting Point shall mean a predetermined point on the Earth's surface from which the Centerline emanates.
Read Cycle shall mean n predetermined, finite periods of time during which n (wherein n is two or greater) identical electromagnetic wave pulses of specific polarizations at a specified frequency, ω, are emitted from the transmit antenna; and, each reflected wave pulse is received by the receive antenna in at least two different orientations within a plane orthogonal to the receive propagation line.
Read Cycle Data Record shall mean the signal (data) recorded at the receive antenna during one Read Cycle.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The present system may be described herein in terms of functional block components and various processing steps. It should be appreciated that such functional blocks may be realized by any number of hardware and/or software components configured to perform the specified functions. For example, the system may employ various integrated circuit, aerodynamic, or optical components, e.g., memory elements, processing elements, logic elements, look-up tables, and the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices. Similarly, the software elements of the present invention may be implemented with any programming or scripting language such as C, C++, Java or the like.
The system, and method, is active (a probing signal is transmitted), using electromagnetic waves wherein the transmitted electromagnetic waves are of two distinct far-field plane polarizations (called “s” and “p” polarizations). Polarization of an electromagnetic field is the orientation, relative to a fixed coordinate system in space, of the electric field vector. For each Read Cycle, n predetermined, finite periods of time during which n (wherein n is two or greater) identical electromagnetic wave pulses of specific polarizations at a specified frequency, are emitted from the transmit antenna while the antenna is fixed; and, each reflected wave pulse is received by the receive antenna in at least two different orientations within a plane orthogonal to the receive propagation line. The reflected intensity and reflected polarization for both “s” and “p” transmit polarizations is hence measured over a range of frequencies, at various angles (incident angles) relative to the Prospecting Point, at incremental angles of revolution about the Centerline. Ionospheric effects are accounted for by signal and/or data manipulation as a function of time. Specifically, the signal transmission time and/or the signal reception and/or the off-line processing of the data is controlled as will be further explained below.
In operation, the prospecting run is advantageously scripted about one or more Prospecting Points. A first Incidence Station is thus specified, and the antenna system caused to come on station. Once on station, the antenna system is held substantially stationary, while a Read Cycle is initiated. The receive antenna rotates in-plane so that the polarization state of the received pulse is ascertained. Advantageously, the prospecting frequencies are then varied and the antenna system is moved to a new Incidence Station, as scripted, and initiates a new Read Cycle. The system and method focus on repeatable data and exclude non-repeatable data, as noise. The received data can then be mapped, based upon known empirical calibrations, to yield both subterranean stratigraphy and related compositional information, such as the presence of oil, or metal ore, such as gold or uranium. In one aspect, the system adapts to frequency/time duality mandated mathematically from using finite duration probing signals in not resolving deep features (which require longer wavelengths) to the same detail that it resolves shallow features.
The system includes a set of antennas, comprising at least one transmit antenna and at least one receive antenna, located in relation to one another and the Prospecting Point. The transmit antenna and the receive antenna are formed of a continuous conductor or collection of continuous conductors. An imaginary line between the geodetic center (a point on a body, such as an antenna, that minimizes the maximum distance to any other point on that body) of the transmit antenna and the Prospecting Point forms a “transmit propagation line” to define an angle with the ground at the Prospecting Point. This angle is the angle of incidence. Likewise, an imaginary line between the geodetic center of the receive antenna and the Prospecting Point forms a “receive propagation line” to define an angle with the ground at the Prospecting Point. This angle is the angle of reflection.
During a Read Cycle, transmit and receive antennas are substantially stationary (except for rotations in a plane to ascertain the received polarization state as described above) and maintain a fixed Incidence Station. The transmit antenna, in the far-field, is positioned along the transmit propagation line, while the receive antenna (which may or may not be in the far-field) is positioned along the receive propagation line. Changes in transmitted wave polarization are effected by discrete rotations of the transmit antenna in a plane perpendicular to the transmit propagation line; measurement of the reflected wave polarization is effected by discrete rotations of the receive antenna in a plane perpendicular to the receive propagation line.
As set forth above, the angle of incidence and angle of reflection are maintained substantially equal to one another during the Read Cycle. The system is programmed to incrementally vary the angle of incidence and angle of reflection at a single position. The system is likewise caused to incrementally revolve 360° about the Centerline. Thus the antenna system is incrementally positioned around the Centerline for each angle of incidence/reflection. It will be realized by the skilled artisan that the system can vary the angle of incidence and angle of reflection at a single station; or, revolve the platform about the Centerline for each angle of incidence and angle of reflection. That is, the order of sequencing makes no difference.
In one embodiment, at each Incidence Station a specified set of frequencies is emitted and/or received at time intervals set so as to avoid the Ionosphere effect, as further discussed below. As set forth above, the far-field polarization of the transmitted electromagnetic waves is changed by rotation of the transmit antenna within a plane defined by perpendicularity to the transmit propagation line, and the reflected wave polarization is measured by rotation of the receive antenna within a plane defined by perpendicularity to the receive propagation line. Once data has been gathered, the antennas are moved to the next stationary position (Incidence Station) about the Prospecting Point and the next reading is taken.
By revolving the transmitting and receiving antennas 360° about the Centerline as the angle of incidence and angle of reflection are varied, and repeating the measurement process, over a specified set of frequencies using both “s” and “p” transmit polarizations, a three-dimensional map of the subterranean stratigraphy can be suitably generated along with identification of geological compositions of the strata. These three-dimensional topologies about a Prospecting Point employ “p” polarized and “s” polarized waves respectively, as set forth above, but any two polarizations that form a basis for all possible polarizations (e.g. “p” polarization and a left-circular polarization) may be used.
By placement of the transmit antenna systems in the far-field the strength of the induction fields is smaller than strength of the radiation fields. It is known that those electromagnetic fields that decay as 1/r 2 (where r is the distance from the geodetic center of the antenna) and that collectively carry no energy away from the source are referred to as induction fields; while those electromagnetic fields that decay as 1/r (where r is the distance from the geodetic center of the antenna) and that collectively carry energy away from the source are referred to as radiation fields. Thus, a region of space close enough to a transmitting antenna so that the strength of the induction fields is larger than strength of the radiation fields is designated herein as the “near field”; whereas, the region of space far enough away from a transmit antenna so that the strength of the induction fields not larger than strength of the radiation fields is referred to herein as the “far-field”. The transmit antenna and the receive antenna are born upon appropriate aerial platforms, as further described below, to obtain sufficient distance between the antenna system and the Prospecting Point and to maintain the transmit antenna in the far-field.
Advantageously, for example, the system employs at least two, tandem pairs, of stationary aerial delivery platforms which allow stationary positioning of a line transmit and a line receive antenna. Both the transmit and receive antennas are positioned in three-dimensional space relative to the Prospecting Point and each other, as previously described, by, for example, coordinated, unmanned aerial vehicles. The receive antenna and the transmit antenna are configured at an Incidence Station, which by definition has the transmit antenna located in the far-field of the Prospecting Point, while a Read Cycle is initiated. Thus, distinct from other current aerial prospecting methods, the method described herein depends on the antennas being held substantially stationary and in strict spatial relationship with each other and the Prospecting Point while the Read Cycle is occurring and data (Read Cycle Data Record) is being gathered.
Advantageously, the receive antenna is located a considerable distance from the transmit antenna, but the exact relative location and geometry of the transmit antenna and receive antenna may be systematically varied to enhance the amount of subterranean information extracted within the parameters of the system. The receive antenna and apparatus detect and record the intensity and polarization of the return wave for two different transmitted polarizations (“s” and “p”). In accordance with known theories of the interaction of electromagnetic waves with ponderous media, the intensity and polarization of the returned wave carries information about the thickness as well as the composition of the subterranean strata of the Earth.
As discussed above, a specified set of frequencies for the emitted electromagnetic wave is used at each Incidence Station to vary the depth of penetration in the Earth's surface using the principles of “skin-depth theory.” In one aspect, the mapping is accomplished in a layered fashion by transmission of polarized plane waves of progressively higher wavelengths, such that the higher frequency waves penetrate to, and are reflected in the shallow features; and, the waves of longer wavelength penetrate to, and reflect in, the deep features. Thus, as a Read Cycle Data Record is collected at a each Incidence Station, the system works in layered manner—mapping the near surface using higher frequencies and the deeper subterranean with lower frequencies. The information gathered is used in a recursive fashion to reconstruct (map) subterranean strata to a working depth.
Since the lower-frequency transmitted wave penetrates deeper into the Earth than a higher-frequency wave, the frequency of the transmitted wave is ratcheted downward as measurements proceed. By using skin-depth relationships in analyzing the data the resultant information can thus be processed in a “wedding cake” (layered) fashion, starting with measurements from the high frequency probes and proceeding to the low frequency data. The subterranean structure and composition of the Earth is found by suitable algorithmic processing of the data which is described below.
As mentioned above, in one aspect, the transmit and/or receive durations are limited such that only waves reflected from the Earth's crust are registered, and no waves attributable to reflection from the Ionosphere are received. The system, as further described, accounts for the frequency/time duality imposed by finite duration signals. In other words, the system does not resolve deep features to the same detail that it resolves shallow features.
In a further aspect, contrary to some prior art methods, the instant method focuses on the steady, repeatable part of the received signal generated by repeated transmit of identical probe signals, e.g., if the same probing signal is sent out twice, any differences in the received signals are attributed to unwanted noise. Thus, over time the noise can be averaged, or otherwise filtered out and discarded. This leads to more accurate reconstruction of the subterranean stratigraphy.
The following is by way of explanation and not limitation, and is provided herein solely to provide the skilled artisan with background and increased understanding of the method and system described herein. In a plane wave, both the electric and magnetic fields are transverse to the direction of wave travel, and both varying harmonically in time and space. The physics of the transmission, propagation, and interaction with ponderous media of plane waves allows an understanding by the skilled artisan of the workings of the system and allows manipulation for specific applications.
It is well known that when a propagating plane wave encounters a boundary between two mediums that have differing refractive indices, both transmission and reflection occur. This is shown in FIG. 1 . The plane defined by propagation vector {right arrow over (k)} and the unit normal to the interface between the two mediums is the plane-of-incidence. Simple kinematics dictates the angle of incidence, Θ i , and the angle of reflection, Θ r are the same, and all three beams (incident, reflected, and transmitted) must lie in the plane-of-incidence. Additionally, the angle of refraction and the angle of incidence are related by Snell's Law.
The above described behavior of plane waves at interfaces may be used to locate such interfaces beneath the Earth's surface as shown in FIG. 2 . As shown in FIG. 2 , a “one layer reflection,” a plane wave is generated at point “S” and propagates into the Earth. It encounters an interface between two different materials, such as, for example, differing rock layers, and a reflected wave is generated which is received at point “R”. If no interface exists, no signal is received at “R”.
Behavior for multi layers follows a similar scheme. For example, three layers are shown in FIG. 3 . There is, theoretically, an infinite progression of reflections and transmissions. However, practically, due to the skin-depth and penetration properties of plane waves, as described below, this infinite progression can be neglected as the wave is completely absorbed and extinguished after a relatively small number of reflections.
Skin-Depth and Penetration
As set forth above, one of the salient aspects of plane waves is how they behave in conductive materials. In a conductive material, a plane wave is attenuated (absorbed) as it travels. The degree of absorption can be described by the skin-depth, δ, which is defined as the distance it takes for the wave to lose approximately 63% of its energy. Analysis shows that
δ = 1 α = 1 ω μ ɛ [ 2 1 + ( σ ω ɛ ) 2 - 1 ] 1 / 2
where
β = ω μ ɛ [ 1 + ( σ ω ɛ ) 2 + 1 2 ] 1 / 2 and α = ω μ ɛ [ 1 + ( σ ω ɛ ) 2 - 1 2 ] 1 / 2
ε is a dielectric, μ is a magnetic permeability, σ is a conductivity. The quantities, ε, μ, and σ can all depend on the frequency, ω.
Materials with small skin-depths absorb waves readily while materials with large skin-depth are not very absorptive.
Thus, plane waves of higher frequency (i.e. smaller wavelength) are more quickly absorbed, and do not propagate as far, into any given (conductive) material. This is shown in FIG. 4 which shows three plane waves of differing frequencies penetrating the Earth's surface. From left to right in the figure, the frequency of the wave decreases. The left-most wave of the highest frequency, is completely extinguished in Layer 1. The middle wave, of intermediate frequency, makes it to the Layer 1/Layer 2 interface and generates a reflected and refracted wave, but both are absorbed before they can interact again or reach the surface. Only the right-most (lowest frequency) wave, leaving point “S”, interacts with the Layer 1/Layer 2 interface and reaches the receive antenna.
Thus, the probe depth can be adjusted by adjusting the frequency of the transmitted wave. Again, lower frequencies penetrate deeper and thus interact deeper in the Earth before returning to a receiver. Though ε and σ can in fact vary over frequency for many materials however the ratio σ/ωε is generally fairly constant with frequency. Table 1 below gives material parameters and resulting skin-depths for some interesting materials at the frequencies of 500 Hz and 2 KHz.
TABLE 1 Approximate Skin-Depths of Various Materials at 500 Hz and 2 KHz Material ε/ε 0 μ/μ 0 σ/ωε δ (500 Hz) δ (2 KHz) Dry Soil 2.8 ≈1.0 0.07 1632 meters 408 meters Sea Water 80 ≈1.0 4 8.5 meters 2 meters Quartz 3.8 ≈1.0 .0075 67000 meters 16000 meters
Polarization of Electromagnetic Waves
Electromagnetic waves of all frequencies can be polarized in a manner similar to visible light, both in and out of the plane of propagation. The electric vector E 0 is the vector giving the electric field at time t=0. E 0 must be transverse to the propagation direction. In an isotropic material, this leaves a two-dimensional plane in which E 0 can exist. The totality of orientations for E 0 can be described mathematically as a superposition of two distinctive cases, called “p” polarization, and “s” polarization respectively. As shown in FIG. 5 , a plane wave in the “p” polarization state has E 0 lined up in the plane-of-incidence; a plane wave in the “s” polarization state has E 0 perpendicular to the plane-of-incidence. It is known that the reflection and refracted properties of the wave differ between the “s” and “p” polarization states. For example, for isotropic, non-conducting media, the “s” and “p” reflection coefficients are
R s = n 1 cos ( Θ i ) - n 2 cos ( Θ t ) n 1 cos ( Θ i ) + n 2 cos ( Θ t ) R p = n 2 cos ( Θ i ) - n 1 cos ( Θ t ) n 2 cos ( Θ i ) + n 1 cos ( Θ t )
which shows differing reflection amounts depending on whether the incident wave is “s” or “p” polarized.
Ellipsometry
In ellipsometry, measurements of Δ (the phase difference between the “p” and “s” reflected wave), and tan ψ (the ratio of the magnitudes of the “p” and “s” reflected wave) are made. This allows one, by well-known relationships, to determine R p /R s . When the measurements are done at a multitude of frequencies and a known angle of incidence, Θ i , then relationships between R p , R s and the properties of the material allow one to determine what material the wave reflected from. In this way, subterranean geological compositions can be suitably determined.
Ionospheric Effects
Due to a conductive layer in the atmosphere called the Ionosphere, the surface of the Earth is actually one side of a resonant cavity, or wave-guide. Electromagnetic radiation emitted in the atmosphere traveling toward space (away from the Earth's surface) undergoes reflection at the Ionosphere boundary, as shown in FIG. 6 . During daylight hours, the Ionosphere begins about 100 km (60 miles) above the surface of the Earth and the peak conductivity region is about 200 km above the Earth. During evening hours, after the sun has set, the beginning of the Ionosphere migrates upward to 270 km. During times of solar flares or storms, the properties and location of the Ionosphere can change quite markedly.
The existence of the Ionosphere has implications for any active electromagnetic-based geophysical prospecting system. It means that an electromagnetic wave generated on the surface or in the Earth or in the air above the surface eventually energizes the Earth-Ionosphere wave guide. An antenna will receive the wave reflected from the Earth's surface, but eventually receive the result of the wave traveling around in the Earth-Ionosphere wave guide.
If the whole Earth-Ionosphere cavity is energized by a transmitted geophysical electromagnetic probe signal, then the received signal carries not only signature of the Earth's crust, but also the signature of the Ionosphere. The Ionosphere is continually, and chaotically, changing its electrical properties due to influence of the solar wind and other factors, so having ionospheric reflections in a received signal places uncertainty in the reading and is undesirable. Because the Ionosphere is unsteady and random, reflections from it are unsteady and random. Hence, if an active electromagnetic exploration method allows these reflections to be received, the recorded data will be unsteady and random.
Minimizing Ionospheric Effects by Suitable Control
In accordance with the instant system, reflections from the Ionosphere are avoided by: suitably controlling the time duration of the transmitted pulse, suitably restricting the receive duration for the received waveform, or synthetically windowing the data offline during processing of the data as a function of transmission sequencing.
In the evening hours, for example, the electromagnetic wave sent from the system will travel to the Ionosphere, reflect, and return in a finite time:
270 km c = 270 300 , 000 ≈ 850 milliseconds
so there is about T=850 milliseconds before reflections from the Ionosphere mix into the data. In accordance with one aspect, night prospecting is advantageous as the Ionosphere is higher, and so longer transmit/receive times are available.
Frequency/Time Duality of Signals
According to Fourier Transform theory, any function of time (periodic or not) can be represented as a superposition of sinusoids and cosinusoids. The sinusoidal pulse of finite
duration 0 for t < 0 sin ( ω 0 t ) for 0 ≤ t ≤ T 0 for t > T
has the Fourier Transform
ⅇ
j
π
-
ω
T
2
[
ⅇ
-
j
ω
0
T
2
sin
(
(
ω
+
ω
0
)
T
)
ω
+
ω
0
-
ⅇ
j
ω
0
T
2
sin
(
(
ω
-
ω
0
)
T
)
ω
-
ω
0
]
The above equation shows that a finite duration sinusoid actually contains multiple frequencies. The range of contained frequencies spreads out as the duration of the pulse becomes shorter. We can sum this up by saying that the shorter the duration of a signal, the more frequencies it must contain. This mathematical fact, called “frequency/time duality”, has implications for the instant system.
Prospecting Implication of Frequency/Time Duality
At the half-power point, a sinusoidal pulse of duration of
T = 850 2 msec ,
has a frequency spread (in Hz) of [f 0 −2.3529 f 0 =2.3529] . The “uncertainty” Δf=4.718 Hz in the sinusoidal pulse limits resolution at deeper depths. Effects can be summed up by the plot in FIG. 9 .
FIG. 9 shows that the resolution becomes less as one progresses deeper into the Earth. This relationship allows analysis of the data received in the instant method and is predicated upon finite time active prospecting methods that avoid Ionosphere interactions.
For example, Table 1 above shows that in dry rich soil a 500 Hz wave probes to about 1.6 Kilometers. FIG. 9 shows that at 500 Hz, there will be about a 2% uncertainty in the skin-depth. Thus, any features uncovered by the 500 Hz data can only be located to within ±32 meters within the Earth's crust.
Antennas
The antennas that are useful include those giving a definite linear polarization in the far-field, and at least one plane of symmetry. Any antenna that has two (or more) orthogonal planes of symmetry, and generates radiation fields with a linear far-field polarization parallel with one of the planes is useful. Examples of such antennas, without limitation, include all line antennas (including top-loaded line antennas), all loop antennas, all plane-symmetric line antenna arrays, and all plane-symmetric loop antenna arrays, biconical antennas, horn antennas and the duals of these antennas in the form of apertures and synthetic apertures.
The behavior of an antenna may be partially described by its radiation pattern. The radiation pattern describes the intensity of the electric and magnetic fields as a function of the spherical coordinates (θ, φ) where φ is the azimuthal angle and θ is the altitude angle. The distance coordinate, r, is not included since the pattern is intended to show the directional behavior of the antenna and radiation fields fall off in a ratio of 1/r so the behavior with r is always known and implied.
Line Antennas
Advantageously, line antennas are used in accordance with one aspect of the system. Simple line antennas are the easiest to mount on an aerial platform, and they meet requirements to be useful. The far-fields of a small line antenna are
B
=
e
→
ϕ
j
I
m
2
λ
sin
θ
exp
[
-
j
2
π
r
/
λ
]
E
=
e
→
θ
j
I
m
η
2
λ
sin
θ
exp
[
-
j2π
r
/
λ
]
where
λ = Δ v / f = 2 π v / ω
is the generalized wavelength associated with a propagation speed of ν and frequency of ω and
η = Δ μ / ɛ
is the intrinsic impedance. Thus, the far-fields are linearly polarized.
Delivery Platform
An exemplary delivery platform for the system is comprised of unmanned aerial vehicles (“UAV's”) which carry and move the antennas and electronics during in flight maneuvers as well as hovering. For example, one pair of Radio Control (“RC”) helicopters may be used to position and feed the transmitting antenna, as shown in FIG. 7 . Then a second, identical, pair positions the receive antenna and electronics. An exemplary transmit/receive configuration using UAV helicopters to position line antennas is shown in FIG. 8 . More complicated antenna shapes allowed by a larger number of coordinated UAV's are also possible and can be advantageous.
Without limitation, useful UAV systems may be powered helicopters of a scale of approximately 2 meters in rotor length, and approximately 2 meters in central boom length. Such craft could be powered by electric motors, which may be self contained or tethered; or, internal combustion engines, including turbines. These power plants are advantageously able to generate 4 or more breaking horsepower to allow adequate lift and maneuverability.
Control of the unmanned aerial vehicles can be accomplished by many ways known in the art. For example, UAV's may be automatically controlled by a microprocessor or other computer. Advantageously, the microprocessor or other computer will have access to GPS (Global Positioning System) information or DGPS (Differential GPS) and, possibly, ground-station generated phase correction signals, and have access to three-dimensional linear and angular acceleration measurements from an IMU (Inertial Measurement Unit). All of these measurements are used to aid in the positioning and maneuvering of the UAV in three-dimensional space. The antenna is positioned and shaped by two or more UAV's, each attached to the antenna at a different point, and each flying a specified maneuver pattern to cooperatively position and shape the antenna. In order to fly a specified maneuver pattern, the programmed prospecting run is calculated by a “master” ground-based computer system and sent via spread-spectrum (900 MHz or higher) communications to the controlling microprocessor or other computer on board each UAV.
In accordance with the operation of the instant system, a transmit antenna having a specific dimension and a receive antenna having a specific dimension are located at an Incidence Station with respect to the Prospecting Point. The antenna systems are ultimately mobile upon aerial platforms such as unmanned aerial vehicles, allowing the Incidence Station to be varied and allowing a revolution of 360° about the Centerline. The distance along the receive propagation line from the Prospect Point can be any distance but advantageously the receive antenna does not actually touch the ground.
The angle of incidence and, therefore, the angle of reflection of the transmit antenna and the receive antenna may be varied within operational limits. For example, angles of greater than 0° and less than 90° are operative. It will be realized by the skilled artisan that the aerial platform mobility and antenna configuration will limit the system and, thus, preclude certain angles. However, all angles greater than 0° and less than 90° are meant to be included within the appended claims.
Likewise, the angle of revolution about the Centerline for a given angle of incidence may be 360° In operation, the system is programmed to accomplish discrete angles of incidence as well as angles of revolution. It will be understood that the smaller the increment of incidence and/or revolution for a given set of readings, the more accurate and defined the mapping about the Prospecting Point. Likewise, the greater the discrete number of electromagnetic wave frequencies emitted for each polarization, the more accurate the definition of the subterranean geology.
It will be realized by the skilled artisan that the power or gain of the transmit antenna will effect the quality of the received information such that the higher the power or gain of the transmit antenna, the less sensitive the receive antenna has to be. In addition, it will be realized that the power or gain of the transmit antenna materially effects the signal-to-noise ratio of the system. In one aspect of the operation of the system, the affect of Ionosphere is mitigated by controlling the transmitted or received signal duration and/or synthetically windowing the data offline.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is, therefore, intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope. All of the methods and systems disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the methods and systems of this invention have been described in terms of embodiments, it will be apparent to those of skill in the art that variations may be applied to the methods and systems and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the invention. Various substitutions can be made to the hardware and software systems described without departing from the spirit of the claimed invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the claimed invention.
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An active system and method for determining the physical characteristics and geological composition of subterranean formations is described. Plane polarized electromagnetic waves at specific frequencies are transmitted by a mobile transmitting antenna held stationary in the far-field about a prospecting point. The plane polarized electromagnetic waves penetrate the Earth and return to the surface to be picked up at a separate mobile receiving antenna held stationary about a prospecting point. The differences in intensity and polarization between transmitted and received waves are measured and carry geological information. Further, a coordinated series of transmissions, receptions, and measurements are made, in which the angle of incidence and the revolution angle about a centerline emanating perpendicularly from the prospecting point are carefully and systematically varied and repeated for a specific set of frequencies. The entire data set is processed to give stratigraphy and geological composition in three-dimensions including, for example, the location of commercially important ore deposits or reservoirs of oil and gas. The transmission time, the reception time, and/or the data window are controlled to minimize the ionospheric effect. The method seeks the steady, repeatable part of a received signature and changes in the received signal for two or more identical probing transmissions are filtered out, as unwanted noise. The system employs a frequency/time duality for not resolving deep features to the same detail as shallow features.
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BACKGROUND OF THE INVENTION
[0001] In the manufacture of paper products, such as facial tissue, bath tissue, paper towels, dinner napkins and the like, a wide variety of product properties are imparted to the final product through the use of chemical additives. Examples of such additives include softeners, debonders, wet strength agents, dry strength agents, sizing agents, opacifiers and the like. In many instances, more than one chemical additive is added to the product at some point in the manufacturing process. Unfortunately, there are instances where certain chemical additives may not be compatible with each other or may be detrimental to the efficiency of the papermaking process, such as can be the case with the effect of wet end chemicals on the downstream efficiency of creping adhesives. Another limitation, which is associated with wet end chemical addition, is the limited availability of adequate bonding sites on the papermaking fibers to which the chemicals can attach themselves. Under such circumstances, more than one chemical functionality compete for the limited available bonding sites, oftentimes resulting in the insufficient retention of one or both chemicals on the fibers.
[0002] Therefore, there is a need for a means of applying more than one chemical functionality to a paper web which mitigates the limitations created by limited number of bonding sites.
SUMMARY OF THE INVENTION
[0003] In certain instances, two or more chemical functionalities can be combined into a single molecule, such that the combined molecule imparts at least two distinct product properties to the final paper product that heretofore have been imparted through the use of two or more different molecules. More specifically, modified polysaccharides (such as starches, gums, chitosans, celluloses, alginates, sugars, etc.), which are commonly used in the paper industry as strengthening agents, surface sizes, coating binders, emulsifiers and adhesives, can be combined into a single molecule with amphiphilic hydrocarbons (e.g. surface active agents) which are commonly utilized in the paper industry to control absorbency, improve softness, enhance surface feel and function as dispersants. The resulting molecule is a modified polysaccharide having surface active moieties which can provide several potential benefits, depending on the specific combination employed, including: (a) strength aids that do not impart stiffness; (b) softeners that do not reduce strength; (c) wet strength with improved wet/dry strength ratio; (d) debonders with reduced tinting and sloughing; (e) strength aids with controlled absorbency; and (g) surface sizing agents with improved tactile properties.
[0004] Hence in one aspect, the invention resides in a modified polysaccharide containing one or more amphiphilic hydrocarbon moieties, said modified polysaccharide having the following structure:
Polysac-Z 3 R 1
or
-Polysac-Z 3 R 1 -Polysac-
[0005] where
[0006] Polysac=any polysaccharide, monosaccharide, or sugar residue, modified or unmodified;
[0007] Z 3 =CH 2 , —COO—, —OOC—, —CONH—, —NHCO—, —O—, —S—, —SO 2 O—, —OCOO—, —NHCOO—, —OOCNH, —NHCONH—, —CONCO—, or any other radical capable of bridging the R 1 group to the polysaccharide backbone portion of the molecule; and
[0008] R 1 =any organofunctional group with the only limitation being that R 1 must contain a moiety consisting of an amphiphilic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with our without sulfonation, with or without hydroxylation, with or without ethoxylation or propoxylation, and having a carbon chain length of 4 or greater.
[0009] In another aspect, the invention resides in a paper sheet, such as a tissue or towel sheet, comprising a modified polysaccharide containing one or more amphiphilic hydrocarbon moieties, said modified polysaccharide having the following structure:
Polysac-Z 3 R 1
or
-Polysac-Z 3 R 1 -Polysac-
[0010] where
[0011] Polysac=any polysaccharide, monosaccharide, or sugar residue, modified or unmodified;
[0012] Z 3 =CH 2 , —COO—, —OOC—, —CONH—, —NHCO—, —O—, —S—, —SO 2 O—, —OCOO—, —NHCOO—, —OOCNH, —NHCONH—, —CONCO—, or any other radical capable of bridging the R 1 group to the polysaccharide backbone portion of the molecule; and
[0013] R 1 =any organofunctional group with the only limitation being that R 1 must contain a moiety consisting of an amphiphilic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with our without sulfonation, with or without hydroxylation, with or without ethoxylation or propoxylation, and having a carbon chain length of 4 or greater.
[0014] In another aspect, the invention resides in a method of making a paper sheet, such as a tissue or towel sheet, comprising the steps of: (a) forming an aqueous suspension of papermaking fibers; (b) depositing the aqueous suspension of papermaking fibers onto a forming fabric to form a web; and (c) dewatering and drying the web to form a paper sheet, wherein a modified polysaccharide is added to the aqueous suspension, said modified polysaccharide having the following structure:
Polysac-Z 3 R 1
or
-Polysac-Z 3 R 1 -Polysac-
[0015] where
[0016] Polysac=any polysaccharide, monosaccharide, or sugar residue, modified or unmodified;
[0017] Z 3 =CH 2 , —COO—, —OOC—, —CONH—, —NHCO—, —O—, —S—, —SO 2 O—, —OCOO—, —NHCOO—, —OOCNH, —NHCONH—, —CONCO—, or any other radical capable of bridging the R 1 group to the polysaccharide backbone portion of the molecule; and
[0018] R 1 =any organofunctional group with the only limitation being that R 1 must contain a moiety consisting of an amphiphilic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with our without sulfonation, with or without hydroxylation, with or without ethoxylation or propoxylation, and having a carbon chain length of 4 or greater.
[0019] The amount of the modified polysaccharide added to the fibers can be from about 0.02 to about 2 weight percent, on a dry fiber basis, more specifically from about 0.05 to about 1 weight percent, and still more specifically from about 0.1 to about 0.75 weight percent. The modified polysaccharide can be added to the fibers at any point in the papermaking process. A preferred addition point is where the fibers are suspended in water. However, modified polysaccharides can also be added topically to a dried paper web.
[0020] As used herein, polysaccharides are carbohydrates that can be hydrolyzed to many monosaccharides and include, but are not limited to, starches (primarily modified starches from potato, corn, waxy maize, tapioca and wheat) which can be unmodified, acid modified, enzyme modified, cationic, anionic or amphoteric;
[0021] carboxymethylcellulose, modified or unmodified; natural gums, modified or unmodified (such as from locust bean and guar); sugars, modified or unmodified; chitosan, modified or unmodified; and dextrins, modified and unmodified.
[0022] “Monosaccharide” is a carbohydrate that cannot be hydrolyzed into simpler compounds.
[0023] “Carbohydrates” are polyhydroxy aldehydes, polyhydroxy ketones or compounds that can be hydrolyzed to them.
[0024] As used herein, amphiphilic hydrocarbon moieties are organic compounds including alkanes, alkenes, alkynes and cyclic aliphatics which contain surface active agents. The amphiphilic hydrocarbons can be linear or branched, saturated or unsaturated, substituted or unsubstituted.
[0025] Methods of making paper products which can benefit from the various aspects of this invention are well known to those skilled in the papermaking art. Exemplary patents include U.S. Pat. No. 5,785,813 issued Jul. 28, 1998 to Smith et al. entitled “Method of Treating a Papermaking Furnish For Making Soft Tissue”; U.S. Pat. No. 5,772,845 issued Jun. 30, 1998 to Farrington, Jr. et al. entitled “Soft Tissue”; U.S. Pat. No. 5,746,887 issued May 5, 1998 to Wendt et al. entitled “Method of Making Soft Tissue Products”; and U.S. Pat. No. 5,591,306 issued Jan. 7, 1997 to Kaun entitled “Method For Making Soft Tissue Using Cationic Silicones”, all of which are hereby incorporated by reference.
DETAILED DESCRIPTION OF THE INVENTION
[0026] To further describe the invention, examples of the synthesis of some of the various chemical species are given below.
Polysaccharides
[0027] Starches
[0028] Unmodified starch has the structure shown in FIG. 1. Unmodified starches can differ in properties such as amylopectin: amylose ratio, granule dimension, gelatinization temperature, and molecular weight. Unmodified starches have very little affinity for fibers, and modifications are widely done to extend the number of wet end starch additives available for use. Modifications to starches generally fall under one of the following categories: 1) Physical modifications, 2) Fractionation into amylose and amylopectin components, 3) Thermomechanical conversion, 4) Acid hydrolysis, 5) Chemical modifications, 6) Oxidation, 7) Derivatization and 8) Enzyme conversion.
[0029] Starch derivatives are the most common type of dry strength additive used in the paper industry. The 1990 edition of the TAPPI publication “Commercially Available Chemical Agents for Paper and Paperboard Manufacture” lists 27 different starch dry strength products. Starch chemistry primarily centers on reactions with the hydroxyl groups and the glucosidic (C—O—C) linkages. Hydroxyl groups being subject to standard substitution reactions and the glucosidic linkages being subject to cleavage. In theory the primary alcohol at the C-6 position should be more reactive than the secondary alcohols at the C-2 and C-3 positions Also, it has been found that the tuber starches are more reactive than the cereal starches.
[0030] A large variety of starch esters and ethers have been described. Few have teen actively marketed due to non-specific properties resulting from the substitution groups. Esters will generally be prepared via reaction of the acid chloride or anhydride with the starch. Hydrophobic type structures can be introduced with this functionalization and such structures have found applications in the paper industry as adhesives, and grease resistant paper size coatings. (Starch Conversion Technology, 1985)
[0031] Cationic starches are recognized as the choice for wet end additives due to their substantivity with cellulose fibers. The cationization of starches is accomplished by reaction with various tertiary and quaternary amine reagents. In general, a reactive chloride or epoxy group on one end of the reagent reacts with a starch hydroxyl group. The cationic portion of the amine then ionizes in the presence of water to form the positively charged derivative which is substantive to fiber. Quaternary ammonium derivatives are most commonly used in the paper.
[0032] Other ionic charged starches are produced by reaction of starch with amino, imino, ammonium, sulfonium, or phosphonium groups, all of which carry an ionic charge. The key factor in their usefulness is their affinity for negatively charged substrates such as cellulose. These ionic starches have found widespread use in the paper industry as wet end additives, surface sizing agents and coating binders. Cationic starches improve sheet strength by promoting ionic bonding and additional hydrogen bonding within the cellulose fibers. Some common reagents used to prepare cationic starches include: 2-diethylaminoethyl chloride (DEC); 2-dimethylaminoethyl chloride; 2-diisopropylaminoethyl chloride; 2-diethylaminoethyl bromide; 2-dimethylaminoisopropyl chloride; N-alkyl-N-(2-haloethyl)-aminomethylphosphonic acids; and 2,3-epoxypropyltrimethylammonium chloride.
[0033] Epichlorohydrin reacts with tertiary amines or their salts in water or nonaqueous solvents to form the quaternary ammonium reagents. Trimethylamine, dimethylbenzyl amine, triethylamine, N-ethyl and N-methyl morpholine, dimethylcyclohexylamine, and dimethyidodecylamine (Paschall, E. F., U.S. Pat. No. 2,876,217, 1959 and U.S. Pat. No. 2,995,513, 1961) have been used.
[0034] Cyanamide and dialkyl cyanamides can be used to attach imino carbamate groups on starches. These groups show cationic activity upon treatment with acids. The acidified products are stable to hydrolysis. Cationic cyanamide starches show useful properties as textile sizes and dry strength additives in paper. (Chamberlain, R. J., U.S. Pat. No. 3,438,970, 1969)
[0035] Aminoethylated starches are produced by treatment of ethyleneimine with starch in organic solvents or dry. Acidified products are useful as wet end paper additives (Hamerstrand, et al, “An evaluation of cationic aminoethyl cereal flours as wet end paper additives” Tappi, 58, 112, 1975). Starches react with isatoic anhydride and its derivatives to form anthranilate esters with primary or secondary amino groups (U.S. Pat. Nos. 3,449,886; 3,511,830; 3,513,156; 3,620,913). Products with primary amino anthranilate groups can be derivatized and used to improve wet rub resistance in paper coatings.
[0036] Cationic starches containing anionic xanthate groups provided both wet strength and dry strength to paper when used as wet end additives in unbleached kraft pulp systems. (Powers, et al, U.S. Pat. No. 3,649,624, 1972). In this system it is believed that the permanent wet strength results from covalent bonding from the xanthate side chain reactions. (Cheng, W. C., et al, Die Starke, 30, 280, 1978)
[0037] Cationic dialdehyde starches are useful wet end additives for providing temporary wet strength to paper. They are produced by periodic acid oxidation of tertiary amino or quaternary ammonium starches, by treating dialdehyde starch with hydrazine or hydrazide compounds containing tertiary amino or quaternary ammonium groups, and several other reactions.
[0038] Graft copolymers of starch are widely known. Some graft copolymers made with starches include: vinyl alcohol; vinyl acetate; methyl methacrylate; acrylonitrile; styrene; acrylamide; acrylic acid; methacrylic acid; and cationic monomers with amino substituents including: 2-hydroxy-3-methacrylopropyltrimethylammonium chloride (HMAC); N,N-dimethylaminoethyl methacrylate, nitric acid salt (DMAEMA*HNO 3 ); N-t-butylaminoethyl methacrylate, nitric acid salt (TBAEMA*HNO 3 ); andN, N,N-trimethylaminoethyl methacrylate methyl sulfate (TMAEMA*MS).
[0039] Polyacrylonitrile (PAN)/starch graft copolymers are well known in the art. Treatment of the PAN/starch graft copolymers with NaOH or KOH converts the nitrile substituents to a mixture of carboxamide and alkali metal carboxylate. Such hydrolyzed starch-g-PAN polymers (HSPAN) are used as thickening agents and as water absorbents. Important applications for HSPAN include use in disposable soft goods designed to absorb bodily fluids (Lindsay, W. F., Absorbent Starch Based Copolymers—Their Characteristics and Applications, Formed Fabrics Industry, 8(5), 20, 1977).
[0040] Copolymers with water-soluble grafts are also well known. Many of the water soluble graft copolymers are used for flocculation and flotation of suspended solids in the paper, mining, oil drilling and other industries. (Burr, R. C., et al, “Starch Graft Copolymers for Water Treatment”, Die Starke, 27, 155, 1975). Graft copolymers from the cationic amine containing monomers are effective retention aids in the manufacture of filled papers. Starch-g-poly(acrylamide-co-TMAEMA*MS) was found to improve drainage rates while increasing dry tensile strength of unfilled paper handsheets. (Heath, H. D., et al, “Flocculating agent-starch blends for interfiber bonding and filler retention, comparative performance with cationic starches”, TAPPI, 57(11), 109, 1974.)
[0041] Thermoplastic-g-starch materials are also known, primarily with acrylate esters, methacrylate esters and styrene. Primary interest for these materials is in preparation of biodegradable plastics. No use of these materials as a paper additive has been found.
[0042] Other miscellaneous graft copolymers are known. Saponified starch-g-poly(vinyl acetate) has been patented as a sizing agent for cotton, rayon and polyester yarns. (Prokofeva, et al, Russian patent 451731, 1975). Graft copolymers have been saponified to convert starch-g-poly(vinyl acetate) copolymers into starch-g-poly(vinyl acetate) copolymers. As with the thermoplastic-g-starch copolymers most of these materials have been evaluated as polymeric materials in their own right and not as additives for paper.
[0043] Carboxymethyl cellulose, methylcellulose, alginate, and animal glues are superior film formers. These materials are typically applied via surface application and not added in the wet end of the process to improve dry strength. The products are relatively expensive and although they can be used alone they are typically employed in conjunction with starches or other materials.
[0044] Gums:
[0045] Gums and mucilages use in papermaking dates back to ancient China. These mucilages were obtained from various plant roots and stems and were used primarily as deflocculating and suspending agents for the long fibered pulps. As papermaking evolved other advantages of using these materials became obvious including the ability of these materials to hold the wet fiber mat together during the drying process. As papermaking evolved to using shorter and shorter fibers these gums found increased use as a means of obtaining paper strength. Since World War II the use of gums in papermaking has increased substantially.
[0046] Water soluble, polysaccharide gums are highly hydrophilic polymers having chemical structures similar to cellulose. The main chain consists of β-1,4 linked mannose sugar units with occurrence of α-1,6 linked galactose side chains. Their similarity to cellulose means they are capable of extensive hydrogen bonding with fiber surfaces. Further enhancement of dry strength occurs due to the linear nature of the molecules.
[0047] They are vegetable gums and include as examples 1) locust bean gum, 2) guar gum, 3) tamarind gum, and 4) karaya, okra and others. Locust bean gum and guar gum are the most commonly used. They have been used in the paper industry since just prior to WWII. Since the natural materials are non-ionic they are not retained on fibers to any great extent. All successful commercial products have cationic groups attached to the main chain which increases the retention of the gums on the fiber surfaces. Typical addition rates for these materials are on the order of 0.1-0.35%.
[0048] The dry strength improvement of paper furnishes through use of polysaccharide gums is derived from the linear nature of the polymer and through hydrogen bonding of the hydroxyl hydrogen of the polymer with similar functional groups on the surface of the cellulosic fibers.
[0049] The most effective gums are quaternary ammonium chloride derivatives containing a cationic charge. The cationic functionality will help the gum retain better to the fibers as well as reducing the usually higher negative zeta potential of the paper furnish, especially when fillers and fines are present in the white water. This change in zeta potential leads to a more thorough agglomeration of the fines in the system by forming more cohesive flocs. These in turn are trapped by longer fibers filling the voids among the larger fibers with additional material that helps in the inter fiber bonding of the wet web, which in turn leads to dry strength improvement.
[0050] Although a variety of guar gum derivatives have been prepared, there are only three dervivatizations which have achieved commercial significance. These are 1) Quaternization, 2) Carboxymethylation and 3) Hydroxypropylation. FIG. 3 shows the structure of guar gum and derivatives.
[0051] Chitosan
[0052] Chitosan is a high molecular weight linear carbohydrate composed of β-1,4-linked 2-amino-2-deoxy-D-glucose units. It is prepared from the hydrolysis of the N-acetyl derivative called chitin. Chitin is isolated in commercial quantities from the shells of crustaceans. Chitin is insoluble in most common solvents, however, chitosan is soluble in acidified water due to the presence of basic amino groups. Depending on the source and degree of deacetylation chitosans can vary in molecular weight and in free amine content. In sufficiently acidic environments the amino groups become protonated and chitosan behaves as a cationic polyelectrolyte. It has been reported that chitosans increase the dry strength of paper more effectively than other common papermaking additives including the polyethylenimines and polyacrylamides.
[0053] Chitosan and starch are both polymers of D-glucose but differ in two aspects. First, chitosan has an amino group on each glucose unit and therefore has a stronger cationic character than cationic starch. Secondly, starch differs in its molecular configuration. Starch contains amylopectin which has a three dimensional molecular structure and amylose, which has linear macromolecules. The glucose molecules of starch have an α-configuration which gives the molecules a helical form. Chitosan resembles cellulose and xylans in that it has β-linked D-monosaccharide units and tends to have straight molecular chains. The functionally reactive groups of a straight Polymer molecule are more easily accessible than those of a branched, random configuration molecule and are expected to interact more effectively with the polar groups on cellulose. FIG. 4 shows the structure of chitosan.
[0054] Sugars
[0055] Also included in the saccharides are the simple sugars. These include the hexoses shown in FIG. 5. These compounds actually exist in the cyclic acetal form as shown in FIG. 6 for glucose. Derivatives of these sugars are included within this definition. Such derivatives include but are not limited to things such as gluconic acid, mucic acid, mannitol, sorbitol, etc. The derivatives generally do not exist in cyclic form.
[0056] Amphiphilic Hydrocarbon Moieties
[0057] Amphiphilic hydrocarbon moieties are a group of surface active agents (surfactants) capable of modifying the interface between phases. Surfactants are widely used by the industry for cleaning (detergency), solubilizing, dispersing, suspending, emulsifying, wetting and foam control. In the papermaking industry, they are often used for deinking, dispersing and foam control. They have an amphiphilic molecular structure: containing at least one hydrophilic (polar) region and at least one lipophilic (non-polar. hydrophobic) region within the same molecule. When placed in a given interface, the hydrophilic end leans toward the polar phase while the lipophilic end orients itself toward the non polar phase.
[0058] The hydrophilic end can be added to a hydrophobe synthetically to create the amphiphilic molecular structure. The following is a schematic pathway for making a variety of surfactants:
[0059] Based on the charge, surfactants can be grouped as amphoteric, anionic, cationic and nonionic.
[0060] First with regard to the amphoteric surfactants, the charges on the hydrophilic end change with the environmental pH: positive in acidic pH, negative at high pH and become zwitterions at the imtermediate pH. Surfactants included in this category include alkylamido alkyl amines and alkyl substituted amino acids.
[0061] Structure commonly shared by alkylamido alkyl amines:
[0062] where
[0063] R 0 =a C 4 or higher alkyl or aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted
[0064] n≧2
[0065] R 1 =hydroxy or carboxy ended alkyl or hydroxyalkyl groups, C chain ≧2C, with or without ethoxylation, propoxylation or other substitution.
[0066] Z=H or other cationic counterion.
[0067] Structure shared commonly by alkyl substituted amino acids:
R 1 —NR′ 2 Z
[0068] where
[0069] R 1 =alkyl or aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, C chain ≧4C,
[0070] n≧2,
[0071] Z=H or other cationic counterion
[0072] R′=carboxylic end of the amino acid.
[0073] With regard to the anionics, the hydrophilic end of the surfactant molecule is negatively charge. Anionics consist of five major chemical structures: acylated amino acids/acyl peptides, carboxylic acids and salts, sulfonic acid derivatives, sulfuric acid derivatives and phosphoric acid derivatives.
[0074] Structure commonly shared by acylated amino acids and acyl peptides:
R 0 OCO—R 1 —COOZ
or
HOOC—R 1 —COOZ
[0075] where
[0076] R 0 =alkyl or aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, C chain ≧4C,
[0077] R 1 =alkyl substituted amino acid moiety; or —NH—CHX—CO) n —H—CHX—
[0078] where n≧1, X=amino acid sidechain; or alkyl-NHCOR′ where R′=aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, C chain ≧4C
[0079] Z=H or other cationic counterion Structure commonly shared by carboxylic acid and salts-.
R—COOZ
[0080] where:
[0081] R=alkyl or aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, C chain ≧4C.
[0082] Z=H or other cationic counterion
[0083] Structure commonly shared by sulfonic acid derivatives:
RCO—NR 1 —(CH 2 ) n —SO 3 Z
or
alkyl aryl-SO 3 Z
or
R—SO 3 Z
or
ROOC—(CH 2 ) n —CHSO 3 —COOZ
or
[RCO—NH—(OCH 2 ) n —OOC—CHSO 3 —COO]2Z
or
R(OCH 2 CH 2 ) n —SO 3 Z
[0084] where
[0085] R=alkyl or aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with or without sulfonation, with or without hydroxylation, C chain ≧4C;
[0086] R 1 =alkyl or hydroxy alkyl, C chain ≧1 C;
[0087] n≧1;
[0088] Z=H or other counterion.
[0089] Structure commonly shared by sulfuric acid derivatives:
R—OSO 3 Z
[0090] where
[0091] R=aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with or without sulfonation, with or without hydroxylation, with or without ethoxylation or propoxylation, C chain ≧4C
[0092] Z=H or other counterion.
[0093] Structure commonly shared by phosphoric acid derivatives:
R—OPO 3 Z
[0094] where
[0095] R=aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with or without sulfonation, with or without hydroxylation, with or without ethoxylation or propoxylation, C chain ≧4C
[0096] Z=H or other counterion.
[0097] With regard to the cationics, these are surfactants with a positively charged nitrogen atom on the hydrophobic end. The charge may be permanent and non pH dependent (such as quaternary ammonium compounds) or pH dependent (such as cationic amines). They include alkyl substituted ammonium salts, heterocyclic ammonium salts, alkyl substituted imidazolinium salts and alkyl amines.
[0098] Structure commonly shared by this group:
N + R 4 Z −
[0099] where:
[0100] R=H, alkyl, hydroxyalkyl, ethoxylated and/or propoxylation alkyl, benzyl, or aliphatic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with or without sulfonation, with or without hydroxylation, with or without carboxylation, with or without ethoxylation or propoxylation, C chain ≧4C
[0101] Z=H or other counterion.
[0102] With regard to the nonionics, in this group the molecule has no charge. The hydrophilic end often contains a polyether (polyoxyethylene) or one or more hydroxyl groups. They generally include alcohols, alkylphenols, esters, ethers, amine oxides, alkylamines, alkylamides, polyalkylene oxide block copolymers.
Modified Polysaccharides Containing Amphiphilic Hydrocarbons
[0103] Two primary methods are envisioned for incorporating amphiphilic moieties into the polysaccharide based materials. In the first scheme the amphiphilic moieties are added via reaction between a functional group on the polysaccharide and a second functional group attached to the reagent containing the amphiphilic moiety. The polysaccharides may be derivatized or non-derivatized, cationic or non-cationic. The general reaction scheme is defined as follows:
Polysac-Z 1 +Z 2 -R 1 →Polysac-Z 3 R 1
[0104] where:
[0105] Z 1 =functional group attached to the polysaccharide molecule and may be present either from the natural state or from a derivatization process. Examples of Z 1 functional groups include but are not limited to —OH, —H 2 , —COOH, —CH 2 X (X=halogen), —CN, —CHO, —CS 2 .
[0106] Z 2 Functional group attached to the R 1 moiety whose purpose is to react with a Z 1 functional group thereby attaching the R 1 moiety covalently to the polysaccharide.
[0107] Z 3 =Bridging ligand formed as a result of reaction of Z 1 with Z 2 .
[0108] R 1 =any organofunctional group with the only limitation being that R 1 must contain a moiety consisting of an amphiphilic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with our without sulfonation, with or without hydroxylation, with or without ethoxylation or propoxylation, C chain ≧4 carbons.
[0109] Such materials in general will have a macroscopic structure as shown in FIG. 7 where the amphiphilic moieties are attached in a pendant fashion to the polysaccharide. Where decreased water solubility becomes an issue a second moiety; containing only a hydrophylic portion may be attached to the polysaccharide. Examples of such materials would include ethylene glycol and its oligomers and polymers.
[0110] In theory the Z 2 -R 1 reactant could be difunctional of the form Z 2 -R 2 -Z 2 , however, in the case of high molecular weight polysaccharides this crosslinking could lead to water insoluble products, suitable for coatings but not useful for wet end applications.
[0111] Synthesis of modified polysaccharides similar to those in FIG. 7 could be prepared via a number of methods. Attachment of the amphiphilic hydrocarbon moiety could be achieved via the following paths:
[0112] (1) Modified cationic polysaccharides prepared via reaction with one of the following or similar reagents:
[0113] Where R 1 , R 2 , R 3 are any alkyl groups, chosen such that at least one of R 1 , R 2 , or R 3 is an amphiphilic hydrocarbon, normal or branched, saturated or unsaturated, substituted or unsubstituted, with or without esterification, with or without etherification, with our without sulfonation, with or without hydroxylation, with or without ethoxylation or propoxylation, C chain ≧4 carbons.
[0114] (2) Dialdehyde polysaccharides, particularly dialdehyde starches, cationic or non-cationic, modified with fatty acid groups via reaction of the aldehyde groups with alcohols, amines, sulfinic acids, sulfyhydryl compounds and the like containing a linear or branched, saturated or unsaturated, substituted or non-substituted C 8 or higher aliphatic hydrocarbon moiety.
[0115] Ethoxylated fatty acid derivatives of the form:
HO—(CH 2 CH 2 O) n R 6
[0116] where R 6 is an organofunctional radical containing a linear or branched, saturated or unsaturated, substituted or non-substituted C 8 or higher aliphatic hydrocarbon moiety, can be used to directly incorporate amphiphilic functionality onto the polysaccharide backbone as shown by example in FIG. 8.
[0117] (3) Direct reaction of a functionalized linear or branched, saturated or unsaturated, substituted or non-substituted amphiphilic hydrocarbon moiety with the hydroxyl or amine groups on the polysaccharide. An example of such a reaction is shown in FIG. 9 for chitosan:
[0118] (4) Graft polymerization of hydrophobic and or hydrophilic units onto the polysaccharide backbone. Modified vinyl monomers are capable of being grafted onto polysaccharide backbones as has been demonstrated for various starches. Use of modified vinyl monomers such as:
[0119] where.
[0120] R 2 =H, C 1-4 alkyl.
[0121] R 4 =Z 2 -R 6 where:
[0122] Z 2 =Ar, CH 2 , COO—, CONH—, —O—, —S—, —OSO 2 O—, —CONHCO—, —CONHCHOHCHOO—, any radical capable of bridging the R 6 group to the vinyl backbone portion of the molecule.
[0123] R 6 =any aliphatic, linear or branched, saturated or unsaturated, substituted or non-substituted amphiphilic hydrocarbon.
[0124] In the second scheme the amphiphilic hydrocarbon moieties are added via reaction between a functional group on the polysaccharide and a second functional group attached to the reagent containing the amphiphilic hydrocarbon moiety, however in this case two functional groups are attached to amphiphilic hydrocarbon containing reagent. The polysaccharides may be derivatized or non-derivatized, cationic or non-cationic. The general reaction scheme is defined as follows:
Polysac-Z 1 +Z 2 -R 1 -Z 2 →Polysac-Z 3 R 1 -Polysac-
[0125] where:
[0126] Z 1 =functional group attached to the polysaccharide molecule and may be present either from the natural state or from a derivatization process. Examples of Z 1 functional groups include but is not limited to —OH, —NH 2 , —COOH, —CH 2 X (X=halogen), —CN, —CHO, —CS 2 .
[0127] Z 2 =Functional group attached to the R 1 moiety whose purpose is to react with a Z 1 functional group thereby attaching the R 1 moiety covalently to the polysaccharide.
[0128] R 1 =any organofunctional group with the only limitation being that R 1 must contain a moiety consisting of a saturated or unsaturated, substituted or unsubstituted, linear or branched amphiphilic hydrocarbon.
[0129] Such materials in general will have a macroscopic structure as shown in FIG. 10 where the amphiphilic moieties are attached in series to the polysaccharide molecules.
[0130] In theory the polysaccharides could be of high molecular weight, however, the crosslinking would be expected to lead to water insoluble products, suitable perhaps for coatings but not useful for wet end applications. For wet end applications, lower molecular weight polysaccharides including the oligomers as well as the monosaccharides are better candidates for this approach.
[0131] Synthesis of modified polysaccharides similar to those in FIG. 10 could be prepared via a number of methods. A few specific examples follow:
[0132] 1) Reaction with diacids or diacid halides of the formula:
[0133] where:
[0134] Z=OH, halogen, other displaceable group.
[0135] Y=any residue chosen such that Y contains an amphiphilic moiety.
[0136] The displaceable groups on the reactants can react with either primary —OH or —NH2 groups on the saccharide to form the corresponding ester or amide.
[0137] 2) Reaction between dialdehyde polysaccharides, cationic or non-cationic and residues chosen from the group of difunctional amphiphilic hydrocarbons where these residues are incorporated into the polysaccharide via reaction with the aldehyde groups on the starch. An example is shown in FIG. 11.
[0138] It will be appreciated that the foregoing examples, given for purposes of illustration, shall not be construed as limiting the scope of this invention, which is defined by the following claims and all equivalents thereto.
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Modified polysaccharides (such as starches, gums, chitosans, celluloses, alginates, sugars, etc.), which are commonly used in the paper industry as strengthening agents, surface sizes, coating binders, emulsifiers and adhesives, can be combined into a single molecule with amphiphilic hydrocarbons (e.g. surface active agents) which are commonly utilized in the paper industry to control absorbency, improve softness, enhance surface feel and function as dispersants. The resulting molecule is a modified polysaccharide having surface active moieties which can provide several potential benefits, depending on the specific combination employed, including: (a) strength aids that do not impart stiffness; (b) softeners that do not reduce strength; (c) wet strength with improved wet/dry strength ratio; (d) debonders with reduced tinting and sloughing; (e) strength aids with controlled absorbency; and (g) surface sizing agents with improved tactile properties.
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BACKGROUND OF THE INVENTION
The present invention relates to wireless technology, and more specifically to a low energy wireless proximity pairing.
In general, Bluetooth wireless technology is a wireless communications system intended to replace the cables connecting electronic devices. Bluetooth low energy wireless technology includes ultra-low peak, average and idle power consumption, an ability to run for years on standard coin-cell batteries, low cost, multi-vendor interoperability and enhanced range. Reduced power consumption means longer battery life. Bluetooth is the link normally used to transport signals in operation, for example audio signals. Bluetooth LE is normally used to transport short pieces of information, for example telemetry signals. Bluetooth and Bluetooth LE use different radios; we refer to a device having both Bluetooth and Bluetooth LE radios as Bluetooth-enabled. In order for two devices to communicate over Bluetooth, they must first be paired. A pairing sequence between two Bluetooth devices requires power consumption, user setup actions on both devices, and time for the Bluetooth devices to discover each other. Bluetooth LE can be used to improve the pairing process by reducing power consumption, simplifying the user actions, and reducing the time for two Bluetooth-enabled devices to discover each other.
SUMMARY OF THE INVENTION
The following presents a simplified summary of the innovation in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is intended to neither identify key or critical elements of the invention nor delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
In a general aspect, an approach disclosed herein provides a way of pairing (e.g., establishing a wireless communication link between) a peripheral with a host device without requiring manual intervention to initiate or establish a pairing mode and/or limiting potential unintended pairing with distant host devices. By limiting initiation of pairing to situations in which the peripheral is in proximity of (e.g., directly adjacent to, within 2 cm of) the host undesired pairing with other hosts is avoided. The requirement for proximity to initiate pairing further provides a degree of security and/or privacy by avoiding such undesired pairing. Furthermore, by requiring proximity of the peripheral device and host device, substantially lower power is needed for the broadcasts by the peripheral than if longer-distance pairing was enabled, thereby conserving power (e.g., in a battery powered peripheral) and potentially reducing radio interference caused by the peripheral. In some examples, the peripheral further reduces power consumption and inadvertent pairing by limiting broadcasts according to particular operating modes, for instance, in an initial power-up mode extending from power-up by a fixed time duration. Lastly, pairing based upon proximity appeals to physical intuition of the end user, resulting in a better user experience.
In general, in one aspect, the invention features a method of pairing devices including causing a Bluetooth-enabled host device and a Bluetooth-enabled peripheral device to be located proximate to each other, the Bluetooth-enabled host device including at least a processor, a memory and an antenna, in the Bluetooth-enabled host device, detecting advertising packets broadcast by the Bluetooth-enabled peripheral device on one or more of a plurality of advertising channels, saving a numeric indicator of each of multiple detected advertising packets, determining an average numeric indicator from the saved numeric indicators of each of the separately detected advertising packets, if the average numeric indicator exceeds a proximity threshold, determining whether a set of conditions are met, and initiating a Bluetooth device pairing sequence between the Bluetooth-enabled host device and the Bluetooth-enabled peripheral device if the set of conditions are met.
Implementations may include, and are not limited to, one or more of the following features. The method may further include completing the Bluetooth device pairing sequence using information in one of the advertising packets.
The proximity threshold may be dependent upon a type of Bluetooth-enabled peripheral device and/or upon a type of Bluetooth-enabled host device.
Each of the advertising packets may be a non-connectable undirected packet containing a field containing a Bluetooth address of the Bluetooth-enabled peripheral device and a field containing an Extended Inquiry Response (EIR) record of the type Tx Power Level containing a predefined value for transmit power (T x Power) of the Bluetooth-enabled peripheral device. The Bluetooth address used by the Bluetooth LE radio is the device address of the Bluetooth radio of the Bluetooth-enabled peripheral device. The predefined value of T x Power of the Bluetooth-enabled peripheral device may be a number not ending in 0 or 5 to indicate to a Bluetooth-enabled host device that the Bluetooth-enabled peripheral device is a proximity pairing device.
The numeric indicator may be a received signal strength indicator (RSSI) of each of the separately detected advertising packets, a highest RSSI of the separately detected advertising packets or a RSSI of a first one of the detected advertising packets.
The set of conditions may include an average RSSI that is greater than the proximity threshold value for 500 milliseconds (ms) and a pre-populated transmit power (T x Power) in the non-connectable undirected packet of Bluetooth-enabled peripheral device that equals −21 dBm.
The Bluetooth-enabled host device may be a smartphone, a tablet computer, a personal computer, a laptop computer, a notebook computer, a netbook computer, a radio, an audio system, an Internet Protocol (IP) phone, a communication system, an entertainment system, a headset and a speaker.
The Bluetooth-enabled peripheral device may be a headphone, a headset, an audio speaker, an entertainment system, a communication system and a smartphone.
In one aspect, the invention features a Bluetooth-enabled peripheral device including a radio transceiver, a baseband unit, a software stack, the software stack configured to advertise using a non-connectable undirected packet (ADV_NONCONN_IND PDU) in all three Bluetooth advertising channels, the non-connectable undirected packet including a field containing a Bluetooth address of the Bluetooth-enabled peripheral device and a field containing an Extended Inquiry Response (EIR) record of a type T x Power Level containing a predefined value for transmit power (T x Power) of the Bluetooth-enabled peripheral device.
Implementations may include, and are not limited to, one or more of the following features. The predefined T x Power of the Bluetooth-enabled peripheral device may be a number not ending in 0 or 5 to indicate to a Bluetooth-enabled host device that the Bluetooth-enabled peripheral device is a proximity pairing device.
These and other features and advantages will be apparent from a reading of the following detailed description and a review of the associated drawings. It is to be understood that both the foregoing general description and the following detailed description are explanatory only and are not restrictive of aspects as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood by reference to the detailed description, in conjunction with the following figures, wherein:
FIG. 1 is a block diagram of an exemplary Bluetooth system.
FIG. 2 is a flow diagram of a Bluetooth Low Energy (BLE) proximity process.
DETAILED DESCRIPTION
The subject innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It may be evident, however, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the present invention.
As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A, X employs B, or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. Moreover, articles “a” and “an” as used in the subject specification and annexed drawings should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form.
As shown in FIG. 1 , an exemplary system 10 includes a Bluetooth-enabled host device 15 and a Bluetooth-enabled peripheral device 20 . Example Bluetooth-enabled host devices 15 , include, but are not limited to, a smartphone, a tablet computer, a personal computer, a laptop computer, a notebook computer, a netbook computer, a radio, an audio system, an Internet Protocol (IP) phone, a communication system, an entertainment system, a headset, a speaker, and so forth. Example Bluetooth-enabled peripheral devices 20 include, but are not limited to, a headphone, a headset, an audio speaker, an entertainment system, a communication system, a smartphone, and so forth. A Bluetooth-enabled device as described herein may change its role from host to peripheral or peripheral to host depending on a specific application.
The Bluetooth-enabled host device 15 can include a controller 25 , a power manager 30 , a memory 35 , and a communication unit 40 . The communication unit 40 includes a Bluetooth module 45 .
The controller 25 controls the general operation of the Bluetooth-enabled host device 15 . For example, the controller 25 performs a process and control for audio and data communication. In addition to the general operation, the controller 25 initiates a Bluetooth function implemented in the Bluetooth module 45 upon detecting certain events, fully described below. The controller 25 initiates an operation (e.g., pairing) necessary for a Bluetooth connection of the Bluetooth-enabled host device 15 and the Bluetooth-enabled peripheral device 20 if specific conditions are satisfied.
The memory 35 may include a Read Only Memory (ROM), a Random Access Memory (RAM), and a flash ROM. The ROM stores a microcode of a program for processing and controlling the controller 25 and a variety of reference data.
The RAM stores data generated during execution of any of the variety of programs performed by the controller 25 . The RAM (or ROM) includes a Bluetooth Low Energy (BLE) proximity process 100 , fully described below. The flash ROM stores various updateable data for safekeeping such as a phone book, outgoing messages, incoming messages and the like.
The Bluetooth module 45 enables a wireless connection using Radio Frequency (RF) communication between the Bluetooth-enabled host device 15 and the Bluetooth-enabled peripheral device 20 . The Bluetooth module 45 exchanges a radio signal including data input/output through an antenna (not shown). For example, in a transmission mode, the Bluetooth module 45 processes data by channel coding and spreading, converts the processed data into a Radio Frequency (RF) signal and transmits the RF signal. In a reception mode, the Bluetooth module 45 converts a received RF signal into a baseband signal, processes the baseband signal by de-spreading and channel decoding and restores the processed signal to data.
The Bluetooth-enabled peripheral device 20 can include a controller 50 , a memory 55 , and a communication unit 60 having a Bluetooth module 65 .
The controller 50 controls a general operation of the Bluetooth-enabled peripheral device 20 .
The Bluetooth module 65 enables a wireless connection using RF communication. The memory 55 stores a microcode of a program for processing and controlling the controller 50 and a variety of reference data. The Bluetooth module 65 exchanges data for a communication connection with the Bluetooth module 45 of the Bluetooth-enabled host device 15 .
In general, the Bluetooth module 45 and Bluetooth module 65 include Bluetooth radios and additional circuitry. More specifically, the Bluetooth module 45 of the Bluetooth-enabled host device 15 and the Bluetooth module 65 of the Bluetooth-enabled peripheral device 20 include both a Bluetooth radio and a Bluetooth LE (BLE) radio. The Bluetooth radio and the BLE radio are typically on the same integrated circuit (IC) and share a single antenna, while in other implementations the Bluetooth radio and BLE radio are implemented as two separate ICs sharing a single antenna or as two separate ICs with two separate antennae.
The Bluetooth specification, i.e., Bluetooth 4.0: Low Energy, provides the Bluetooth-enabled peripheral device 20 with forty channels on 2 MHz spacing. The forty channels are labeled 0 through 39 , which include 3 advertising channels and 37 data channels. The channels labeled as 37 , 38 and 39 are designated as advertising channels in the Bluetooth specification while the remaining channels 0 - 36 are designated as data channels in the Bluetooth specification.
In a preferred embodiment, an actual transmit power of the BLE radio of the Bluetooth-enabled peripheral device 20 is set to be a negative dBm to reduce a range over which a signal from Bluetooth-enabled peripheral device 20 is detected by the Bluetooth-enabled host device 15 .
A value reported as T x Power of the Bluetooth-enabled peripheral device 20 is further selected to have a value in dBm not ending in 0 or 5 to indicate to the Bluetooth-enabled host device 15 that this Bluetooth-enabled peripheral device 20 is a proximity pairing device. Although this is not enough information for the Bluetooth-enabled host device 15 to verify for certain that Bluetooth-enabled peripheral device 20 is a proximity pairing device, it is a good indication because traditionally Bluetooth Low Energy (BLE) devices are set to a transmit power of 0 dBm or +10 dBm and report that set value as Tx Power, for example.
In traditional BLE devices, the ADV_NONCONN_IND (non-connectable undirected packet) PDU (Packet Data Unit) can be used in advertising channels and includes AdvA and AdvData fields. The AdvA field contains the advertiser's public or random device address as indicated by PDU Type and the AdvData field may contain Advertising Data from the advertiser's host.
In the present invention, the Bluetooth-enabled peripheral device 20 advertising packet includes the AdvA and AdvData fields. Field AdvA, the Bluetooth-enabled peripheral device's 20 address, is set to BD_ADDR, the address of the Bluetooth radio of the Bluetooth-enabled peripheral device 15 . Field AdvData is set to an Extended Inquiry Response (EIR) record of T x Power, with T x Power set to, for example, −21 dBm, regardless of the actual transmit power of the Bluetooth-enabled peripheral device 20 . In various implementations, the predefined T x Power can be any pre-agreed upon number between the Bluetooth-enabled host device 15 and the Bluetooth-enabled peripheral device 20 that would typically be a negative number not ending in 0 or 5.
The Bluetooth-enabled peripheral device 20 is configured to advertise using the ADV_NONCONN_IND PDU on all three advertising channels, i.e., channels 37 , 38 and 39 , sequentially at a rate of 100 ms. Advertising on all three channels constitutes one advertising event. The peripheral may also be configured to advertise on just one or two channels within one advertising event.
As shown in FIG. 2 , the Bluetooth Low Energy (BLE) proximity process 100 includes scanning ( 105 ) for advertising packets periodically, e.g., every 100 ms.
When an advertising packet is detected, the BLE proximity process 100 stores ( 110 ) a Received Signal Strength Indicator (RSSI) in decibels (dB) in any of the following three ways. First, a RSSI of each packet received on each of the three advertising channels is saved. Or second, a highest RSSI of the three packets received in one advertising event can be saved. Or third, a RSSI from only one packet in no deterministic order may be saved.
The BLE proximity process 100 calculates ( 115 ) a geometric average of RSSIs over three advertising events from same AdvA.
The BLE proximity process 100 determines ( 120 ) whether the calculated RSSI average is greater than a proximity threshold. If so, the device originating the advertising events is considered in proximity. Proximity generally refers to a separation distance between the Bluetooth-enabled host device 10 and the Bluetooth-enabled peripheral device 20 . This separation distance is typically less than 20 centimeters (cm), and preferably 2 cm or less. In implementations, once proximity is established, i.e., proximity=TRUE, the BLE proximity process 100 may change the proximity threshold so that the Bluetooth-enabled peripheral device would have to move further away from the Bluetooth-enabled host device before proximity becomes FALSE.
Once the BLE proximity process 100 determines that the Bluetooth-enabled peripheral device 20 is in proximity, the BLE proximity process 100 initiates ( 125 ) a Bluetooth device pairing sequence between the Bluetooth-enabled host device 15 and the Bluetooth-enabled peripheral device 20 if a set of conditions are met. Initiating ( 125 ) the Bluetooth device pairing sequence can include waiting for an input from a user. Initiating ( 125 ) the Bluetooth device pairing sequence can include a handshake with the Bluetooth controller 25 to indicate TRUE for proximity and a passing along the BD_ADDR of the Bluetooth-enabled peripheral device 20 by extracting it from AdvA of the ADV_NONCONN_IND PDU received from the Bluetooth-enabled peripheral device 20 . The Bluetooth controller 25 can then decide whether to initiate pairing or perform one or more associated actions, such as seeking user permission to pair. If the Bluetooth controller 25 decides to initiate pairing, the Bluetooth controller 25 can use BD_ADDR to skip an Inquiry phase of pairing and go directly to a Page phase of pairing.
The set of conditions include the RSSI remaining above the proximity threshold for 500 ms, reported T x Power of the Bluetooth-enabled peripheral device equaling −21 dBm in AdvData, and the ADV_NONCONN_PDU being used in the advertising channels.
The above description provides an embodiment that is compatible with BLUETOOTH SPECIFICATION Version 4.0 [Vol 0], 30 Jun. 2010. However it should be understood that the approach is equally applicable to other wireless protocols (e.g., non-Bluetooth, future versions of Bluetooth, and so forth) in which communication channels are selectively established between pairs of stations. Furthermore, although certain embodiments are described above as not requiring manual intervention to initiate pairing, in some embodiments manual intervention may be required to complete the pairing (e.g., “Are you sure?” presented to a user of the host device), for instance to provide further security aspects to the approach.
In some implementations, the host-based elements of the approach are implemented in a software module (e.g., an “App”) that is downloaded and installed on the host (e.g., a “smartphone”), in order to provide the pairing capability according to the approaches described above. In some instances, this software module is particularly tailored to a particular peripheral, peripheral type, peripheral manufacturer, and so forth, thereby limiting pairing further, which may provide a further security aspect to the approach.
While the above describes a particular order of operations performed by certain embodiments of the invention, it should be understood that such order is exemplary, as alternative embodiments may perform the operations in a different order, combine certain operations, overlap certain operations, or the like. References in the specification to a given embodiment indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic.
While given components of the system have been described separately, one of ordinary skill will appreciate that some of the functions may be combined or shared in given instructions, program sequences, code portions, and the like.
The foregoing description does not represent an exhaustive list of all possible implementations consistent with this disclosure or of all possible variations of the implementations described. A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the systems, devices, methods and techniques described here. Accordingly, other implementations are within the scope of the following claims.
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A method of pairing devices includes causing a Bluetooth-enabled host device and a Bluetooth-enabled peripheral device to be located proximate to each other, the Bluetooth-enabled host device comprising at least a processor, a memory and an antenna, in the Bluetooth-enabled host device, detecting advertising packets broadcast by the Bluetooth-enabled peripheral device on one or more of a plurality of advertising channels, saving a numeric indicator of each of multiple detected advertising packets, determining an average numeric indicator from the saved numeric indicators of each of the separately detected advertising packets, if the average numeric indicator exceeds a proximity threshold, determining whether a set of conditions are met, and initiating a Bluetooth device pairing sequence between the Bluetooth-enabled host device and the Bluetooth-enabled peripheral device if the set of conditions are met.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a transgenic C. elegans which expresses an amyloid precursor protein (APP) or a part thereof, to the transgene itself, to the protein encoded by the transgene, and also to a process for preparing the transgenic C. elegans and to its use.
2. Description of Related Art
Several publications are referenced in the application. These references describe the state of the art to which this invention pertains, and are incorporated herein by reference.
Alzheimer's disease (morbus Alzheimer) is a neurodegenerative disorder of the brain which, at the cellular level, is accompanied by a massive loss of neurons in the limbic system and in the cerebral cortex. At the molecular level, it is possible to detect protein depositions, so-called plaques, in the affected areas of the brain, which depositions constitute an important feature of Alzheimer's disease. The protein which most frequently occurs in these plaques is a peptide of from 40 to 42 amino acids in size which is termed the Aβ peptide. This peptide is a cleavage product of a substantially larger protein of from 695 to 751 amino acids, the so-called amyloid precursor protein (APP).
APP is an integral transmembrane protein which traverses the lipid double layer once. By far the largest part of the protein is located extracellularly, while the shorter C-terminal domain is directed into the cytosol (FIG. 1 ). The Aβ peptide is shown in dark gray in FIG. 1 . About two thirds of the Aβ peptide are derived from the extracellular domain of APP and about one third from the transmembrane domain.
In addition to the APP which is located in the membrane, it is also possible to detect a secreted form of the amyloid precursor protein, which form comprises the large ectodomain of the APP and is termed APPsec (“secreted APP”). APPsec is formed from APP by proteolytic cleavage which is effected by α-secretase. The proteolytic cleavage takes place at a site in the amino acid sequence of APP which lies within the amino acid sequence of the Aβ peptide (after amino acid residue 16 of the Aβ peptide). Proteolysis of APP by the α-secretase consequently rules out the possibility of the Aβ peptide being formed.
The Aβ peptide can consequently only be formed from APP by an alternative processing route. It is postulated that two further proteases are involved in this processing route, with one of the proteases, which is termed β-secretase, cutting the APP at the N terminus of the Aβ peptide and the second protease, which is termed γ-secretase, releasing the C terminus of the Aβ peptide (Kang, J. et al., Nature, 325, 733) (FIG. 1 ).
It has not as yet been possible to identify any of the three secretases or proteases (α-secretase, β-secretase and γ-secretase). However, knowledge of the secretases is of great interest, in particular within the context of investigations with regard to Alzheimer's disease and with regard to identifying the proteins involved, which proteins can then in turn be employed as targets in follow-up studies since, on the one hand, inhibition of the β-secretase, and in particular of the γ-secretase, could lead to a decrease in Aβ production and, on the other hand, activation of the α-secretase would increase the processing of APP into APPsec and thereby simultaneously reduce formation of the Aβ peptide.
There is a large amount of evidence that the Aβ peptide is a crucial factor in the development of Alzheimer's disease. Inter alia, Aβ fibrils are postulated to be neurotoxic in cell culture (Yankner, B. A. et al., (1990) Proc Natl Acad Sci USA,87, 9020). Furthermore, the neuropathology which is characteristic of Alzheimer's disease already appears at the age of 30 in Down's syndrome patients, who have an additional copy of APP. In this case, it is assumed that overexpression of APP is followed by an increased conversion into the Aβ peptide (Rumble, B. et al., (1989), N. Engl. J. Med., 320,1446).
The familial forms of Alzheimer's disease constitute what is probably the most powerful evidence of the central role of the Aβ peptide. In these forms, there are mutations in the APP gene around the region of the β-secretase and γ-secretase cleavage sites or in two further AD-associated genes (presenilins) which, in cell culture, lead to a substantial increase in Aβ production (Scheuner, D. et al., (1996), Nature Medicine, 2, 864).
While C. elegans has already been used as a model organism in Alzheimer's disease, these studies do not relate to the processing of APP into the Aβ peptide. Some of the studies are concerned with two other Alzheimer-associated proteins, i.e. the presenilins. The presenilins are transmembrane proteins which traverse the membrane 6-8 times. They are of great importance in familial cases of Alzheimers since specific mutations in the presenilin genes lead to Alzheimer's disease. In this connection, it was shown that homologs to the human presenilins (sel-12, spe-4 and hop-1) are present in C. elegans , with the function of the presenilins being conserved in humans and worm (Levitan D, Greenwald I (1995) Nature 377, 351; Levitan et al.(1996) Proc Natl Acad Sci USA, 93, 14940; Baumeister R (1997) Genes & Function 1, 149; Xiajun Li and Iva Greenwald (1997) Proc Natl Acad Sci USA, 94, 12204).
Other studies deal with the APP homolog in C. elegans , which is termed Apl-1, and with expression of the Aβ peptide in C. elegans . However, Apl-1 does not possess any region which is homologous with the amino acid sequence of the Aβ peptide; C. elegans does not therefore possess any endogenous Aβ peptide (Daigle I, Li C (1993) Proc Natl Acad Sci USA, 90 (24), 12045).
C. D. Link, Proc Natl Acad Sci USA (1995) 92, 9368 described the expression of Aβ peptide (but not that of an Aβ precursor protein) in C. elegans . These studies involve preparing transgenic worms which express an Aβ1-42 peptide (i.e. the Aβ peptide which consists of 42 amino acids) as a fusion protein together with a synthetic signal peptide and under the control of the muscle-specific promoter unc 54. Muscle-specific protein depositions which reacted with anti-β-amyloid antibodies were detected in the studies.
Other studies (e.g. C. Link et al. personal communication) relate to investigations of the aggregation and toxicity of the Aβ peptide in the C. elegans model system.
Transgenic C. elegans lines were established in the present study in order to investigate the existence of a processing machinery in C. elegans which is involved in the formation of Aβ peptide and to identify potential secretases in this worm.
SUMMARY OF THE INVENTION
In this invention, APP genes have been transferred into C. elegans to create a transgenic C. elegans organism. This transgenic C. elegans can then be used to investigate the processing machinery involved in the formation of the Aβ peptide and to identify potential secretases.
The present invention relates to a transgene (a gene that has been transferred from one species to another by genetic engineering) which contains
a) a nucleotide sequence encoding an amyloid precursor protein (APP) or a part thereof, wherein the nucleotide sequence comprising the APP peptide or part thereof, contains, as part of the sequence, a nucleotide sequence comprising a complete Aβ peptide or a part of the Aβ peptide, and
b) where appropriate, one or more further coding and/or non-coding nucleotide sequences, and
c) a promoter for expression in a cell of the nematode Caenorhabditis elegans ( C. elegans ).
The nucleotide sequence preferably encodes the 100 carboxyterminal amino acids of APP, beginning with the sequence of the Aβ peptide and ending with the carboxyterminal amino acid of APP (C100 fragment). The APP is preferably one of the isoforms APP695 (695 amino acids), APP751 (751 amino acids), APP770 (770 amino acids) and L-APP. All the isoforms are formed from the same APP gene by means of alternative splicing. In APP695, exons 7 and 8 were removed by splicing, whereas only exon 8 is lacking in APP751 and exon 7 and 8 are present in APP770. In addition to this, other splicing forms of APP exist in which exon 15 has been removed by splicing. These forms are termed L-APP and are likewise present in the forms which are spliced with regard to exons 7 and 8.
In one particular embodiment of the invention, the transgene contains the nucleotide sequence SEQ ID NO.: 1 or a part thereof or a sequence homologous to SEQ ID No. 1.
The transgene can preferably contain an additional coding nucleotide sequence which is located at the 5′ end of the nucleotide sequence encoding APP or a part thereof. In one particular embodiment of the invention, the additional nucleotide sequence encodes a signal peptide or a part thereof, for example encodes the APP signal peptide (SP) having the amino acid sequence SEQ ID NO.:9 or a part thereof. The sequence from the N terminus of the Aβ peptide to the C terminus of APP consists of 99 amino acids. The APP signal peptide consists of 17 amino acids. When a fusion product comprising the N terminus of the Aβ peptide to the C terminus of APP and the APP signal peptide is cloned, one or more spacer amino acids is/are preferably inserted between these two parts of the fusion product, with preference being given to inserting one amino acid, for example leucine. The C-terminal fragment is therefore given different designations, e.g. C100 (C=C terminus), LC99 (L=leucine), LC1-99, C99 or SPA4CT (SP=signal peptide, A4=Aβ peptide and CT=C terminus).
In one particular embodiment of the invention, the transgene contains the nucleotide sequence SEQ ID NO.: 2 or a part thereof and/or the nucleotide sequence SEQ ID NO.: 3 or a part thereof.
In addition to this, the transgene can also contain one or more additional non-coding and/or one or more additional coding nucleotide sequences.
For example, the transgene can contain, as an additional non-coding nucleotide sequence, a sequence from an intron of the APP gene, e.g. a sequence which is derived from the 42 bp intron of the APP gene and exhibits the sequence SEQ ID NO.: 4. A transgene which contains the nucleotide sequence SEQ ID NO.: 5 is part of the subject-matter of the invention.
The transgene also preferably contains one or more gene-regulating sequences for regulating expression of the encoded protein, preferably a constitutive promoter or a promoter which can be regulated. For example, the promoter can be active in the neuronal, muscular or dermal tissue of C. elegans or be ubiquitously active in C. elegans . A promoter can, for example, be selected from the group of the C. elegans promoters unc-54, hsp 16-2, unc-119, goa-1 and sel-12. In one particular embodiment of the invention, the transgene contains a promoter having the nucleotide sequence SEQ ID NO.: 6. In one particular embodiment, the transgene contains the nucleotide sequence SEQ ID NO.: 7.
The transgene can be present in a vector, for example in an expression vector. For example, a recombinant expression vector can contain the nucleotide sequence SEQ ID NO.: 8.
The invention also relates to the preparation of an expression vector, with a transgene being integrated into a vector in accordance with known methods. In particular, the invention relates to the use of an expression vector for preparing a transgenic cell, with it being possible for this cell to be part of a non-human organism, e.g. C. elegans.
The invention also relates to the preparation of the transgene, with suitable part sequences being ligated in the appropriate order and in the correct reading frame, where appropriate while inserting linkers. In particular, the invention relates to the use of the transgene, for example for preparing a transgenic cell, with it being possible for this cell to be part of a non-human organism. For example, the cell can be a C. elegans cell.
One particular embodiment of the invention relates to a transgenic C. elegans which contains the transgene. The transgene can also be present in the C. elegans in an expression vector. The transgene can be present in the C. elegans intrachromosomally and/or extrachromosomally. One or more transgenes or expression vectors which contain the transgene can be present intrachromosomally and/or extrachromosomally as long tandem arrays. A transgenic cell or a transgenic organism preferably contains another expression vector as well, which vector contains a nucleotide sequence which encodes a marker, with the marker either being a temperature-sensitive marker or a phenotypic marker. For example, the marker can be a visual marker or a behaviorally phenotypic marker. Examples are fluorescent markers, e.g. GFP (green fluorescent protein) or EGFP (enhanced green fluorescent protein), marker genes which encode a dominant, mutated form of a particular protein, e.g. a dominant Rol6 mutation, or marker sequences which encode antisense RNA, e.g. the antisense RNA of Unc-22.
One or more copies of the transgene and/or of the expression vector and, where appropriate, of an additional expression vector are preferably present in the germ cells and/or the somatic cells of the transgenic C. elegans.
The invention also relates to a process for preparing a transgenic C. elegans , with a transgene and/or an expression vector, where appropriate in the presence of an additional expression vector which contains a nucleotide sequence which encodes a marker, being microinjected into the germ cells of a C. elegans . A DNA construct which expresses SP-C100 (SP=signal peptide) under the control of a neuron-specific promoter can, for example, be used for preparing the transgenic C. elegans lines (FIG. 2 ). Since C100 is composed of the Aβ sequence and the C terminus of APP, only the γ-secretase cleavage is required in order to release the Aβ peptide from C100. C100 is also a substrate for the γ-secretase.
The invention also relates to the use of a transgenic C. elegans , for example for expressing an SP-C100 fusion protein. An SP-C100 fusion protein having the amino acid sequence SEQ ID NO.: 10 is part of the subject-matter of the invention.
In particular, the invention relates to the use of a transgenic C. elegans for identifying a γ-secretase activity and/or an α-secretase activity in C. elegans , to its use in methods for identifying and/or characterizing substances which inhibit the γ-secretase activity, to its use in methods for identifying and/or characterizing substances which increase the α-secretase activity, and to its use in methods for identifying and/or characterizing substances which can be used as active compounds for treating and/or preventing Alzheimer's disease.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the present study, the nematode Caenorhabditis elegans ( C. elegans ) was chosen as the model organism for identifying secretases which are involved in processing APP into the Aβ peptide. This worm is outstandingly suitable for genetic studies and has therefore in the past been employed on many occasions for investigating universally important processes such as programmed cell death, neuronal guidance and RAS/MAP kinase signaling (Riddle, D. L. et al. (1997)).
The important points which make C. elegans especially appropriate for such studies include the following (C. Kenyon, Science (1988) 240, 1448; P. E. Kuwabara (1997), TIG, 13, 454):
Its small genome, which is composed of about 19,000 genes or 97 Mb and which was sequenced completely in December 1998. (The C. elegans Sequencing Consortium, Science (1998), 282, 2012).
Its reproduction by self fertilization. In the case of the two sexes of C. elegans , a distinction is made between males and hermaphrodites, i.e. hermaphroditic animals which fertilize their eggs themselves before laying. A crucial advantage of this type of reproduction is that, after a transgene has been introduced into the germ line, a hermaphrodite can automatically generate homozygous transgenic descendants. There is therefore no need for any further crossing steps, as in the case of Drosophila, for example, for preparing transgenic lines.
Its easy handling in the laboratory due to its small size (about 1 mm in length) and its relatively undemanding growth conditions. As a result, a large number of worms can be handled routinely in the laboratory.
Its short generation time of 3 days, which makes it possible to obtain large quantities of biological material for analysis within a very short time.
A complete cell description for the development and anatomy of C. elegans is available.
Detailed genetic maps and methods for genetic analysis in C. elegans are available.
Technologies for preparing knock-out animals are available. In the same way, technologies exist for mutagenizing the C. elegans genome (transposon mutagenesis and ethyl methanesulfonate (EMS) mutagenesis).
The following are possible uses of the transgenic C. elegans lines:
1. Identification of a γ-secretase-like activity in C. elegans using mutagenesis approaches. It is planned that a transposon mutagenesis, which destroys the γ-secretase-like activity, should be carried out and that the corresponding gene should be sought by detecting the worms which no longer possess this activity. Such a screening method is described in the literature: Korswagen H. C. et al., (1996), 93, 14680 Proc Natl Acad Sci USA.
Alternative approaches would be mutagenesis using ethyl methanesulfonate (EMS) or else anti-sense RNA approaches. In the latter case, an attempt could be made to find motifs which were common to all C. elegans proteases and to downregulate these proteases specifically using anti-sense RNAs which were directed against these motifs. Screening for the Aβ peptide could then show whether one of the proteases was involved in Aβ peptide production.
2. Identification of a γ-secretase-like activity in C. elegans , perhaps by a similar route to that described in item 1.
3. Armed with knowledge of a γ-secretase or γ-secretase-like activity in C. elegans , it is possible to search for human γ-secretase or γ-secretase-like activity by means of a homology comparison.
4. Identification of drugs which
inhibit the activity of γ-secretase, in order to inhibit Aβ production from the amyloid precursor protein directly.
activate γ-secretase and thereby indirectly inhibit formation of the Aβ peptide by increasing APPsec production.
This approach could take place in a 96-well format since C. elegans can be maintained in suspension in 96-well plates.
Since the screening is carried out on a whole organism, it is possible, to a large extent, to exclude drugs which have an unspecific toxic effect.
5. Investigation of the aggregation behavior, and of a possible neurotoxic effect, of the Aβ peptide in C. elegans . Screening for drugs which inhibit aggregation of the Aβ peptide.
6. Investigation of the modulation of APP processing by other proteins (e.g. presenilins or ApoE) as a result of their overexpression or knock-out. Since the presenilins are Alzheimer-associated proteins and ApoE constitutes a risk factor in Alzheimer's disease, these proteins could have an effect on formation of the Aβ peptide and, as a consequence, their role in the APP processing pathway could be investigated.
7. Where appropriate, validation of an α-secretase and/or γ-secretase activity which has been found using other experimental approaches known to the skilled person.
FIG. 1 : FIG. 1 shows the amyloid precursor protein (APP695 isoform and APP770 and APP751 isoforms) and secretase cleavage products.
FIG. 2 : FIG. 2 describes the construction of the transgenic vector “Unc-119-SP-C100”, which contains an unc-119 promoter, an APP signal peptide and the C100 fragment from APP, with “unc-119” being a neuron-specific C. elegans promoter, the APP signal peptide corresponding to amino acids 1 to 24 of APP and C100 corresponding to the 100 C-terminal amino acids of APP (=C100). C100 is composed of the Aβ sequence and the C terminus of APP (Shoji, M et al., (1992) Science 258, 126). The vector Unc-119-SP-C100 possesses 5112 base pairs.
EXAMPLES
The following examples are illustrative of some of the products and compositions and methods of making and using the same falling within the scope of the present invention.
Example 1
Preparing an Expression Vector Which Contains the Transgene
Two vectors, i.e. pSKLC1-99, which encodes SP-C100, and pBY103, which contains the unc-119 promoter, were used for the cloning, with the SP-C100-encoding DNA being cloned into the pBY103 vector behind the unc-119 promoter. The basic vector pBY103 is composed of the vector backbone pPD49.26, which is described in “ Caenorhabditis elegans : Modern Biological Analysis of an Organism” (1995) Ed. Epstein et al., Vol 48, pp. 473, into which the unc-119 promoter (Maduro et al. Genetics (1995), 141, p. 977) has been cloned by way of the HindIII/BamHI sites. The plasmid unc-119-SP-C100 was prepared by KpnI/SacI digestion of pSKLC1-99 and cloning of the LC99 fragment into pBY103 (Shoji et al. (1992).
Example 2
Preparing the Transgenic C. elegans Lines
The method of microinjection was used for preparing the transgenic C. elegans lines (Mello et al., (1991) EMBO J. 10 (12) 3959; C. Mello and A. Fire, Methods in Cell Biology, Academic Press Vol. 48, pp. 451, 1995; C. D. Link, Proc Natl Acad Sci USA (1995) 92, 9368).
Two different C. elegans strains, i.e. wild-type N2 and him-8 (high incidence of males), were used. The unc-119-SP-C100 construct was microinjected into the gonads of young adult hermaphrodites using a microinjection appliance. The DNA concentration was about 20 ng/μl.
A marker plasmid was injected together with the unc-119-SP-C100 construct. This marker plasmid is the plasmid ttx3-GFP, which encodes the green fluorescent protein under the control of the ttx3 promoter. The activity of the ttx3 promoter is specific for particular neurons of the C. elegans head, the so-called AIY neurons, which play a role in the thermotaxis of the worm.
When plasmid DNA is microinjected, it is assumed that long tandem arrays, which are composed of many copies of plasmid DNA (in our case, of the ttx3-GFP plasmid and the unc-119-SP-C100 plasmid), are formed by recombination. A certain percentage of these arrays integrate into the C. elegans genome. However, the arrays are more likely to be present extrachromosomally.
Worms which had been injected successfully exhibit a green fluorescence in the AIY neurons of the head region when stimulated with light of a wavelength of about 480 nm. It was possible to detect such nematodes.
Example 3
Describing the C100 Transgenic C. elegans Lines
1. Phenotypic Features
Following stimulation with light of a wavelength of 480 nm, C100-transgenic worms exhibit a green fluorescence in the AIY neurons of the head region. Since it was also possible to detect green fluorescence in the head neurons once again in the descendants of the worms, it can be assumed that the plasmids are able to pass down through the germ line. However, the penetrance is not 100%, which makes it possible to conclude that the long tandem arrays composed of ttx3-GFP marker DNA and unc-119-SP-C100 are present extrachromosomally rather than being integrated into the genome.
Example 4
Detecting C100 Expression in a Blot
Six different transgenic C100 C. elegans lines (three in an N2 wt background and three in a him 8 background) were examined in a Western blot for expression of the C100 fragment using a polyclonal antiserum directed against the C terminus of APP. A band having the appropriate molecular weight of about 10 kDa was detectable in all the six lines.
Example 5
Detecting the C100 in an ELISA
In an Aβ Sandwich ELISA, signals which were above the background level, and which were statistically significant in two cases, were detected in cell extracts from transgenic animals. This indicates that C. elegans could possess a γ-secretase-like activity.
In the Aβ Sandwich ELISA assay, 96-well plates are first of all incubated with the monoclonal antibody clone 6E10 (SENETEK PLC., MO, USA), which reacts specifically with the Aβ peptide (amino acids 1-17), and then coated with worm extracts from transgenic worms or control worms. The Aβ peptide is detected using the monoclonal Aβ antibody 4G8 (SENETEK PLC., MO, USA), which recognizes amino acids 17-24 in the Aβ peptide and is labeled with biotin. The detection is effected by way of the alkaline phosphatase reaction using an appropriate antibody which is directed against biotin. Disruption of the worms involves detergent treatment, nitrogen shock freezing, sonication and rupture of the cells using glass beads.
The ELISA signal from the above-described experiment can be based either on weak expression of the Aβ peptide or on expression of the C100 precursor protein, since the appropriate epitopes are present in both proteins.
Expression of the Aβ peptide could, for example, also be specifically detected in an analogous manner: for this, Aβ-specific antibodies which do not react with the C100 precursor would have to be employed in an Aβ Sandwich ELISA. An Aβ-specific antibody could, for example, be a monoclonal antibody which specifically recognizes the C-terminal end of the Aβ form, which is composed of 40 or 42 amino acids. In parallel, the Aβ peptide could be detected in a Western blot using the monoclonal antibodies 4G8 and 6E10 and then be distinguished from the larger C100 precursor by its molecular weight of 4 kD.
The vectors can be obtained from Andrew Fire (Department of Embryology, Carnegie Institution of Washington, Baltimore, Md. 21210, USA) in the case of pPD49.26 and LC99 (amyloid precursor protein), which is deposited under ATCC number 106372. The unc-119 promoter can be obtained from Maduro, M. (Department of Biological Science, Universitiy of Alberta Edmonton, Canada), while unc-54 and unc-16.2 can be obtained from Andrew Fire.
The above description of the invention is intended to be illustrative and not limiting. Various changes or modifications in the embodiments described may occur to those skilled in the art. These can be made without departing from the spirit or scope of the invention.
SEQ ID NO.1: Nucleotide sequence of C100
CTGGATGC AGAATTCCGA CATGACTCAG GATATGAAGT TCATCATCAAAAATTGGTGT
TCTTTGCAGA AGATGTGGGT TCAAACAAAG GTGCAATCAT TGGACTCATGGTGGGCGGTG
TTGTCATAGC GACAGTGATC GTCATCACCT TGGTGATGCT GAAGAAGAAACAGTACACAT
CCATTCATCA TGGTGTGGTG GAGGTTGACG CCGCTGTCAC CCCAGAGGAGCGCCACCTGT
CCAAGATGCA GCAGAACGGC TACGAAAATC CAACCTACAA GTTCTTTGAGCAGATGCAGA ACTAG
SEQ ID NO.2: Nucleotide sequence of SP
ATG CTGCCCGGTT TGGCACTGTT CCTGCTGGCC GCCTGGACGG CTCGGGCG
SEQ ID NO.3: Nucleotide sequence of SP+C100
ATG CTGCCCGGTT TGGCACTGTT CCTGCTGGCC GCCTGGACGG CTCGGGCGCT G
GATGC AGAATTCCGA CATGACTCAG GATATGAAGT TCATCATCAA AAATTGGTGT
TCTTTGCAGA AGATGTGGGT TCAAACAAAG GTGCAATCAT TGGACTCATG
GTGGGCGGTG TTGTCATAGC GACAGTGATC GTCATCACCT TGGTGATGCT GAAGAAGAAA
CAGTACACAT CCATTCATCA TGGTGTGGTG GAGGTTGACG CCGCTGTCAC CCCAGAGGAG
CGCCACCTGT CCAAGATGCA GCAGAACGGC TACGAAAATC CAACCTACAA GTTCTTTGAG
CAGATGCAGA ACTAG
SEQ ID NO.4: Nucleotide sequence of the 42bp intron
GTATGTTTCGAATGATACTAACATAACATAGAACATTTTCAG
SEQ ID NO.5: Nucleotide sequence of intron+SP+C100
GTATGTTTCGAATGATACTAACATAACATAGAACATTTTCAGGAGGACCCTTGGCTAGCGTCGACGGT
ACCGGGCCCCCCCTCGAGGTCGACGGTATCGATAACCTTCACAGCAGCGCACTCGGTGCCCCGCG
CAGGGTCGCGATG CTGCCCGGTT TGGCACTGTT CCTGCTGGCCGCCTGGACGG CTCGGGCGCT
GGATGC AGAATTCCGAATGACTCAGGATATGAAGTCATCATCAAAAATTGGTGT TCTTTGCAGA
AGATGTGGGT TCAAACAAAG GTGCAATCAT TGGACTCATG GTGGGCGGTG TTGTCATAGC
GACAGTGATC GTCATCACCT TGGTGATGCT GAAGAAGAAA CAGTACACAT CCATTCATCA
TGGTGTGGTG GAGGTTGACG CCGCTGTCAC CCCAGAGGAGCGCCACCTGT CCAAGATGCA
GCAGAACGGC TACGAAAATC CAACCTACAA GTTCTTTGAG CAGATGCAGA ACTAG
SEQ ID NO.6: Nucleotide sequence of unc-119
AAGCTTCAGTAAAAGAAGTAGAATTTTATAGTTTTTTTTCTGTTTGAAAAATTCTCCCCATCAATGTTCT
TTCAAATAAATACATCACTAATGCAAAGTATTCTATAACCTCATATCTAAATTCTTCAAAATCTTAACAT
ATC
TTATCATTGCTTTAAGTCAACGTAACATTAAAAAAAATGTTTTGGAAAATGTGTCAAGTCTCTCAAAATT
CAGTTTTTTAAACCACTCCTATAGTCCTATAGTCCTATAGTTACCCATGAAATCCTTATATATTACTGTA
AAATGTTTCAAAAACCATTGGCAAATTGCCAGAACTGAAAATTTCCGGCAAATTGGGGAACCGGCAA
ATTGCCAATTTGCTGAATTTGCCGGAAACGGTAATTGCCGAAAGTTTTTGACACGAAAATGGCAAATT
GTGGTTTTAAAATTTTTTTTTTTGGAAATTTCAGAATTTCAATTTTAATCGGCAAAACTGTAGGCATCCT
AAGAATGTTCCTACATCTATTTTGAAAAGTAAGCGAATTAATTCTATGAAAATGTCTAAAGAAAATGGG
GAAACAATTTCAAAAAGGCACAGTTTCAATGGTTTCCGAATTATACTAAATCCCTCTAAAAACTTCCGG
CAAATTGATATCCGTAAAAGAGCAAATCCGCATTTTTGCCGAAAATTAAAATTTCCGACAAATCGGCA
AACCGGCAATTTGGCGAAATTTGCCGGAACGATTGCCGCCCACCCCTGTTCCAGAGGTTCAAACTG
GTAGCAAAGCTCAAAATTTCTCAAATTCTCCAATTTTTTTTTGAATTTTGGCAGTGTACCAAAATGACA
TTCAGTCATATTGGTTTATTATAGATTTATTTAGATAAAATCCTAAATGATTCTACCTTTAAAGATGCCC
ACTTTAAAAGTAATGACTCAAACTTCAAATTGCTCTAAGATTCTATTGAATTACCATCTTTTCCTCTCAT
TTTCTCTCACTGTCTATTTCATCACAAATTCATCCCTCTCTCCTCTCTTCTCTCTCCCTCTCTCTCTCTT
TCTCTTTGCTCATCATCTGTCATTTTGTCCGTTCCTCTCTCTGCGCCCTCAGCGTTCCCCACACTCTC
TCGCTTCTCTTTTCCTAGACGTCTTCTTTTTTCATCTTCTTCAGCCTTTTTCGCCATTTTCCATCTCTGT
CAATCATTACGGACGACCCCCATTATCGAT
SEQ ID NO.7: Nucleotide sequence of unc-119+intron+SP+C100
AAGCTTCAGTAAAAGAAGTAGAATTTTATAGTTTTTTTTCTGTTTGAAAAATTCTCCCCATCA
ATGTTCTTTCAAATAAATACATCACTAATGCAAAGTATTCTATAACCTCATATCTAAATTCTTCAAAATC
TTAACATATCTTATCATTGCTTTAAGTCAACGTAACATTAAAAAAAATGTTTTGGAAAATGTGTCAAGTC
TCTCAAAATTCAGTTTTTTAAACCACTCCTATAGTCCTATAGTCCTATAGTTACCCATGAAATCCTTATA
TATTACTGTAAAATGTTTCAAAAACCATTGGCAAATTGCCAGAACTGAAAATTTCCGGCAAATTGGGG
AACCGGCAAATTGCCAATTTGCTGAATTTGCCGGAAACGGTAATTGCCGAAAGTTTTTGACACGAAAA
TGGCAAATTGTGGTTTTAAAATTTTTTTTTTTGGAAATTTCAGAATTTCAATTTTAATCGGCAAAACTGT
AGGCATCCTAAGAATGTTCCTACATCTATTTTGAAAAGTAAGCGAATTAATTCTATGAAAATGTCTAAA
GAAAATGGGGAAACAATTTCAAAAAGGCACAGTTTCAATGGTTTCCGAATTATACTAAATCCCTCTAA
AAACTTCCGGCAAATTGATATCCGTAAAAGAGCAAATCCGCATTTTTGCCGAAAATTAAAATTTCCGA
CAAATCGGCAAACCGGCAATTTGGCGAAATTTGCCGGAACGATTGCCGCCCACCCCTGTTCCAGAG
GTTCAAACTGGTAGCAAAGCTCAAAATTTCTCAAATTCTCCAATTTTTTTTTGAATTTTGGCAGTGTAC
CAAAATGACATTCAGTCATATTGGTTTATTATAGATTTATTTAGATAAAATCCTAAATGATTCTACCTTT
AAAGATGCCCACTTTAAAAGTAATGACTCAAACTTCAAATTGCTCTAAGATTCTATTGAATTACCATCT
TTTCCTCTCATTTTCTCTCACTGTCTATTTCATCACAAATTCATCCCTCTCTCCTCTCTTCTCTCTCCCT
CTCTCTCTCTTTCTCTTTGCTCATCATCTGTCAT
TTTGTCCGTTCCTCTCTCTGCGCCCTCAGCGTTCCCCACACTCTCTCGCTTCTCTTTTCCTAGACGTC
TTCTTTTTTCATCTTCTTCAGCCTTTTTCGCCATTTTCCATCTCTGTCAATCATTACGGACGACCCCCA
TTATCGATAAGATCTCCACGGTGGCCGCGAATTCCTGCAGCCCGGGGGATCCCCGGGATTGGCCAA
AGGACCCAAAGGTATGTTTCGAATGATACTAACATAACATAGAACATTTTCAGGAGGACCCTTGGCTA
GCGTCGACGGTACCGGGCCCCCCCTCGAGGTCGACGGTATCGATAACCTTCACAGCAGCGCACTC
GGTGCCCCGCGCAGGGTCGCGATGCTGCCCGGTT
TGGCACTGTTCCTGCTGGCCGCCTGGACGGCTCGGGCGCTGGATGCAGAATTCCGA
CATGACTCAGGATATGAAGTTCATCATCAAAAATTGGTGTTCTTTGCAGAAGATGTGGGTTCAAACAA
AG GTGCAATCAT TGGACTCATGGTGGGCGGTGTTGTCATAGCGACAGTGATCGTCATCACCT
TGGTGATGCT GAAGAAGAAACAGTACACAT CCATTCATCA TGGTGTGGTG GAGGTTGACG
CCGCTGTCAC CCCAGAGGAGCGCCACCTGT CCAAGATGCA GCAGAACGGC TACGAAAATC
CAACCTACAA GTTCTTTGAGCAGATGCAGA ACTAG
SEQ ID NO.8: Nucleotide sequence of the expression vector
ACCCCCGCCACAGCAGCCTCTGAAGTTGGACACGGATCCACTAGTTCTAGAGCGGCCGCCACCGC
GGTGGAGCTCCGCATCGGCCGCTGTCATCAGATCGCCATCTCGCGCCCGTGCCTCTGACTTCTAAG
TCCAATTACTCTTCAACATCCCTACATGCTCTTTCTCCCTGTGCTCCCACCCCCTATTTTTGTTATTAT
CAAAAAAACTTCTTCTTAATTTCTTTGTTTTTTAGCTTCTTTTAAGTCACCTCTAACAATGAAATTGTGT
AGATTCAAAAATAGAATTAATTCGTAATAAAAAGTCGAAAAAAATTGTGCTCCCTCCCCCCATTAATAA
TAATTCTATCCCAAAATCTACACAATGTTCTGTGTACACTTCTTATGTTTTTTTTACTTCTGATAAATTTT
TTTTGAAACATCATAGAAAAAACCGCACACAAAATACCTTATCATATGTTACGTTTCAGTTTATGACCG
CAATTTTTATTTCTTCGCACGTCTGGGCCTCTCATGACGTCAAATCATGCTCATCGTGAAAAAGTTTT
GGAGTATTTTTGGAATTTTTCAATCAAGTGAAAGTTTATGAAATTAATTTTCCTGCTTTTGCTTTTTGGG
GGTTTCCCCTATTGTTTGTCAAGAGTTTCGAGGACGGCGTTTTTCTTGCTAAAATCACAAGTATTGAT
GAGCACGATGCAAGAAAGATCGGAAGAAGGTTTGGGTTTGAGGCTCAGTGGAAGGTGAGTAGAAGT
TGATAATTTGAAAGTGGAGTAGTGTCTATGGGGTTTTTGCCTTAAATGACAGAATACATTCCCAATATA
CCAAACATAACTGTTTCCTACTAGTCGGCCGTACGGGCCCTTTCGTCTCGCGCGTTTCGGTGATGAC
GGTGAAAACCTCTGACACATGCAGCTCCCGGAGACGGTCACAGCTTGTCTGTAAGCGGATGCCGGG
AGCAGACAAGCCCGTCAGGGCGCGTCAGCGGGTGTTGGCGGGTGTCGGGGCTGGCTTAACTATGC
GGCATCAGAGCAGATTGTACTGAGAGTGCACCATATGCGGTGTGAAATACCGCACAGATGCGTAAG
GAGAAAATACCGCATCAGGCGGCCTTAAGGGCCTCGTGATACGCCTATTTTTATAGGTTAATGTCAT
GATAATAATGGTTTCTTAGACGTCAGGTGGCACTTTTCGGGGAAATGTGCGCGGAACCCCTATTTGT
TTATTTTTCTAAATACATTCAAATATGTATCCGCTCATGAGACAATAACCCTGATAAATGCTTCAATAAT
ATTGAAAAAGGAAGAGTATGAGTATTCAACATTTCCGTGTCGCCCTTATTCCCTTTTTTGCGGCATTTT
GCCTTCCTGTTTTTGCTC
ACCCAGAAACGCTGGTGAAAGTAAAAGATGCTGAAGATCAGTTGGGTGCACGAGTGGGTTACATCG
AACTGGATCTCAACAGCGGTAAGATCCTTGAGAGTTTTCGCCCCGAAGAACGTTTTCCAATGATGAG
CACTTTTAAAGTTCTGCTATGTGGCGCGGTATTATCCCGTATTGACGCCGGGCAAGAGCAACTCGGT
CGCCGCATACACTATTCTCAGAATGACTTGGTTGAGTACTCACCAGTCACAGAAAAGCATCTTACGG
ATGGCATGACAGTAAGAGAATTATGCAGTGCTGCCATAACCATGAGTGATAACACTGCGGCCAACTT
ACTTCTGACAACGATCGGAGGACCGAAGGAGCTAACCGCTTTTTTGCACAACATGGGGGATCATGTA
ACTCGCCTTGATCGTTGGGAACCGGAGCTGAATGAAGCCATACCAAACGACGAGCGTGACACCACG
ATGCCTGTAGCAATGGCAACAACGTTGCGCAAACTATTAACTGGCGAACTACTTACTCTAGCTTCCC
GGCAACAATTAATAGACTGGATGGAGGCGGATAAAGTTGCAGGACCACTTCTGCGCTCGGCCCTTC
CGGCTGGCTGGTTTATTGCTGATAAATCTGGAGCCGGTGAGCGTGGGTCTCGCGGTATCATTGCAG
CACTGGGGCCAGATGGTAAGCCCTCCCGTATCGTAGTTATCTACACGACGGGGAGTCAGGCAACTA
TGGATGAACGAAATAGACAGATCGCTGAGATAGGTGCCTCACTGATTAAGCATTGGTAACTGTCAGA
CCAAGTTTACTCATATATACTTTAGATTGATTTAAAACTTCATTTTTAATTTAAAAGGATCTAGGTGAAG
ATCCTTTTTGATAATCTCATGACCAAAATCCCTTAACGTGAGTTTTCGTTCCACTGAGCGTCAGACCC
CGTAGAAAAGATCAAAGGATCTTCTTGAGATCCTTTTTTTCTGCGCGTAATCTGCTGCTTGCAAACAA
AAAAACCACCGCTACCAGCGGTGGTTTGTTTGCCGGATCAAGAGCTACCAACTCTTTTTCCGAAGGT
AACTGGCTTCAGCAGAGCGCAGATACCAAATACTGTCCTTCTAGTGTAGCCGTAGTTAGGCCACCAC
TTCAAGAACTCTGTAGCACCGCCTACATACCTCGCTCTGCTAATCCTGTTACCAGTGGCTGCTGCCA
GTGGCGATAAGTCGTGTCTTACCGGGTTGGACTCAAGACGATAGTTACCGGATAAGGCGCAGCGGT
CGGGCTGAACGGGGGGTTCGTGCACACAGCCCAGCTTGGAGCGAACGACCTACACCGAACTGAGA
TACCTACAGCGTGAGCATTGAGAAAGCGCCACGCTTCCCGAAGGGAGAAAGGCGGACAGGTATCCG
GTAAGCGGCAGGGTCGGAACAGGAGAGCGCACGAGGGAGCTTCCAGGGGGAAACGCCTGGTATCT
TTATAGTCCTGTCGGGTTTCGCCACCTCTGACTTGAGCGTCGATTTTTGTGATGCTCGTCAGGGGGG
CGGAGCCTATGGAAAAACGCCAGCAACGCGGCCTTTTTACGGTTCCTGGCCTTTTGCTGGCCTTTTG
CTCACATGTTCTTTCCTGCGTTATCCCCTGATTCTGTGGATAACCGTATTACCGCCTTTGAGTGAGCT
GATACCGCTCGCCGCAGCCGAACGACCGAGCGCAGCGAGTCAGTGAGCGAGGAAGCGGAAGAGC
GCCCAATACGCAAACCGCCTCTCCCCGCGCGTTGGCCGATTCATTAATGCAGCTGGCACGACAGGT
TTCCGGACTGGAAAGCGGGCAGTGAGCGCAACGCAATTAATGTGAGTTAGCTCACTCATTAGGCAC
CCCAGGCTTTACACTTTATGCTTCCGGCTCGTATGTTGTGTGGAATTGTGAGCGGATAACAATTTCAC
ACAGGAAACAGCTATGACCATGATTACGCCAAGCTT
SEQ ID NO.9: Amino acid sequence of SP
MLPGLALFLL AAWTARA
SEQ ID NO.10: Amino acid sequence of the fusion protein
MLPGLALFLL AAWTARALDA EFRHDSGYEV HHQKLVFFAE DVGSNKGAII
GLMVGGVVIA TVIVITLVML KKKQYTSIHH GVVEVDAAVT PEERHLSKMQ
QNGYENPTYK FFEQMQN
SEQ ID NO. 11: Nucleotide sequence of the vector unc-119-SP-C100
ATGACCATGATTACGCCAAGCTTCAGTAAAAGAAGTAGAATTTTATAGTTTTTTTTCTGTTTGAAAAAT
TCTCCCCATCAATGTTCTTTCAAATAAATACATCACTAATGCAAAGTATTCTATAACCTCATATCTAAAT
TCTTCAAAATCTTAACATATCTTATCATTGCTTTAAGTCAACGTAACATTAAAAAAAATGTTTTGGAAAA
TGTGTCAAGTCTCTCAAAATTCAGTTTTTTAAACCACTCCTATAGTCCTATAGTCCTATAGTTACCCAT
GAAATCCTTATATATTACTGTAAAATGTTTCAAAAACCATTGGCAAATTGCCAGAACTGAAAATTTCCG
GCAAATTGGGGAACCGGCAAATTGCCAATTTGCTGAATTTGCCGGAAACGGTAATTGCCGAAAGTTT
TTGACACGAAAATGGCAAATTGTGGTTTTAAAATTTTTTTTTTTGGAAATTTCAGAATTTCAATTTTAAT
CGGCAAAACTGTAGGCATCCTAAGAATGTTCCTACATCTATTTTGAAAAGTAAGCGAATTAATTCTAT
GAAAATGTCTAAAGAAAATGGGGAAACAATTTCAAAAAGGCACAGTTTCAATGGTTTCCGAATTATAC
TAAATCCCTCTAAAAACTTCCGGCAAATTGATATCCGTAAAAGAGCAAATCCGCATTTTTGCCGAAAA
TTAAAATTTCCGACAAATCGGCAAACCGGCAATTTGGCGAAATTTGCCGGAACGATTGCCGCCCACC
CCTGTTCCAGAGGTTCAAACTGGTAGCAAAGCTCAAAATTTCTCAAATTCTCCAATTTTTTTTTGAATT
TTGGCAGTGTACCAAAATGACATTCAGTCATATTGGTTTATTATAGATTTATTTAGATAAAATCCTAAAT
GATTCTACCTTTAAAGATGCCCACTTTAAAAGTAATGACTCAAACTTCAAATTGCTCTAAGATTCTATT
GAATTACCATCTTTTCCTCTCATTTTCTCTCACTGTCTATTTCATCACAAATTCATCCCTCTCTCCTCTC
TTCTCTCTCCCTCTCTCTCTCTTTCTCTTTGCTCATCATCTGTCATTTTGTCCGTTCCTCTCTCTGCGC
CCTCAGCGTTCCCCACACTCTCTCGCTTCTCTTTTCCTAGACGTCTTCTTTTTTCATCTTCTTCAGCCT
TTTTCGCCATTTTCCATCTCTGTCAATCATTACGGACGACCCCCATTATCGATAAGATCTCCACGGTG
GCCGCGAATTCCTGCAGCCCGGGGGATCCCCGGGATTGGCCAAAGGACCCAAAGGTATGTTTCGAA
TGATACTAACATAACATAGAACATTTTCAGGAGGACCCTTGGCTAGCGTCGACGGTACCGGGCCCCC
CCTCGAGGTCGACGGTATCGATAACCTTCACAGCAGCGCACTCGGTGCCCCGCGCAGGGTCGCGA
TG CTGCCCGGTT TGGCACTGTT CCTGCTGGCCGCCTGGACGG CTCGGGCGCT GGATGC
AGAATTCCGA CATGACTCAG GATATGAAGT TCATCATCAAAAATTGGTGT TCTTTGCAGA
AGATGTGGGT TCAAACAAAG GTGCAATCAT TGGACTCATGGTGGGCGGTG TTGTCATAGC
GACAGTGATC GTCATCACCT TGGTGATGCT GAAGAAGAAACAGTACACAT CCATTCATCA
TGGTGTGGTG
GAGGTTGACG CCGCTGTCAC CCCAGAGGAGCGCCACCTGT CCAAGATGCA GCAGAACGGC
TACGAAAATCCAACCTACAATTCTTTGAGCAGATGCAGAACTAGACCCCCGCCACAGCAGCCTCTGA
AGTTGGACACGGATCCACTAGTTCTAGAGCGGCCGCCACCGCGGTGGAGCTCCGCATCGGCCGCT
GTCATCAGATCGCCATCTCGCGCCCGTGCCTCTGACTTCTAAGTCCAATTACTCTTCAACATCCCTAC
ATGCTCTTTCTCCCTGTGCTCCCACCCCCTATTTTTGTTATTATCAAAAAAACTTCTTCTTAATTTCTTT
GTTTTTTAGCTTCTTTTAAGTCACCTCTAACAATGAAATTGTGTAGATTCAAAAATAGAATTAATTCGTA
ATAAAAAGTCGAAAAAAATTGTGCTCCCTCCCCCCATTAATAATAATTCTATCCCAAAATCTACACAAT
GTTCTGTGTACACTTCTTATGTTTTTTTTACTTCTGATAAATTTTTTTTGAAACATCATAGAAAAAACCG
CACACAAAATACCTTATCATATGTTACGTTTCAGTTTATGACCGCAATTTTTATTTCTTCGCACGTCTG
GGCCTCTCATGACGTCAAATCATGCTCATCGTGAAAAAGTTTTGGAGTATTTTTGGAATTTTTCAATCA
AGTGAAAGTTTATGAAATTAATTTTCCTGCTTTTGCTTTTTGGGGGTTTCCCCTATTGTTTGTCAAGAG
TTTCGAGGACGGCGTTTTTCTTGCTAAAATCACAAGTATTGATGAGCACGATGCAAGAAAGATCGGA
AGAAGGTTTGGGTTTGAGGCTCAGTGGAAGGTGAGTAGAAGTTGATAATTTGAAAGTGGAGTAGTGT
CTATGGGGTTTTTGCCTTAAATGACAGAATACATTCCCAATATACCAAACATAACTGTTTCCTACTAGT
CGGCCGTACGGGCCCTTTCGTCTCGCGCGTTTCGGTGATGACGGTGAAAACCTCTGACACATGCAG
CTCCCGGAGACGGTCACAGCTTGTCTGTAAGCGGATGCCGGGAGCAGACAAGCCCGTCAGGGCGC
GTCAGCGGGTGTTGGCGGGTGTCGGGGCTGGCTTAACTATGCGGCATCAGAGCAGATTGTACTGAG
AGTGCACCATATGCGGTGTGAAATACCGCACAGATGCGTAAGGAGAAAATACCGCATCAGGCGGCC
TTAAGGGCCTCGTGATACGCCTATTTTTATAGGTTAATGTCATGATAATAATGGTTTCTTAGACGTCAG
GTGGCACTTTTCGGGGAAATGTGCGCGGAACCCCTATTTGTTTATTTTTCTAAATACATTCAAATATGT
ATCCGCTCATGAGACAATAACCCTGATAAATGCTTCAATAATATTGAAAAAGGAAGAGTATGAGTATT
CAACATTTCCGTGTCGCCCTTATTCCCTTTTTTGCGGCATTTTGCCTTCCTGTTTTTGCTCACCCAGAA
ACGCTGGTGAAAGTAAAAGATGCTGAAGATCAGTTGGGTGCACGAGTGGGTTACATCGAACTGGAT
CTCAACAGCGGTAAGATCCTTGAGAGTTTTCGCCCCGAAGAACGTTTTCCAATGATGAGCACTTTTAA
AGTTCTGCTATGTGGCGCGGTATTATCCCGTATTGACGCCGGGCAAGAGCAACTCGGTCGCCGCAT
ACACTATTCTCAGAATGACTTGGTTGAGTACTCACCAGTCACAGAAAAGCATCTTACGGATGGCATGA
CAGTAAGAGAATTATGCAGTGCTGCCATAACCATGAGTGATAACACTGCGGCCAACTTACTTCTGAC
AACGATCGGAGGACCGAAGGAGCTAACCGCTTTTTTGCACAACATGGGGGATCATGTAACTCGCCTT
GATCGTTGGGAACCGGAGCTGAATGAAGCCATACCAAACGACGAGCGTGACACCACGATGCCTGTA
GCAATGGCAACAACGTTGCGCAAACTATTAACTGGCGAACTACTTACTCTAGCTTCCCGGCAACAAT
TAATAGACTGGATGGAGGCGGATAAAGTTGCAGGACCACTTCTGCGCTCGGCCCTTCCGGCTGGCT
GGTTTATTGCTGATAAATCTGGAGCCGGTGAGCGTGGGTCTCGCGGTATCATTGCAGCACTGGGGC
CAGATGGTAAGCCCTCCCGTATCGTAGTTATCTACACGACGGGGAGTCAGGCAACTATGGATGAAC
GAAATAGACAGATCGCTGAGATAGGTGCCTCACTGATTAAGCATTGGTAACTGTCAGACCAAGTTTA
CTCATATATACTTTAGATTGATTTAAAACTTCATTTTTAATTTAAAAGGATCTAGGTGAAGATCCTTTTT
GATAATCTCATGACCAAAATCCCTTAACGTGAGTTTTCGTTCCACTGAGCGTCAGACCCCGTAGAAAA
GATCAAAGGATCTTCTTGAGATCCTTTTTTTCTGCGCGTAATCTGCTG
CTTGCAAACAAAAAAACCACCGCTACCAGCGGTGGTTTGTTTGCCGGATCAAGAGCTACCAACTCTT
TTTCCGAAGGTAACTGGCTTCAGCAGAGCGCAGATACCAAATACTGTCCTTCTAGTGTAGCCGTAGT
TAGGCCACCACTTCAAGAACTCTGTAGCACCGCCTACATACCTCGCTCTGCTAATCCTGTTACCAGT
GGCTGCTGCCAGTGGCGATAAGTCGTGTCTTACCGGGTTGGACTCAAGACGATAGTTACCGGATAA
GGCGCAGCGGTCGGGCTGAACGGGGGGTTCGTGCACACAGCCCAGCTTGGAGCGAACGACCTACA
CCGAACTGAGATACCTACAGCGTGAGCATTGAGAAAGCGCCACGCTTCCCGAAGGGAGAAAGGCG
GACAGGTATCCGGTAAGCGGCAGGGTCGGAACAGGAGAGCGCACGAGGGAGCTTCCAGGGGGAA
ACGCCTGGTATCTTTATAGTCCTGTCGGGTTTCGCCACCTCTGACTTGAGCGTCGATTTTTGTGATGC
TCGTCAGGGGGGCGGAGCCTATGGAAAAACGCCAGCAACGCGGCCTTTTTACGGTTCCTGGCCTTT
TGCTGGCCTTTTGCTCACATGTTCTTTCCTGCGTTATCCCCTGATTCTGTGGATAACCGTATTACCGC
CTTTGAGTGAGCTGATACCGCTCGCCGCAGCCGAACGACCGAGCGCAGCGAGTCAGTGAGCGAGG
AAGCGGAAGAGCGCCCAATACGCAAACCGCCTCTCCCCGCGCGTTGGCCGATTCATTAATGCAGCT
GGCACGACAGGTTTCCCGACTGGAAAGCGGGCAGTGAGCGCAACGCAATTAATGTGAGTTAGCTCA
CTCATTAGGCACCCCAGGCTTTACACTTTATGCTTCCGGCTCGTATGTTGTGTGGAATTGTGAGCGG
ATAACAATTTCACACAGGAAACAGCT
REFERENCES
Baumeister R (1997) Genes & Function 1, 149
Daigle I, Li C (1993), 90 (24), 12045
Kang, J., Lemaire, H. G., Unterbeck, A., Salbaum J. M., Masters C. L., Grzeschik, K. H., Multhaupt, G., Beyreuther, K., Mueller-Hill, B. (1987) Nature, 325, 733
Kenyon, C., Science (1988) 240, 1448
Korswagen H. C., Durbin, R. M., Smits, M. T., Plasterk, R. H. A. (1996), 93, 14680 Proc Natl Acad Sci USA
Kuwabara, P. E. (1997), Trends in Genetics, 13, 454
Levitan D., Doyle T G, Brousseau D., Lee M K. Thinakaran G., Slunt H H., Sisodia S S. Greenwald I. (1996) Proc Natl Acad Sci USA, 93,14940
Levitan D, Greenwald I (1995) Nature 377, 351
Link C. D. (1995) Proc Natl Acad Sci USA, 92, 9368
Mello, C. and Fire, A., Methods in Cell Biology, Academic Press Vol. 48, pp 451, 1995
Riddle et al. (1997) C. elegans II, Cold Spring Harbor Laboratory Press
Rumble, B., Retallack, R., Hilbich, C., Simms, G., Multhaup, G., Martins, R., Hockey, A., Montgomery, P., Beyreuther, K., Masters, C. L., (1989), N. Engl. J. Med., 320, 1446
Scheuner, D., Eckman, C., Jensen, M., Song, X., Citron, M., Suzuki, N., Bird, T., Hardy, M., Hutton, W., Kukull, W., Farson, E., Levy-Lahad, E., Vitanen, M., Peskind, E., Poorkaj, P., Schellenberg, G., Tanzi, R., Wasco, W., Lannfeld, D., Selkoe, D., Younkin, S. G. (1996), Nature Medicine, 2, 864
Shoji M., Golde T E., Ghiso J., Cheung T T., Estus S., Shaffer L M., Cai X-D., McKay D M., Tintner R., Fraggione B., Younkin S G. (1992) Science 258,126
Xiajun Li and Iva Greenwald (1997) Proc Natl Acad Sci USA, 94,12204
Yankner, B. A., Caceres, A., Duffy, L. K. (1990) Proc Natl Acad Sci USA, 87, 9020
11
1
303
DNA
Caenorhabditis elegans
1
ctggatgcag aattccgaca tgactcagga tatgaagttc atcatcaaaa attggtgttc 60
tttgcagaag atgtgggttc aaacaaaggt gcaatcattg gactcatggt gggcggtgtt 120
gtcatagcga cagtgatcgt catcaccttg gtgatgctga agaagaaaca gtacacatcc 180
attcatcatg gtgtggtgga ggttgacgcc gctgtcaccc cagaggagcg ccacctgtcc 240
aagatgcagc agaacggcta cgaaaatcca acctacaagt tctttgagca gatgcagaac 300
tag 303
2
51
DNA
Caenorhabditis elegans
2
atgctgcccg gtttggcact gttcctgctg gccgcctgga cggctcgggc g 51
3
354
DNA
Caenorhabditis elegans
3
atgctgcccg gtttggcact gttcctgctg gccgcctgga cggctcgggc gctggatgca 60
gaattccgac atgactcagg atatgaagtt catcatcaaa aattggtgtt ctttgcagaa 120
gatgtgggtt caaacaaagg tgcaatcatt ggactcatgg tgggcggtgt tgtcatagcg 180
acagtgatcg tcatcacctt ggtgatgctg aagaagaaac agtacacatc cattcatcat 240
ggtgtggtgg aggttgacgc cgctgtcacc ccagaggagc gccacctgtc caagatgcag 300
cagaacggct acgaaaatcc aacctacaag ttctttgagc agatgcagaa ctag 354
4
42
DNA
Caenorhabditis elegans
4
gtatgtttcg aatgatacta acataacata gaacattttc ag 42
5
495
DNA
Caenorhabditis elegans
5
gtatgtttcg aatgatacta acataacata gaacattttc aggaggaccc ttggctagcg 60
tcgacggtac cgggcccccc ctcgaggtcg acggtatcga taaccttcac agcagcgcac 120
tcggtgcccc gcgcagggtc gcgatgctgc ccggtttggc actgttcctg ctggccgcct 180
ggacggctcg ggcgctggat gcagaattcc gaatgactca ggatatgaag tcatcatcaa 240
aaattggtgt tctttgcaga agatgtgggt tcaaacaaag gtgcaatcat tggactcatg 300
gtgggcggtg ttgtcatagc gacagtgatc gtcatcacct tggtgatgct gaagaagaaa 360
cagtacacat ccattcatca tggtgtggtg gaggttgacg ccgctgtcac cccagaggag 420
cgccacctgt ccaagatgca gcagaacggc tacgaaaatc caacctacaa gttctttgag 480
cagatgcaga actag 495
6
1207
DNA
Caenorhabditis elegans
6
aagcttcagt aaaagaagta gaattttata gttttttttc tgtttgaaaa attctcccca 60
tcaatgttct ttcaaataaa tacatcacta atgcaaagta ttctataacc tcatatctaa 120
attcttcaaa atcttaacat atcttatcat tgctttaagt caacgtaaca ttaaaaaaaa 180
tgttttggaa aatgtgtcaa gtctctcaaa attcagtttt ttaaaccact cctatagtcc 240
tatagtccta tagttaccca tgaaatcctt atatattact gtaaaatgtt tcaaaaacca 300
ttggcaaatt gccagaactg aaaatttccg gcaaattggg gaaccggcaa attgccaatt 360
tgctgaattt gccggaaacg gtaattgccg aaagtttttg acacgaaaat ggcaaattgt 420
ggttttaaaa tttttttttt tggaaatttc agaatttcaa ttttaatcgg caaaactgta 480
ggcatcctaa gaatgttcct acatctattt tgaaaagtaa gcgaattaat tctatgaaaa 540
tgtctaaaga aaatggggaa acaatttcaa aaaggcacag tttcaatggt ttccgaatta 600
tactaaatcc ctctaaaaac ttccggcaaa ttgatatccg taaaagagca aatccgcatt 660
tttgccgaaa attaaaattt ccgacaaatc ggcaaaccgg caatttggcg aaatttgccg 720
gaacgattgc cgcccacccc tgttccagag gttcaaactg gtagcaaagc tcaaaatttc 780
tcaaattctc caattttttt ttgaattttg gcagtgtacc aaaatgacat tcagtcatat 840
tggtttatta tagatttatt tagataaaat cctaaatgat tctaccttta aagatgccca 900
ctttaaaagt aatgactcaa acttcaaatt gctctaagat tctattgaat taccatcttt 960
tcctctcatt ttctctcact gtctatttca tcacaaattc atccctctct cctctcttct 1020
ctctccctct ctctctcttt ctctttgctc atcatctgtc attttgtccg ttcctctctc 1080
tgcgccctca gcgttcccca cactctctcg cttctctttt cctagacgtc ttcttttttc 1140
atcttcttca gcctttttcg ccattttcca tctctgtcaa tcattacgga cgacccccat 1200
tatcgat 1207
7
1773
DNA
Caenorhabditis elegans
7
aagcttcagt aaaagaagta gaattttata gttttttttc tgtttgaaaa attctcccca 60
tcaatgttct ttcaaataaa tacatcacta atgcaaagta ttctataacc tcatatctaa 120
attcttcaaa atcttaacat atcttatcat tgctttaagt caacgtaaca ttaaaaaaaa 180
tgttttggaa aatgtgtcaa gtctctcaaa attcagtttt ttaaaccact cctatagtcc 240
tatagtccta tagttaccca tgaaatcctt atatattact gtaaaatgtt tcaaaaacca 300
ttggcaaatt gccagaactg aaaatttccg gcaaattggg gaaccggcaa attgccaatt 360
tgctgaattt gccggaaacg gtaattgccg aaagtttttg acacgaaaat ggcaaattgt 420
ggttttaaaa tttttttttt tggaaatttc agaatttcaa ttttaatcgg caaaactgta 480
ggcatcctaa gaatgttcct acatctattt tgaaaagtaa gcgaattaat tctatgaaaa 540
tgtctaaaga aaatggggaa acaatttcaa aaaggcacag tttcaatggt ttccgaatta 600
tactaaatcc ctctaaaaac ttccggcaaa ttgatatccg taaaagagca aatccgcatt 660
tttgccgaaa attaaaattt ccgacaaatc ggcaaaccgg caatttggcg aaatttgccg 720
gaacgattgc cgcccacccc tgttccagag gttcaaactg gtagcaaagc tcaaaatttc 780
tcaaattctc caattttttt ttgaattttg gcagtgtacc aaaatgacat tcagtcatat 840
tggtttatta tagatttatt tagataaaat cctaaatgat tctaccttta aagatgccca 900
ctttaaaagt aatgactcaa acttcaaatt gctctaagat tctattgaat taccatcttt 960
tcctctcatt ttctctcact gtctatttca tcacaaattc atccctctct cctctcttct 1020
ctctccctct ctctctcttt ctctttgctc atcatctgtc attttgtccg ttcctctctc 1080
tgcgccctca gcgttcccca cactctctcg cttctctttt cctagacgtc ttcttttttc 1140
atcttcttca gcctttttcg ccattttcca tctctgtcaa tcattacgga cgacccccat 1200
tatcgataag atctccacgg tggccgcgaa ttcctgcagc ccgggggatc cccgggattg 1260
gccaaaggac ccaaaggtat gtttcgaatg atactaacat aacatagaac attttcagga 1320
ggacccttgg ctagcgtcga cggtaccggg ccccccctcg aggtcgacgg tatcgataac 1380
cttcacagca gcgcactcgg tgccccgcgc agggtcgcga tgctgcccgg tttggcactg 1440
ttcctgctgg ccgcctggac ggctcgggcg ctggatgcag aattccgaca tgactcagga 1500
tatgaagttc atcatcaaaa attggtgttc tttgcagaag atgtgggttc aaacaaaggt 1560
gcaatcattg gactcatggt gggcggtgtt gtcatagcga cagtgatcgt catcaccttg 1620
gtgatgctga agaagaaaca gtacacatcc attcatcatg gtgtggtgga ggttgacgcc 1680
gctgtcaccc cagaggagcg ccacctgtcc aagatgcagc agaacggcta cgaaaatcca 1740
acctacaagt tctttgagca gatgcagaac tag 1773
8
3344
DNA
Caenorhabditis elegans
8
acccccgcca cagcagcctc tgaagttgga cacggatcca ctagttctag agcggccgcc 60
accgcggtgg agctccgcat cggccgctgt catcagatcg ccatctcgcg cccgtgcctc 120
tgacttctaa gtccaattac tcttcaacat ccctacatgc tctttctccc tgtgctccca 180
ccccctattt ttgttattat caaaaaaact tcttcttaat ttctttgttt tttagcttct 240
tttaagtcac ctctaacaat gaaattgtgt agattcaaaa atagaattaa ttcgtaataa 300
aaagtcgaaa aaaattgtgc tccctccccc cattaataat aattctatcc caaaatctac 360
acaatgttct gtgtacactt cttatgtttt ttttacttct gataaatttt ttttgaaaca 420
tcatagaaaa aaccgcacac aaaatacctt atcatatgtt acgtttcagt ttatgaccgc 480
aatttttatt tcttcgcacg tctgggcctc tcatgacgtc aaatcatgct catcgtgaaa 540
aagttttgga gtatttttgg aatttttcaa tcaagtgaaa gtttatgaaa ttaattttcc 600
tgcttttgct ttttgggggt ttcccctatt gtttgtcaag agtttcgagg acggcgtttt 660
tcttgctaaa atcacaagta ttgatgagca cgatgcaaga aagatcggaa gaaggtttgg 720
gtttgaggct cagtggaagg tgagtagaag ttgataattt gaaagtggag tagtgtctat 780
ggggtttttg ccttaaatga cagaatacat tcccaatata ccaaacataa ctgtttccta 840
ctagtcggcc gtacgggccc tttcgtctcg cgcgtttcgg tgatgacggt gaaaacctct 900
gacacatgca gctcccggag acggtcacag cttgtctgta agcggatgcc gggagcagac 960
aagcccgtca gggcgcgtca gcgggtgttg gcgggtgtcg gggctggctt aactatgcgg 1020
catcagagca gattgtactg agagtgcacc atatgcggtg tgaaataccg cacagatgcg 1080
taaggagaaa ataccgcatc aggcggcctt aagggcctcg tgatacgcct atttttatag 1140
gttaatgtca tgataataat ggtttcttag acgtcaggtg gcacttttcg gggaaatgtg 1200
cgcggaaccc ctatttgttt atttttctaa atacattcaa atatgtatcc gctcatgaga 1260
caataaccct gataaatgct tcaataatat tgaaaaagga agagtatgag tattcaacat 1320
ttccgtgtcg cccttattcc cttttttgcg gcattttgcc ttcctgtttt tgctcaccca 1380
gaaacgctgg tgaaagtaaa agatgctgaa gatcagttgg gtgcacgagt gggttacatc 1440
gaactggatc tcaacagcgg taagatcctt gagagttttc gccccgaaga acgttttcca 1500
atgatgagca cttttaaagt tctgctatgt ggcgcggtat tatcccgtat tgacgccggg 1560
caagagcaac tcggtcgccg catacactat tctcagaatg acttggttga gtactcacca 1620
gtcacagaaa agcatcttac ggatggcatg acagtaagag aattatgcag tgctgccata 1680
accatgagtg ataacactgc ggccaactta cttctgacaa cgatcggagg accgaaggag 1740
ctaaccgctt ttttgcacaa catgggggat catgtaactc gccttgatcg ttgggaaccg 1800
gagctgaatg aagccatacc aaacgacgag cgtgacacca cgatgcctgt agcaatggca 1860
acaacgttgc gcaaactatt aactggcgaa ctacttactc tagcttcccg gcaacaatta 1920
atagactgga tggaggcgga taaagttgca ggaccacttc tgcgctcggc ccttccggct 1980
ggctggttta ttgctgataa atctggagcc ggtgagcgtg ggtctcgcgg tatcattgca 2040
gcactgggcc agatggtaag ccctcccgta tcgtagttat ctacacgacg gggagtcagg 2100
caactatgga tgaacgaaat agacagatcg ctgagatagg tgcctcactg attaagcatt 2160
ggtaactgtc agaccaagtt tactcatata tactttagat tgatttaaaa cttcattttt 2220
aatttaaaag gatctaggtg aagatccttt ttgataatct catgaccaaa atcccttaac 2280
gtgagttttc gttccactga gcgtcagacc ccgtagaaaa gatcaaagga tcttcttgag 2340
atcctttttt tctgcgcgta atctgctgct tgcaaacaaa aaaaccaccg ctaccagcgg 2400
tggtttgttt gccggatcaa gagctaccaa ctctttttcc gaaggtaact ggcttcagca 2460
gagcgcagat accaaatact gtccttctag tgtagccgta gttaggccac cacttcaaga 2520
actctgtagc accgcctaca tacctcgctc tgctaatcct gttaccagtg gctgctgcca 2580
gtggcgataa gtcgtgtctt accgggttgg actcaagacg atagttaccg gataaggcgc 2640
agcggtcggg ctgaacgggg ggttcgtgca cacagcccag cttggagcga acgacctaca 2700
ccgaactgag atacctacag cgtgagcatt gagaaagcgc cacgcttccc gaagggagaa 2760
aggcggacag gtatccggta agcggcaggg tcggaacagg agagcgcacg agggagcttc 2820
cagggggaaa cgcctggtat ctttatagtc ctgtcgggtt tcgccacctc tgacttgagc 2880
gtcgattttt gtgatgctcg tcaggggggc ggagcctatg gaaaaacgcc agcaacgcgg 2940
cctttttacg gttcctggcc ttttgctggc cttttgctca catgttcttt cctgcgttat 3000
cccctgattc tgtggataac cgtattaccg cctttgagtg agctgatacc gctcgccgca 3060
gccgaacgac cgagcgcagc gagtcagtga gcgaggaagc ggaagagcgc ccaatacgca 3120
aaccgcctct ccccgcgcgt tggccgattc attaatgcag ctggcacgac aggtttcccg 3180
actggaaagc gggcagtgag cgcaacgcaa ttaatgtgag ttagctcact cattaggcac 3240
cccaggcttt acactttatg cttccggctc gtatgttgtg tggaattgtg agcggataac 3300
aatttcacac aggaaacagc tatgaccatg attacgccaa gctt 3344
9
17
PRT
Caenorhabditis elegans
9
Met Leu Pro Gly Leu Ala Leu Phe Leu Leu Ala Ala Trp Thr Ala Arg
1 5 10 15
Ala
10
117
PRT
Caenorhabditis elegans
10
Met Leu Pro Gly Leu Ala Leu Phe Leu Leu Ala Ala Trp Thr Ala Arg
1 5 10 15
Ala Leu Asp Ala Glu Phe Arg His Asp Ser Gly Tyr Glu Val His His
20 25 30
Gln Lys Leu Val Phe Phe Ala Glu Asp Val Gly Ser Asn Lys Gly Ala
35 40 45
Ile Ile Gly Leu Met Val Gly Gly Val Val Ile Ala Thr Val Ile Val
50 55 60
Ile Thr Leu Val Met Leu Lys Lys Lys Gln Tyr Thr Ser Ile His His
65 70 75 80
Gly Val Val Glu Val Asp Ala Ala Val Thr Pro Glu Glu Arg His Leu
85 90 95
Ser Lys Met Gln Gln Asn Gly Tyr Glu Asn Pro Thr Tyr Lys Phe Phe
100 105 110
Glu Gln Met Gln Asn
115
11
5109
DNA
Caenorhabditis elegans
11
atgaccatga ttacgccaag cttcagtaaa agaagtagaa ttttatagtt ttttttctgt 60
ttgaaaaatt ctccccatca atgttctttc aaataaatac atcactaatg caaagtattc 120
tataacctca tatctaaatt cttcaaaatc ttaacatatc ttatcattgc tttaagtcaa 180
cgtaacatta aaaaaaatgt tttggaaaat gtgtcaagtc tctcaaaatt cagtttttta 240
aaccactcct atagtcctat agtcctatag ttacccatga aatccttata tattactgta 300
aaatgtttca aaaaccattg gcaaattgcc agaactgaaa atttccggca aattggggaa 360
ccggcaaatt gccaatttgc tgaatttgcc ggaaacggta attgccgaaa gtttttgaca 420
cgaaaatggc aaattgtggt tttaaaattt ttttttttgg aaatttcaga atttcaattt 480
taatcggcaa aactgtaggc atcctaagaa tgttcctaca tctattttga aaagtaagcg 540
aattaattct atgaaaatgt ctaaagaaaa tggggaaaca atttcaaaaa ggcacagttt 600
caatggtttc cgaattatac taaatccctc taaaaacttc cggcaaattg atatccgtaa 660
aagagcaaat ccgcattttt gccgaaaatt aaaatttccg acaaatcggc aaaccggcaa 720
tttggcgaaa tttgccggaa cgattgccgc ccacccctgt tccagaggtt caaactggta 780
gcaaagctca aaatttctca aattctccaa tttttttttg aattttggca gtgtaccaaa 840
atgacattca gtcatattgg tttattatag atttatttag ataaaatcct aaatgattct 900
acctttaaag atgcccactt taaaagtaat gactcaaact tcaaattgct ctaagattct 960
attgaattac catcttttcc tctcattttc tctcactgtc tatttcatca caaattcatc 1020
cctctctcct ctcttctctc tccctctctc tctctttctc tttgctcatc atctgtcatt 1080
ttgtccgttc ctctctctgc gccctcagcg ttccccacac tctctcgctt ctcttttcct 1140
agacgtcttc ttttttcatc ttcttcagcc tttttcgcca ttttccatct ctgtcaatca 1200
ttacggacga cccccattat cgataagatc tccacggtgg ccgcgaattc ctgcagcccg 1260
ggggatcccc gggattggcc aaaggaccca aaggtatgtt tcgaatgata ctaacataac 1320
atagaacatt ttcaggagga cccttggcta gcgtcgacgg taccgggccc cccctcgagg 1380
tcgacggtat cgataacctt cacagcagcg cactcggtgc cccgcgcagg gtcgcgatgc 1440
tgcccggttt ggcactgttc ctgctggccg cctggacggc tcgggcgctg gatgcagaat 1500
tccgacatga ctcaggatat gaagttcatc atcaaaaatt ggtgttcttt gcagaagatg 1560
tgggttcaaa caaaggtgca atcattggac tcatggtggg cggtgttgtc atagcgacag 1620
tgatcgtcat caccttggtg atgctgaaga agaaacagta cacatccatt catcatggtg 1680
tggtggaggt tgacgccgct gtcaccccag aggagcgcca cctgtccaag atgcagcaga 1740
acggctacga aaatccaacc tacaattctt tgagcagatg cagaactaga cccccgccac 1800
agcagcctct gaagttggac acggatccac tagttctaga gcggccgcca ccgcggtgga 1860
gctccgcatc ggccgctgtc atcagatcgc catctcgcgc ccgtgcctct gacttctaag 1920
tccaattact cttcaacatc cctacatgct ctttctccct gtgctcccac cccctatttt 1980
tgttattatc aaaaaaactt cttcttaatt tctttgtttt tagcttcttt taagtcacct 2040
ctaacaatga aattgtgtag attcaaaaat agaattaatt cgtaataaaa agtcgaaaaa 2100
aattgtgctc cctcccccca ttaataataa ttctatccca aaatctacac aatgttctgt 2160
gtacacttct tatgtttttt ttacttctga taaatttttt ttgaaacatc atagaaaaaa 2220
ccgcacacaa aataccttat catatgttac gtttcagttt atgaccgcaa tttttatttc 2280
ttcgcacgtc tgggcctctc atgacgtcaa atcatgctca tcgtgaaaaa gttttggagt 2340
atttttggaa tttttcaatc aagtgaaagt ttatgaaatt aattttcctg cttttgcttt 2400
ttgggggttt cccctattgt ttgtcaagag tttcgaggac ggcgtttttc ttgctaaaat 2460
cacaagtatt gatgagcacg atgcaagaaa gatcggaaga aggtttgggt ttgaggctca 2520
gtggaaggtg agtagaagtt gataatttga aagtggagta gtgtctatgg ggtttttgcc 2580
ttaaatgaca gaatacattc ccaatatacc aaacataact gtttcctact agtcggccgt 2640
acgggccctt tcgtctcgcg cgtttcggtg atgacggtga aaacctctga cacatgcagc 2700
tcccggagac ggtcacagct tgtctgtaag cggatgccgg gagcagacaa gcccgtcagg 2760
gcgcgtcagc gggtgttggc gggtgtcggg gctggcttaa ctatgcggca tcagagcaga 2820
ttgtactgag agtgcaccat atgcggtgtg aaataccgca cagatgcgta aggagaaaat 2880
accgcatcag gcggccttaa gggcctcgtg atacgcctat ttttataggt taatgtcatg 2940
ataataatgg tttcttagac gtcaggtggc acttttcggg gaaatgtgcg cggaacccct 3000
atttgtttat ttttctaaat acattcaaat atgtatccgc tcatgagaca ataaccctga 3060
taaatgcttc aataatattg aaaaaggaag agtatgagta ttcaacattt ccgtgtcgcc 3120
cttattccct tttttgcggc attttgcctt cctgtttttg ctcacccaga aacgctggtg 3180
aaagtaaaag atgctgaaga tcagttgggt gcacgagtgg gttacatcga actggatctc 3240
aacagcggta agatccttga gagttttcgc cccgaagaac gttttccaat gatgagcact 3300
tttaaagttc tgctatgtgg cgcggtatta tcccgtattg acgccgggca agagcaactc 3360
ggtcgccgca tacactattc tcagaatgac ttggttgagt actcaccagt cacagaaaag 3420
catcttacgg atggcatgac agtaagagaa ttatgcagtg ctgccataac catgagtgat 3480
aacactgcgg ccaacttact tctgacaacg atcggaggac cgaaggagct aaccgctttt 3540
ttgcacaaca tgggggatca tgtaactcgc cttgatcgtt gggaaccgga gctgaatgaa 3600
gccataccaa acgacgagcg tgacaccacg atgcctgtag caatggcaac aacgttgcgc 3660
aaactattaa ctggcgaact acttactcta gcttcccggc aacaattaat agactggatg 3720
gaggcggata aagttgcagg accacttctg cgctcggccc ttccggctgg ctggtttatt 3780
gctgataaat ctggagccgg tgagcgtggg tctcgcggta tcattgcagc actggggcca 3840
gatggtaagc cctcccgtat cgtagttatc tacacgacgg ggagtcaggc aactatggat 3900
gaacgaaata gacagatcgc tgagataggt gcctcactga ttaagcattg gtaactgtca 3960
gaccaagttt actcatatat actttagatt gatttaaaac ttcattttta atttaaaagg 4020
atctaggtga agatcctttt tgataatctc atgaccaaaa tcccttaact gagttttcgt 4080
tccactgagc gtcagacccc gtagaaaaga tcaaaggatc ttcttgagat cctttttttc 4140
tgcgcgtaat ctgctgcttg caaacaaaaa aaccaccgct accagcggtg gtttgtttgc 4200
cggatcaaga gctaccaact ctttttccga aggtaactgg cttcagcaga gcgcagatac 4260
caaatactgt ccttctagtg tagccgtagt taggccacca cttcaagaac tctgtagcac 4320
cgcctacata cctcgctctg ctaatcctgt taccagtggc tgctgccagt ggcgataagt 4380
cgtgtcttac cgggttggac tcaagacgat agttaccgga taaggcgcag cggtcgggct 4440
gaacgggggg ttcgtgcaca cagcccagct tggagcgaac gacctacacc gaactgagat 4500
acctacagcg tgagcattga gaaagcgcca cgcttcccga agggagaaag gcggacaggt 4560
atccggtaag cggcagggtc ggaacaggag agcgcacgag ggagcttcca gggggaaacg 4620
cctggtatct ttatagtcct gtcgggtttc gccacctctg acttgagcgt cgatttttgt 4680
gatgctcgtc aggggggcgg agcctatgga aaaacgccag caacgcggcc tttttacggt 4740
tcctggcctt ttgctggcct tttgctcaca tgttctttcc tgcgttatcc cctgattctg 4800
tggataaccg tattaccgcc tttgagtgag ctgataccgc tcgccgcagc cgaacgaccg 4860
agcgcagcga gtcagtgagc gaggaagcgg aagagcgccc aatacgcaaa ccgcctctcc 4920
ccgcgcgttg gccgattcat taatgcagct ggcacgacag gtttcccgac tggaaagcgg 4980
gcagtgagcg caacgcaatt aatgtgagtt agctcactca ttaggcaccc caggctttac 5040
actttatgct tccggctcgt atgttgtgtg gaattgtgag cggataacaa tttcacacag 5100
gaaacagct 5109
|
The present invention relates to a transgenic C. elegans which expresses an amyloid precursor protein (APP) or a part thereof, to the transgene itself, to the protein encoded by the transgene, and also to a process for preparing the transgenic C. elegans and to its use.
| 2
|
This application is a continuation of application Ser. No. 08/794,446, filed on Feb. 04, 1997, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device and method to stabilize a sheet between the press section and the dryer section of a paper machine. More particularly, the present invention is directed to such an apparatus and method for guiding a fibrous web from a press section to a drying section, in which the web is guided and supported on a drying felt wire as the web is guided into the drying section, e.g., around an initial group of drying cylinders.
2. Description of the Related Art
After pressing, a fibrous web, e.g., a paper web prepared in a paper machine, is extremely weak. A large number of breaks in the web tend to occur in the run thereof between the press section and a first drying cylinder within a drying section.
The prior art is familiar with a press section which comprises a closed roll combination having four press rolls, in which the first nip was formed between a hollow-faced roll and a suction roll, and was provided with two pressing felts. The second single-felt nip of the press section was formed between the suction roll and a centre roll of the press section. The centre roll of the press section was a smooth-faced stone roll, the third, final, nip of the press section being formed in connection with this stone roll and being provided with its own felt. The running fibrous web was detached from the smooth face of the stone roll in the press section by extending or stretching the web in the running direction.
In recent years the running speeds of paper machines have been increasing constantly up to 1500 meters per minute. At such speeds, fluttering of the web becomes a serious problem deteriorating the running quality. When the running speed of a paper machine becomes higher than 1000 m/min., the air flows produced by the wires greatly affect the running quality. Unless these air flows are controlled, the result is fluttering of the web, wrinkles, uneven drying, and even web breaks, with costly standstills resulting from them. The passing of the web from the press section into the drying section and the supporting of the web cannot be effectively controlled by means of the methods and devices suggested in the prior art.
It is presently the opinion in the industry that web flutter is mainly the result of strong air current flows within the pockets defined within the drying section and by pressure differentials in the pockets as well as in the nips formed by the web, drying wire and cylinder surfaces. The strong air flows and pressure differentials are the consequence of boundary layer flows induced by the moving wire, web and cylinder surfaces.
The pockets mentioned above are formed by the free web draws, free cylinder surfaces, and wires or felts guided by guide rolls. These pockets are closed except at their transverse ends and the ventilation of the pockets is considered to be an important factor from the viewpoint of efficiency and uniformity of the moisture profile obtained.
A typical arrangement between the press section and the dryer section includes the following components: a felt roll, the first dryer, the felt or fabric that supports the sheet; and the sheet itself. The problem in this arrangement is that the sheet separates from the fabric as it travels over a relatively long span between the press section and the dryer section. Since it separates, it becomes prone to wrinkles and possibly to tearing, thus causing sheet breaks. The main cause of the problem is due to machine speed. As machine speeds increase, the amount of air entrained by a fabric increases greatly. The area formed by the fabric as it comes around the felt roll is a pocket into which air is pumped, with the only escape being back through the fabric. As the air forces through the fabric in all directions, it also forces the sheet away from the fabric. The sheet can form bubbles, it can flutter and form wrinkles and break.
Some solutions proposed to alleviate this problem use high velocity jets of air to entrain surrounding air and evacuate this pocket. Any high velocity air jet has negative pressure in its wake which will cause surrounding air to be entrained with the jet. Therefore, if properly directed, this arrangement can expel air from a given area. In such typical layout, a box with high velocity jets, properly placed will evacuate much of the air being pushed through the felt and onto the paper. Although these systems work, such solution is qualitative in nature since the relationship between the nozzle flow and velocity and the amount of entrained air cannot be firmly established.
Some recently suggested solutions to these problems have allegedly been provided by the following patents:
U.S. Pat. No. 4,551,203 patented Nov. 5, 1987 by P. Eskelinen (and its corresponding Canadian Patent No. 1,243,197 issued Oct. 13, 1988) provided a method and arrangement for guiding a paper web from the press section to the drying section. The patented apparatus for guiding a fibrous web from a press section to a drying section, included a guide roll which was adapted to guide the web passing from the press section onto a drying wire from the drying section passing about the guide roll. Means were provided for urging the web and drying wire against one another as the web was passed to the drying section, the urging means being disposed between the guide roll and the drying section in a running direction of the web and wire, the guide roll constituting means for passing the web in an open draw from the press section onto the drying wire. The urging means included means for generating a negative pressure in a space adjacent a side of the drying wire opposite a side which contacted the web, to urge the web and drying wire against each other. The negative pressure generating means comprised at least one blowing box having gas discharge means extending substantially over an entire width of the web. The blowing box directed a gas stream through the gas discharge means in a direction which was substantially-parallel to the running direction of the web and supporting drying wire. The discharge speed of the gas was greater than a running speed of the drying wire. This created negative pressure between the blowing box and the drying wire in order to urge the web and drying wire against one another.
The patented method for guiding a fibrous web from a press section to a drying section, included the step of passing the web from the press section in an open draw onto a drying wire passing about a guide roll. The next step involved urging the web and drying wire against each other as the drying wire passed from the guide roll to the drying section. This urging was accomplished by ejecting gas out of blowing means on a side of the drying wire opposite to a side supporting the web in a direction which was substantially-parallel to a running direction of the drying wire and web and at a speed greater than a running speed of the drying wire in order to generate negative pressure in a space between the blowing means and the drying wire.
U.S. Pat. No. 4,694,587 patented Sep. 22, 1987 by P. Eskelinen (and its corresponding Canadian Patent No. 1,336,107 issued Aug. 08, 1995) provided a method and apparatus in a twin-wire cylinder drying section of a paper machine. The twin-wire drying section of a paper machine included upper and lower rows of drying cylinders with an upper drying wire guided by the upper drying cylinders and upper guide rolls situated between the upper drying cylinders and with a lower drying wire guided by the lower drying cylinders, and lower guide rolls situated between the lower drying cylinders. A web was pressed by the upper wire in direct drying contact with the surfaces of the upper drying cylinders and was pressed by the upper wire in direct drying contact with the surfaces of the lower drying cylinders and had a free draw of a certain length between a drying cylinder of one row and a drying cylinder of another row. A vacuum zone was arranged on a run of a drying wire between a drying cylinder and the next guide roll which caused the web to be suctioned against the drying wire so that the length of the free run of the web was substantially shortened. The suction was created by directing air jets in directions opposite to the running directions of the drying wire run and the guide roll which ejected air from spaces behind them thereby ereating the vacuum zone.
SUMMARY OF THE INVENTION
The above purported solutions do not effectively or completely solve the problem outlined. Accordingly, it is a first object of the present invention to provide a new and improved apparatus and method for guiding a fibrous web, e.g., a paper web, from a press section to a drying section, in which such web can be smoothly and securely guided in the run from the press section to the drying section.
It is another object of the present invention to provide a new and improved method and apparatus for guiding a fibrous web from a press section to a drying section, which substantially eliminates any detrimental fluttering of the web as it passes from the press section to the drying section.
It is a further object of the present invention to provide a new and improved apparatus and method for guiding a fibrous web from a press section to a drying section, in which such web is suitably guided on a suitable running support.
A still further object of the present invention is to exhaust air from the pocket which is formed by the felt, or the like, and the felt roll.
Yet a further object of the present invention is to exhaust any air carried by the felt between the felt roll and the first dryer.
A still further object of the present invention is to create a suction (negative pressure) above the felt, in the span between the felt roll and the first dryer.
The present invention provides a method for guiding a wet fibrous web from a press section to a drying section of a paper-making machine, which includes the steps of passing the wet fibrous web from the press section in an open draw onto a felt, the felt, passing about a guide roll, and urging the wet fibrous web and the felt, against each other as a drying wire of the drying section passes from the guide roll to a drying cylinder, by the generation of negative pressure in the space on the side of the felt, which is opposite to the side of the felt, which supports the fibrous web, the negative pressure being generated using the combination of (i) an inlet Venturi, which is located adjacent to the guide roll in order to draw up and exhaust air from an area where the web separates from the surface of the guide roll, (ii) an outlet Venturi which is situated adjacent to the drying cylinder to draw away air from a gap between the dryer cylinder and an inlet opening to the outlet Venturi, and (iii) a main Venturi, which is disposed between the inlet Venturi and the outlet Venturi to draw away air from, and to maintain a negative static pressure over, an unsupported span between the guide roll and the dryer cylinder.
By several features of the above-described method, the negative pressure at the inlet Venturi is generated at each of the inlet Venturi, at the outlet Venturi and at the main Venturi, by at least one of (a) at the inlet Venturi, by expelling a jet of air at a high velocity into the throat of the inlet Venturi and by discharging the jet of air angularly away from the plane of the felt, (b) at the outlet Venturi, by expelling a jet of air at a high velocity into the throat of the outlet Venturi and by discharging the jet of air angularly away from the plane of the felt, and (c) at the main Venturi, by expelling a first jet of air at a high velocity into the throat of the main Venturi, and by discharging the first jet of air perpendicularly to the plane of the felt, or by discharging the first jet of air angularly away from the plane of the felt. In step (c), negative pressure at the main Venturi may be generated by additionally expelling a second jet of air at a high velocity into the throat of the main Venturi, and by discharging the second jet of air perpendicularly to the plane of the felt, or by discharging the second jet of air angularly, away from the plane of the felt.
By still another feature of the above-described method, the primary air flow is at least one of the following: from about 50 to about 200 CFM/ft from an inlet to the outlet Venturi into the throat of the outlet Venturi; (b) of from about 50 to about 200 CFM/ft from an inlet to the inlet Venture into the throat of the inlet Venturi; and (c) of from about 50 to about 400 CFM/ft. from one inlet to the main Venturi into the throat of the main Venturi.
By still another feature of the above-described method, the distance between the web and the inlet to the inlet Venturi, and the distance between the web and the inlet to the outlet Venturi is from about 1/4 inch to about 3/4 inch.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings,
FIG. 1 is a schematic view of the area of a paper machine of a typical prior art installation between the press section and the drying section;
FIG. 2 is a schematic view of the area of a paper machine between the press section and the drying section according to one embodiment of the present invention;
FIG. 3 is an enlarged view of the sheet stabilizer of the present invention shown in FIG. 2, and
FIGS. 4 and 5 are graphs which show the performance of the sheet stabilizer.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 (the prior art) shows three blow FIG. 1 (the prior art) shows three blow boxes one after the other. The blow boxes each have a planar bottom face which is located at a distance Δ from the opposite drying wire. The distance Δ is preferably within the range of about 10 to about 25 mm. At both ends of the planar bottom wall of the blow boxes, nozzle slots are located, by means of which the blow jets are generated. The downstream nozzle slot of the last nozzle box is located substantially at the position at which the drying wire and the sheet achieve contact with the first drying cylinder. The fetching roll may also be arranged as a suction roll, and the suction zone a of the roll is shown in broken lines.
Additional air jets of the blow boxes are directed opposite to the direction of movement of the wire or web and of the roll. According to the prior art, it was alleged that the ejection effect of the jets prevented generation of detrimental positive pressures.
As seen in FIG. 2, the present invention provides a sheet stabilizer 10 disposed above the felt 11 between the felt roll 12 and the first dryer cylinder 13. The sheet stabilizer is in the shape of a box 14, extending transversely across the entire width of the felt 11 and the sheet 15. The sheet stabilizer 10 is provided with an inlet Venturi 16, a main Venturi 17 and an outlet Venturi 18.
The detailed internal structure of the sheet stabilizer 10 of FIG. 2 is shown in FIG. 3. As shown in FIG. 3, the inlet Venturi 16 is formed by the surface 20 and surfaces 21,22 which are substantially-parallel thereto. Primary air from one nozzle 23 (or from a series of nozzles) is discharged into the throat 24 which is formed by surfaces 20, and 21,22. The suction thus created draws air in through opening 25, as shown by arrows A. The combined air is discharged through inlet discharge opening 26.
Air which is carried along by the felt, or the like, 11 is exhausted through the outlet Venturi 17. The outlet Venturi 17 is formed by the surface 30 and surfaces 31,32 substantially-parallel thereto. Primary air from one nozzle 33 (or from a series of nozzles) is discharged into the throat 34 which is formed by surfaces 30 and 31,32. The suction thus created draws air in through opening 35, as shown by arrow B. The combined air is discharged through outlet discharge opening 36.
The main function of the sheet stabilizer 10 is to create a negative pressure above the felt, or the like, 11 so as to keep the sheet 15 in close contact with the felt, or the like, 11. This is primarily achieved by the main Venturi 18. Air is exhausted from the plenum C, by the main Venturi 18. The main Venturi 18 is formed by the surfaces 40,41 and 42,43. Primary air from a nozzle 44 or 45, (or from a series of such nozzles), or from both nozzles 44,45, (or from all of a series of such nozzles), is discharged into the throat 46 which is formed by surfaces 40,41 and 42,43. The suction thus created draws air in through opening 47, as shown by arrow D. The combined air is discharged through main discharge 48 opening.
The main Venturi 18, in addition, generates a negative pressure in plenum C which, in turn, creates a negative pressure over the surface of the felt 11 between the guide roll 12 and the dryer cylinder 13.
Air under pressure enters the interior 50,51 of the sheet stabilizer 10. By means of damper 52 which is operatively disposed in opening 52a in wall 52b, damper 53 which is operatively disposed in opening 53a in wall 53b in interior 51 of the sheet stabilizer 10, damper 54 which is operatively disposed in opening 54a in wall 54b, and damper 55 which is operatively disposed in opening 55a in wall 45b in interior 50 of the sheet stabilizer 10, primary air to each Venturi nozzle 23,44,45,33, (respectively), may be controlled and, thereby, the amount of exhaust and suction that is generated by the sheet stabilizer 10 can be controlled. In addition, such separate dampers 52,53,54,55 allow the modulation or biasing of the entrained air volume and suction pressure generated.
A recessed central section between forward wall 60 and rear wall 61 helps to create a plenum effect in order to enhance the effect of the negative static pressure.
FIG. 4 shows the relationship between suction pressure and the distance between the felt, or the like, and the sheet stabilizer. Up to 1.0 inches of negative pressure can be developed with a 1/2" gap. This suction, however, drops off rapidly above 1/2". Consequently, 1/2" has been selected as an optimum operating point.
FIG. 5 shows the amount of induced air from the main Venturi as a function of the distance between the sheet stabilizer and the felt. The main Venturi has a constant air flow while the flow from the outlet Venturis increase with distance.
As described hereinabove, the aims of the present invention have been met by the sheet stabilizer which provides a direct and measurable relationship between the amount of air supplied and the amount of air entrained. This sheet stabilizer is based on the use of a Venturi. A Venturi is a device in which air with a high static pressure and low velocity is forced through a "throat" where the velocity is increased to a high level. The static pressure is converted to velocity pressure. If the velocity is high enough, the static pressure in the throat can actually become negative. Proper design of the Venturi will ensure that the desired pressure are obtained. Equations governing Venturi design are well known. A Venturi, properly designed, will have a suction that is definitive and quantitative. This suction, in turn, is used to evacuate air from above the felt, or the like, and to stabilize the sheet.
As described above, the sheet stabilizer of broad embodiments of the present invention includes three Venturis, namely an inlet Venturi, an outlet Venturi and a main Venturi. The inlet Venturi is located as close as possible to the guide roll in order to exhaust air from the area where the felt, or the like, separates from the surface of the guide roll. Air in this region would have the highest tendency to push through the felt, or the like, and would cause the initial bubbling and fluttering of the sheet.
The outlet Venturi expels a large quantity of air from the gap between the dryer cylinder and the bottom of the sheet stabilizer.
The main Venturi is also designed to expel a large quantity of air and, in conjunction with the outlet Venturi, maintains a negative static pressure over the unsupported span between the felt roll and the dryer.
The sheet stabilizer of embodiments of this invention includes dampers. Each Venturi has a separate damper which allows the modulation or biassing of the entrained air volume and suction pressure generated.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. Consequently, such changes and modifications are properly, equitably, and "intended" to be, within the full range of equivalence of the following claims.
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A novel sheet transfer stabilizer is provided for transferring a fibrous wet sheet from a press section to a dryer section of a paper-making machine by way of a felt, or the like. The sheet transfer stabilizer includes a composite Venturi box which is disposed between a felt roll of the press section and a first dryer. The Venturi box includes three side-by-side Venturis, namely an inlet Venturi, an outlet Venturi, and a main Venturi, such Venturi boxes are used to create and maintain a vacuum in the felt/web system.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Application No. 60/929,206, filed Jun. 18, 2007, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a detection method for an antigen such as a chemical compound, a peptide, a protein, an RNA, a DNA, a cell (proteins released in situ), or a virus particle (proteins released in situ). In particular, the present invention provides a method and composition useful for performing ELISA assays, which also can be used for Western blot and Dot blot assays.
2. Description of the Prior Art
Immunological methods have become important tools useful for detecting antigens including, for example, peptides, proteins, nucleic acids, biological cells, and virus particles. A wide variety of methods have been developed for the detection or quantitation of antigens. Among them, Western Blot, Dot Blot, ELISA and Immunohistology are the four most commonly used methods.
Enzyme-linked Immunosorbent Assays (ELISAs), which combine the high specificity of antibodies with the high sensitivity of enzyme assays by using antibodies or antigens coupled to an easily assayed enzyme that possesses a high turnover number such as alkaline phosphatase (AP) or horseradish peroxidase (HRP), are very useful tools both for determining antibody concentrations (antibody titer) in sera as well as for detecting the presence of antigen.
There are two main variations on this method: ELISA can be used to detect the presence of antigens that are recognized by a detection agent or it can be used to test for detection agents that recognize an antigen. There are many different types of ELISAs. Four of the most common types of ELISA are “Direct ELISA,” “Indirect ELISA,” “Sandwich ELISA” and Cell-based ELISA (C-ELISA).
A conventional direct ELISA ( FIG. 1 ) is comprised of the following steps: (i) coating a solid phase with an antigen dissolved in a coating buffer; (ii) incubating the solid phase from Step (i) with a blocking reagent for 1 hour to block non-specific binding sites on the solid phase; (iii) washing the solid phase from Step (ii) three times with PBS or PBST for 1 min each; (iv) incubating the solid phase from Step (iii) with a primary detection agent which binds to the antigen; (v) washing the solid support from Step (iii) five times for 1 min each in PBS or PBST to remove the non-specifically bound primary detection agent; and (vi) using a detection system such as UV, fluorescence, chemiluminescence or other detection methods to detect the bound primary detection agent. The primary detection agent can be, without limitation, a detection agent linked (coupled) to a fluorescent dye, or a reporter enzyme such as alkaline phosphatase (AP) or horseradish peroxidase (HRP), which can convert a colorless substrate to a colored product whose optical densities can be measured on an ELISA plate reader at target wavelengths.
A conventional indirect ELISA ( FIG. 3 ) is comprised of the following steps: (i) coating a solid phase with an antigen dissolved in a coating buffer; (ii) incubating the solid phase from Step (i) with a blocking reagent for 1 hour to block non-specific binding sites on the solid phase; (iii) washing the solid phase from Step (ii) three times with PBS or PBST for 1 min each; (iv) incubating the solid phase from Step (iii) with a primary detection agent diluted in a solution for 1 hour; (v) washing the solid support from Step (iv) three times for 1 min in PBS or PBST to remove the non-specifically bound primary detection agent; (vi) incubating the solid support from step (v) with a secondary detection agent diluted in a solution for 1 hour; (vii) washing the solid support from Step (vi) five times for 1 min each in PBS or PBST to remove the non-specifically bound secondary detection agent; and (viii) using a detection system such as UV, fluorescence, chemiluminescence or other methods to detect the bound secondary detection agent. The secondary detection agent binds the primary detection agent. The secondary detection agent can be, without limitation, a detection agent linked (coupled) to a reporter enzyme such as alkaline phosphatase (AP) or horseradish peroxidase (HRP), which can convert a colorless substrate to a colored product whose optical densities can be measured on an ELISA plate reader at target wavelengths.
The complete direct ELISA procedure involves at least three incubation steps: the first is incubation between the solid support and the antigen; the second is incubation between the solid support and the blocking reagent; and the third one is incubation between the solid support and the primary detection agent. The incubation step is a two-phase reaction and involves the binding reaction between the antigen on the solid support and the detection agent.
The complete indirect ELISA procedure involves at least four incubation steps: the first is incubation between the solid support and an antigen; the second is incubation between the solid support and the blocking reagent; the third one is incubation between the solid support and the primary detection agent; and the fourth is incubation between the solid support and the secondary detection agent. The incubation step is a two-phase reaction and involves the binding reaction between the antigen on the solid support and the detection agent.
In a conventional direct ELISA, the first incubation step, antigen coating, takes at least 2 hours and each other incubation step takes about 1 hour. A conventional direct ELISA, as described above, therefore, takes at least 4 hours.
In a conventional indirect ELISA, the first incubation step, antigen coating, takes at least 2 hours and each other incubation step takes about 1 hour. A conventional indirect ELISA, as described above, will take at least 5 hours. Because conventional direct and indirect ELISA consumes valuable time, there is a need for a simple and rapid process to address these conventional time-consuming assays.
The cell-based ELISA (C-ELISA) is a moderate throughput format for detecting and quantifying cellular proteins including post-translational modifications associated with cell activation (e.g., phosphorylation and degradation). Cells are plated, treated according to experimental requirements, fixed directly in the wells, and then permealized. After permealizing, fixed cells are treated similar to a conventional immunoblot, including blocking, incubation with a first antibody, washing, incubation with a second antibody, addition of chemilumescent substrates and development.
In 1971, Engvall and Perlmann (Immunochem., 8:871-874, 1971) coined the term “enzyme-linked immunosorbent assay,” which is better known by the acronym “ELISA”, to describe an enzyme-based immunoassay method which is very useful for measuring antigen concentrations. Since then, ELISA has not only become one of the most commonly used methods for protein and antibody detection and identification but also the basic immunoassay upon which many of the modern assays are based.
A rapid method for microwave mediated enzyme-linked immunosorbent assay (M-ELISA) (U.S. Pat. No. 6,498,016) was developed to perform ELISA rapidly. However, this procedure requires a carefully-controlled microwave which needs optimization.
Although there have been substantive improvements in all of these immuno-detection methods, including the quality of reagents, solid phase plates and plastics, microplate readers, washers, and statistical software, the basic methodology has remained virtually unchanged.
SUMMARY OF THE INVENTION
The present invention provides improved methods and compositions for performing a rapid enzyme-linked immunosorbent assay (ELISA).
In an aspect of the present invention, there is provided a method for performing a direct rapid enzyme-linked immunosorbent assay (ELISA), comprising the steps of coating a solid phase with an antigen dissolved in a quick coating buffer for between about two to twenty minutes, preferably for about five minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase with a primary detection agent in solution; washing the solid phase to remove any unbound primary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound primary detection agent.
In another aspect of the present invention, there is provided a method for performing an indirect rapid enzyme-linked immunosorbent assay (ELISA), comprising coating a solid phase with an antigen dissolved in a quick coating buffer for between about two to twenty minutes, preferably for about five minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase with a primary detection agent in solution and then washing the solid phase to remove any unbound primary detection agent; incubating the solid phase with a secondary detection agent and then washing the solid phase to remove any unbound secondary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound secondary detection agent.
In a further aspect of the present invention, there is provided a method for performing an indirect rapid enzyme-linked immunosorbent assay (ELISA), comprising coating a solid phase with an antigen dissolved in a quick coating buffer for between about two to twenty minutes, preferably for about five minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase simultaneously with a primary detection agent and a secondary detection agent and then washing the solid phase to remove any unbound primary detection agent and secondary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound secondary detection agent.
In another aspect of the present invention, there is provided a method for performing an indirect rapid enzyme-linked immunosorbent assay (ELISA), comprising coating a solid phase with an antigen dissolved in a quick coating buffer for between about two to twenty minutes, preferably for about five minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase with a primary detection agent in solution and then washing the solid phase to remove any unbound primary detection agent; incubating the solid phase with a secondary detection agent and then washing the solid phase to remove any unbound secondary detection agent; incubating the solid phase with a tertiary detection agent and then washing the solid phase to remove any unbound tertiary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound tertiary detection agent.
In still another aspect of the present invention, there is provided a method for performing an indirect rapid enzyme-linked immunosorbent assay (ELISA), comprising coating a solid phase with an antigen dissolved in a quick coating buffer for between about two to twenty minutes, preferably for about five minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase simultaneously with a primary detection agent, a secondary detection agent and a tertiary detection agent and then washing the solid phase to remove any unbound primary, secondary and tertiary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound tertiary detection agent.
In still another aspect of the present invention, there is provided a method for performing a rapid cell-based enzyme-linked immunosorbent assay (C-ELISA), comprising lysing cells in a quick lysis and coating buffer; coating a solid phase with cellular proteins released in situ in the quick lysis and coating buffer for about two to twenty minutes, preferably for about five to ten minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase with a primary detection agent in solution; washing the solid phase to remove any unbound primary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound primary detection agent.
In still another aspect of the present invention, there is provided a method for performing a rapid cell-based enzyme-linked immunosorbent assay (C-ELISA), comprising lysing cells in a quick lysis and coating buffer; coating a solid phase with cellular proteins released in situ in the quick lysis and coating buffer for about two to twenty minutes, preferably for about five to ten minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase with a primary detection agent in solution and then washing the solid phase to remove any unbound primary detection agent; incubating the solid phase with a secondary detection agent and then washing the solid phase to remove any unbound secondary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound secondary detection agent.
In still another aspect of the present invention, there is provided a method for performing a rapid cell-based enzyme-linked immunosorbent assay (C-ELISA), comprising lysing cells in a quick lysis and coating buffer; coating a solid phase with cellular proteins released in situ in the quick lysis and coating buffer for about two to twenty minutes, preferably for about five to ten minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase simultaneously with a primary detection agent and a secondary detection agent; washing the solid phase to remove any unbound primary and secondary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound secondary detection agent.
In another aspect of the present invention, there is provided a method for performing an indirect rapid cell-based enzyme-linked immunosorbent assay (C-ELISA), comprising lysing cells in a quick lysis and coating buffer; coating a solid phase with cellular proteins released in situ in the quick lysis and coating buffer for two to twenty minutes, preferably for about five minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase with a primary detection agent in solution and then washing the solid phase to remove any unbound primary detection agent; incubating the solid phase with a secondary detection agent and then washing the solid phase to remove any unbound secondary detection agent; incubating the solid phase with a tertiary detection agent and then washing the solid phase to remove any unbound tertiary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound tertiary detection agent.
In still a further aspect of the present invention, there is provided a method for performing a rapid cell-based enzyme-linked immunosorbent assay (C-ELISA), comprising lysing cells in a quick lysis and coating buffer; coating a solid phase with cellular proteins released in situ in the quick lysis and coating buffer for about two to twenty minutes, preferably for about five to ten minutes; blocking the solid phase with a blocking reagent dissolved in a quick blocking buffer for between about two to ten minutes, preferably for about five minutes; incubating the solid phase simultaneously with a primary detection agent, a secondary detection agent and a tertiary detection agent; washing the solid phase to remove any unbound primary, secondary and tertiary detection agent; and detecting the presence of an agent bound on the solid phase with a detection system that detects the bound tertiary detection agent.
In still another aspect of the present invention, there is provided a rapid enzyme-linked immunosorbent assay (ELISA), comprising a quick coating buffer and a blocking reagent in a quick blocking buffer. The quick coating buffer is comprised of water and a metal hydroxide such as, without limitation, sodium hydroxide, potassium hydroxide or rubidium hydroxide. Preferably, the metal hydroxide is sodium hydroxide. The concentration of the metal hydroxide can range from between about 0.004 g/l to 40 g/l of buffer, and preferably is about 4 g/l of buffer. The pH of the quick coating buffer can range from between about 10.0 to 14.0, and preferably is about 13.0. The quick blocking buffer is comprised of water and a metal hydroxide selected from the group consisting of sodium hydroxide, potassium hydroxide and rubidium hydroxide, and preferably is potassium hydroxide. The concentration of the metal hydroxide can range from between about 0.0056 g/l to 56 g/l of buffer, and preferably is about 5.6 g/l of buffer. The pH of the quick blocking buffer can range from between about 10.0 to 14.0, and preferably is about 13.0.
In still a further aspect of the present invention, there is provided a kit for performing a rapid enzyme-linked immunosorbent assay (ELISA), a western blot assay or a dot blot assay, comprising a quick coating buffer and a blocking reagent dissolved in a quick blocking buffer. The blocking reagent can include, without limitation, non-fat milk, casein, bovine serum albumin, fish gelatin or other suitable chemical reagents known in the art. The quick coating buffer is comprised of water and a metal hydroxide such as, without limitation, sodium hydroxide, potassium hydroxide or rubidium hydroxide. Preferably, the metal hydroxide is sodium hydroxide. The concentration of the metal hydroxide can range from between about 0.004 g/l to 40 g/l of buffer, and preferably is about 4 g/l of buffer. The pH of the quick coating buffer can range from between about 10.0 to 14.0, and preferably is about 13.0. The quick blocking buffer is comprised of water and a metal hydroxide selected from the group consisting of sodium hydroxide, potassium hydroxide and rubidium hydroxide, and preferably is potassium hydroxide. The concentration of the metal hydroxide can range from between about 0.0056 g/l to 56 g/l of buffer, and preferably is about 5.6 g/l of buffer. The pH of the quick blocking buffer can range from between about 10.0 to 14.0, and preferably is about 13.0.
An object of the present invention, therefore, is to provide improved rapid direct and indirect ELISA methods for the detection and quantification of antibodies by using an improved coating buffer. Accordingly, the coating time can be reduced from more than two hours to about five minutes.
Another object of the present invention is to provide improved rapid direct and indirect ELISA methods for the detection and quantification of antibodies by using an improved blocking reagent. Accordingly, the blocking time can be reduced from one hour to about five minutes.
Still another object of the invention is to provide a novel and rapid cell-based ELISA (C-ELISA) method for the detection and quantification of proteins released in situ from cells by using a novel cell lysis and coating reagent, in which the cells are lyzed, the cellular proteins are released and coated onto the surface of plate wells at the same time in a single buffer in as little as five minutes. This removes both the cell fixing step, cell permealizing step and the wash steps related to those two steps.
It is a further object of the invention to provide an improved rapid direct and indirect ELISA method for the detection and quantification of antibodies by using both the improved coating buffer and the blocking reagents. Accordingly, the time can be reduced from more than four hours to about two hours or less (e.g., to about one hour).
A further object of the present invention is to provide an improved rapid indirect ELISA method for the detection and quantification of antibodies by integrating conventional indirect ELISA containing two steps into a one step method, and thus providing a more efficient process.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1 schematically illustrates procedures of a classical direct ELISA;
FIG. 2 schematically illustrates procedures of a direct ELISA process of the invention;
FIG. 3 schematically illustrates procedures of a classical indirect ELISA;
FIG. 4 schematically illustrates procedures of an indirect ELISA process of the invention;
FIG. 5 schematically illustrates procedures of a further indirect ELISA process of the invention; and
FIG. 6 shows an example of an indirect ELISA of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this invention pertains. All publications and patents referred to herein are incorporated by reference.
The invention provides methods and compositions useful for performing antigen or antibody detection or diagnostics using ELISA. In one aspect, the invention provides a significant improvement over conventional ELISA techniques. The invention provides a method whereby several steps in a classical ELISA procedure can be performed or completed in a few minutes instead of hours. The invention also provides a method whereby several steps in a classical ELISA procedure time can be combined into one step or two steps. The methods of the invention greatly reduce the time for detection assays as well as associated costs.
As used herein “antigen” and “antibody” are to be taken in their broadest context. An “antigen” can be any molecule, cell, virus, or particle. For example, an antigen includes, but is not limited to, a chemical molecule, a peptide molecule, a protein molecule, an RNA molecule, a DNA molecule, a traditional antibody, e.g., two heavy chains and two light chains, a recombinant antibody or fragment, a bacterial cell, a virus particle, a cell, a particle, and a product comprising crosslinking any two or more of the above.
An antigen can be in a pure form, or it can exist in a mixture. An antigen can be in a modified form (e.g., modified by chemicals) or can be in an unmodified form.
Reference herein to an “antibody” is to be taken in its broadest context. “An antibody” is a polypeptide that binds to “an antigen.” An antibody includes, but is not limited to, a traditional antibody, a fragment of a traditional antibody containing an antigen binding site, a recombinant antibody containing an antigen binding site, a protein which binds to an antigen, and a product comprising crosslinking any two or more of the above.
An antibody can be in a pure form, or it can exist in a mixture. An antibody can be in a modified form (e.g., modified by a chemical) or can be in an unmodified form.
The term “detection agent” refers to an agent that is used to detect an antigen or antibody. A detection agent can be either an “antigen” or an “antibody.” A detection agent can be either a labeled “antigen” or “antibody” or an unlabeled “antigen” or “antibody.” Suitable labeling methods that can be used in the present invention include, without limitation, isotope labeling, chemical modification, enzyme conjugation, fluorescent dye labeling, luminescence and other labeling methods commonly known by those skilled in the art. Therefore, a detection agent includes, but is not limited to, a chemical molecule, a peptide molecule, a protein molecule, an RNA molecule, a DNA molecule, a traditional antibody, a fragment of a traditional antibody containing an antigen binding site, a recombinant antibody containing an antigen binding site, a protein which binds to an antigen, a bacterial cell, a viral particle, a cell, a particle, and a product comprising crosslinking any two or more of the above.
A detection agent can be in a pure form, or it can be an impure form (e.g., contained in a mixture with other compounds or materials). A detection agent can be in a modified form or can be an unmodified form. According to the order of a “detection agent” used in a method, a “detection agent” can be referred as “a primary detection agent,” “secondary detection agent,” “a tertiary detection agent” or “a fourth detection agent,” and the like.
The term “detection system” refers to a system which can be used to give a readout comprising information related to the quantity or quality of a protein or agent in a sample (e.g., a blot, cell and the like). The choice of a detection system depends on the choice of the detection agent used in a method of the invention. For example, a detection system includes, but is not limited to, X-ray film or other beta/gamma sensitive material if the detection agent is isotope-labeled; if the detection agent is enzyme-labeled, a chemical reaction which can result in color or a chemiluminescence signal that can be detected by, for example, a CCD camera, visual inspection or other device capable of sensing a signal can be used; and if the detection agent is fluorescence-labeled, a fluorescence microscope, a fluorescence cell sorter, a fluorescence scanner or camera can be used.
The invention provides compositions useful in ELISAs. One of the compositions is referred to herein as a quick coating buffer. A quick coating buffer of the invention comprises sodium hydroxide (NaOH) and water. Sodium hydroxide may be substituted with similar elements known in the art that function in solution in substantially the same way. For example, sodium hydroxide can be substituted with potassium hydroxide (KOH) or rubidium hydroxide (RbOH). In one aspect, the quick coating buffer comprises about 0.004 grams to 40 grams per liter of buffer, typically about 4 grams. The quick coating buffer can have a pH in the range of about 10.0 to about 14.0, but typically is about 13.0.
A quick coating buffer of the invention can be bottled and used as typically performed in research and diagnostic laboratories. The quick coating buffer of the present invention is made in sterile water or distilled water that is sterile filtered and/or autoclaved. The quick coating buffer of the invention can be used with ELISA assays. The quick coating buffer can be included in an article of manufacture or kit for use in ELISAs and the like.
The invention provides a second composition useful in ELISAs. The composition is referred to herein as a quick blocking buffer. A quick blocking buffer of the invention comprises potassium hydroxide (KOH) and water. Potassium hydroxide may be substituted with similar elements known in the art that function in solution in substantially the same way. For example, potassium hydroxide can be substituted with sodium hydroxide (NaOH) or rubidium hydroxide (RbOH). In one aspect, the quick blocking buffer comprises about 0.0056 grams to 56 grams per liter of buffer, typically about 5.6 grams. The quick blocking buffer can have a pH in the range of about 10.0 to about 14.0, but typically is about 13.0.
The invention provides a third composition useful in Cell-based ELISA (C-ELISA). The composition is referred to herein as a quick lysis and coating buffer. A quick lysis and coating buffer of the invention comprises potassium hydroxide and water. Potassium hydroxide may be substituted with similar elements known in the art that function in solution in substantially the same way. For example, potassium hydroxide can be substituted with sodium hydroxide (NaOH) or rubidium hydroxide (RbOH). In one aspect, the quick lysis and coating buffer comprises about 0.0056 grams to 56 grams per liter of buffer, typically about 5.6 grams. The quick lysis and coating buffer can have a pH in the range of about 10.0 to about 14.0, but typically is about 13.0.
The quick coating buffer, quick blocking buffer a quick lysis and coating buffer of the present invention can be the same or different.
A quick blocking buffer of the invention can be bottled and used as typically performed in research and diagnostic laboratories. The quick blocking buffer is made in sterile water or distilled water that is sterile filtered and/or autoclaved. The quick blocking buffer of the invention can be used with ELISA assays. The quick blocking buffer can be included in an article of manufacture or kit for use in ELISAs and the like. The quick lysis and coating buffer can also be included in an article of manufacture or kit for use in ELISAs and the like.
The invention mainly can be used in three types of ELISA methods: (1) direct ELISA (antibody capture); (2) indirect ELISA; and (3) Cell-based ELISA.
Direct ELISA (antibody capture assay) is one ELISA method. For detecting or quantitating an antigen or a detection agent (e.g. an antibody) that recognizes an antigen, the antigen is coated on the wells of microtiter plates and incubated with test solutions containing specific detection agents. Usually a reporter-molecule labeled primary detection agent is added to the test solutions containing specific detection agents. After incubation, any unbound labeled primary detection agent is washed away. An incubation with a substrate of reporter enzyme also may be needed. A detection system such as UV, fluorescence, chemiluminescence or other methods is used to detect the bound primary detection agent, which is proportional to the amount of the detection agent to be detected in the test solution.
A conventional direct ELISA is comprised of the steps enumerated in FIG. 1 . Three major steps are needed before the final detection step. These steps comprise an antigen coating step, a blocking step and primary detection agent binding step. Each of these steps is necessary in conventional direct ELISA to obtain acceptable results. In conventional direct ELISA, the coating step takes 2 hours at 37° C. or 4° C. o/n. The blocking step takes 1 hour to complete.
The invention provides a direct ELISA that differs from conventional techniques in that each of the coating step and the blocking step of conventional indirect ELISA can be done in just five minutes instead of one or two hours. The new method can greatly cut down the time required for indirect ELISA analysis.
As shown in FIG. 2 , the direct ELISA method of the invention comprises (i) coating a solid phase with an antigen dissolved in the coating buffer of the invention (five minutes only are needed); (ii) blocking a solid phase with a blocking reagent dissolved in the blocking buffer of the invention (five minutes only are needed); (iii) incubating the solid phase of (ii) with a primary detection agent in a solution followed by (iv) detecting the presence of an agent on the solid phase with a detection system that measures, for example, UV, fluorescence, luminescence, calorimetric or other signal to detect the bound primary detection agent.
Indirect ELISA (detection agent capture assay) is one ELISA method that commonly is used for screening and titer determination of antibodies during the course of their production (Douillard, J. Y. and Hoffman, T., 1983). For detecting a detection agent (e.g. an antibody) that recognizes an antigen, the antigen is coated on the wells of microtiter plates and incubated with test solutions containing specific detection agents. Unbound detection agents are washed away. Then a second incubation with a solution containing a secondary detection agent (e.g. alkaline phosphatase conjugated to protein A, protein G, or antibodies against the detection agents of interest) is needed. After incubation, unbound labeled secondary detection agent is washed away. An incubation with a substrate of reporter enzyme also may be needed. A detection system such as UV, fluorescence, chemiluminescence or other methods is used to detect the bound secondary detection agent, which is proportional to the amount of the detection agent to be detected in the test solution.
A conventional indirect ELISA is comprised of the steps enumerated in FIG. 3 . In conventional indirect ELISA, four major steps are needed before the final detection step. These steps comprise an antigen coating step, a blocking step, primary detection agent binding step and secondary detection agent binding step. Each of these steps is necessary in conventional indirect ELISA to obtain acceptable results. The blocking step blocks remaining hydrophobic binding sites on the solid phase to prevent non-specific protein binding of the detection agent used for detection of the target protein, thereby reducing background and/or preventing false positive results. The primary detection agent and secondary detection agent are incubated with the solid phase separately, and then washed away to avoid non-specific binding and to reduce the background.
The invention provides an indirect ELISA that differs from conventional techniques in that each of the coating step and the blocking step of conventional indirect ELISA can be done in just five minutes instead of one or two hours. The new method can greatly cut down the time required for indirect ELISA analysis.
As shown in FIG. 4 , the indirect ELISA method of the invention comprises (i) coating a solid phase with an antigen dissolved in the coating buffer of the invention (five minutes only are needed); (ii) blocking a solid phase with a blocking reagent dissolved in the blocking buffer of the invention (five minutes only are needed); (iii) incubating the solid phase of (ii) with a primary detection agent in a solution followed by (iv) incubating the solid phase of (iii) with a secondary detection agent; and (iv) detecting the presence of an agent on the solid phase with a detection system that measures, for example, UV, fluorescence, luminescence, colorimetric or other signal to detect the bound secondary detection agent.
In another embodiment of the invention, as shown in FIG. 5 , the indirect ELISA of the invention comprises (i) coating a solid phase with an antigen dissolved in the coating buffer of the invention (five minutes only are needed); (ii) blocking a solid phase with a blocking reagent dissolved in the blocking buffer of the invention (five minutes only are needed); (iii) incubating the solid phase of (ii) with a primary detection agent and a secondary detection agent; and (iv) detecting the presence of an agent on the solid phase with a detection system that measures, for example, UV, fluorescence, luminescence, calorimetric or other signal to detect the bound secondary detection agent.
In yet another embodiment of the invention, the indirect ELISA method of the invention comprises (i) coating a solid phase with an antigen dissolved in the coating buffer of the invention (five minutes only are needed); (ii) blocking a solid phase with a blocking reagent dissolved in the blocking buffer of the invention (five minutes only are needed); (iii) incubating the solid phase of (ii) with a primary, secondary, and tertiary detection agent in a solution; and (iv) detecting the presence of an agent on the solid phase with a detection system that measures, for example, UV, fluorescence, luminescence, colorimetric or other signal to detect the bound secondary or tertiary detection agent.
A conventional Cell-based ELISA (C-ELISA) is comprised of five major steps before the final detection step. These steps comprise a cell fixing step, a cell permealizing step, a blocking step, primary detection agent binding step and secondary detection agent binding step. Each of these steps is necessary in conventional Cell-based ELISA (C-ELISA) to obtain acceptable results. The cell fixing step will hold cells to the bottom of plate wells so that they will not be washed away in the process. The cell permealizing step will make the cellular proteins available for immunoassays. The blocking step blocks remaining hydrophobic binding sites on the solid phase to prevent non-specific protein binding of the detection agent used for detection of the target protein, thereby reducing background and/or preventing false positive results. The primary detection agent and secondary detection agent are incubated with the solid phase separately, and then washed away to avoid non-specific binding and to reduce the background.
The invention provides a Cell-based ELISA (C-ELISA) that differs from conventional techniques in that a cell fixing step and a cell permealizing step of conventional Cell-based ELISA are replaced by a single lysis and coating in just five to ten minutes. The blocking step of conventional Cell-based ELISA also can be done in just five minutes instead of one or two hours. The improved method of the present invention can greatly cut down the time required for Cell-based ELISA (C-ELISA).
The Cell-based ELISA (C-ELISA) method of the invention comprises (i) lysing cells and coating a solid surface with the cellular proteins released in situ in the lysis and coating buffer of the invention (five to ten minutes only are needed); (ii) blocking a solid phase with a blocking reagent dissolved in the blocking buffer of the invention (five minutes only are needed); (iii) incubating the solid phase of (ii) with a primary detection agent in a solution followed by (iv) incubating the solid phase of (iii) with a secondary detection agent; and (v) detecting the presence of an agent on the solid phase with a detection system that measures, for example, UV, fluorescence, luminescence, calorimetric or other signal to detect the bound secondary detection agent.
In another embodiment of the invention, the Cell-based ELISA (C-ELISA) of the invention comprises (i) lysing cells and coating a solid surface with the cellular proteins released in situ in the lysis and coating buffer of the invention (five to ten minutes only are needed); (ii) blocking a solid phase with a blocking reagent dissolved in the blocking buffer of the invention (five minutes only are needed); (iii) incubating the solid phase of (ii) with a primary detection agent and a secondary detection agent; and (iv) detecting the presence of an agent on the solid phase with a detection system that measures, for example, UV, fluorescence, luminescence, colorimetric or other signal to detect the bound secondary detection agent.
In yet another embodiment of the invention, the Cell-based ELISA (C-ELISA) of the invention comprises (i) lysing cells and coating a solid surface with the cellular proteins released in situ in the lysis and coating buffer of the invention (five to ten minutes only are needed); (ii) blocking a solid phase with a blocking reagent dissolved in the blocking buffer of the invention (five minutes only are needed); (iii) incubating the solid phase of (ii) with a primary detection agent, a secondary detection agent and a tertiary detection agent in a solution; and (iv) detecting the presence of an agent on the solid phase with a detection system that measures, for example, UV, fluorescence, luminescence, calorimetric or other signal to detect the bound secondary or tertiary detection agent.
In the above-mentioned embodiments, those skilled in the art will know how to select a detection agent for a specific antigen. A detection agent can be, but is not limited to, a chemical molecule, a peptide molecule, a protein molecule, an RNA molecule, a DNA molecule, an antibody, a fragment of an antibody, a recombinant antibody, a bacteria cell, a virus particle, a cell, or a particle. One of the most commonly used detection agents is an antibody. Antibodies can be derived from different species, and they include, but are not limited to, rabbit, mouse, rat, sheep, goat, and chicken antibodies. Commercially available antibodies to a wide variety of antigens are known in the art.
Another one of the more commonly used detection agents comprise protein A, G, L, A/G or other antibody-binding polypeptides. These polypeptides can bind to the conserved region in an antibody. Yet another one of the most used detection agents is avidin or strepavidin. Avidin or streptavidin can bind to biotinylated antibodies or polypeptides. The detection agent in the above-mentioned embodiments can be a labeled detection agent or an unlabeled detection agent.
In the above-mentioned embodiments, those skilled in the art will know that there are a variety of labeling methods for a detection agent. The labeling methods include, but are not limited to, an enzyme such as horseradish peroxidase (HRP), alkaline phosphatase (AP), beta-galactosidase or other enzymes. A detection agent also can be labeled with radioactive isotopes of iodine or other isotopes. A detection agent also can be labeled by a fluorochrome (a fluorescent dye) that can be detected by fluorescence microscope or fluorometer or scanner or camera. A detection agent also can be labeled by a lumichrome which can be detected by luminescence methods. Alternatively, a detection agent also can be labeled by biotin, which can bind to avidin or streptavidin.
In the above-mentioned embodiments, those skilled in the art will be aware of different detection systems used in ELISAs that can be applied to the methods of the invention described herein. These detection systems include, but are not limited to, detection systems using chromogenic reactions of reporter enzymes such as horseradish peroxidase (HRP) and alkaline phosphatase (AP). The reporter enzymes can use different substrates for chromogenic detection. For example, HRP can use 4 CN (4-chloro-1-napthol), DAB/NiCl2 (3,3′-diaminobenzidine/NiCl2), or TMB as substrates for chromogenic detection.
In the above-mentioned embodiments, those skilled in the art will be aware of modifications to further improve the signal to noise ratio. These modifications include, but are not are limited to, adding one or multiple steps to the above embodiment.
Examples of blocking agents useful in the invention include, but are not limited to, non-fat milk, casein, BSA, or fish gelatin, or other chemical reagents. The pH of the working solution can be in the range of 10 to 14, typically 13.0.
The invention also provides kits comprising one or more components useful for performing an ELISA and instructions for carrying out a method of the invention. For example, such instructions can include methods for preparing a coating buffer and a blocking buffer of the invention. In another aspect, the kit may be compartmentalized to receive a coating buffer and/or a blocking buffer and one or more components for performing an ELISA.
Various embodiments of the invention have now been described. It is to be noted, however, that this description of these specific embodiments is merely illustrative of the principles underlying the inventive concept. It is therefore contemplated that various modifications of the disclosed embodiments will, without departing from the spirit and scope of the invention, be apparent to persons skilled in the art.
The present invention is more particularly described in the following non-limiting examples, which are intended to be illustrative only, as numerous modifications and variations therein will be apparent to those skilled in the art.
Example I
Indirect ELISA for the Titration of Antibody
Purified GST protein (Genscript, Cat. No. Z02039) was coated on 96-well plates at 4 μg/ml following standard method (C and D) and the quick coating method of the invention (A and B), respectively. The plate was blocked following standard method (C and D) and the quick coating method of the invention (A and B), respectively. Rabbit anti GST serum was diluted and added to the plate wells for 1 hour at 37° C. for classic method, and 30 minutes at room temperature for the quick method of the invention. Plates were washed three times, Goat anti rabbit HRP (GenScript, Cat. A00098) was diluted 1:10000 and added to the plate wells for 1 hour at 37° C. for classic method, and 20 minutes at room temperature for the quick method of the invention. Finally the plate wells were washed and developed with TMB system (Genscript, Cat. No. M00078). The absorbance at 450 nm was measured using a microtiter plate spectrophotometer. The results are shown in FIG. 6 .
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications that are within the spirit and scope of the invention, as defined by the appended claims.
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The present invention provides improved and rapid detection methods for an antigen such as a chemical compound, a peptide, a nucleic acid, or a protein released from cells or virus particles in situ. The detection time for an antigen can be dramatically reduced relative to conventional technologies. The technology can particularly be used, for example, to modify and reduce the detection time significantly in traditional ELISA, and also Western blot or Dot blot assays. The improved ELISA method is rapid, economical, reproducible, simple and automatable. Also provided are compositions and kits for using the improved ELISA methods for the rapid detection of antigens.
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CROSS-REFERENCES TO RELATED APPLICATIONS
The present invention is an improvement of the invention disclosed in copending application Ser. No. 07/224,408, filed: Jul. 26, 1988, now U.S. Pat. No. 5,013,291 and the division thereof, Ser. No. 07/641,723, filed: Jan. 15, 1991 and Ser. No. 07/487,198, filed Mar. 1, 1990. The subject matter of said U.S. patent applications are incorporated in their entireties by reference.
BACKGROUND OF THE INVENTION
There is considerable art relative to the art of dispensing web material such as paper towels from a roll of paper. Ideally such devices not only dispense the paper towel when a roll containing the paper towel is pulled but also cut the paper towel to provide discrete portions.
As paper towels have become thinner it has been found advantageous to increase the feel of bulkiness of such materials by folding longitudinally the paper towel. Also the folds which give a pleated effect provide greater strength to the towel to thereby resist breaking or tearing when the paper towel is pulled.
Therefore the object of the invention relates to the technical sector of devices to dispense wiping materials which may be fabricated of paper, cotton, wool, non-woven and other types.
According to the basic patent application FR 89.03416 and the aforementioned copending U.S. patent and patent applications, the cutting device consists of two interacting metal blades with an elastical mount between two pairs of edge facing toothed drive wheels. The to-be-dispensed web wiping material is dispensed between the edges of wheels of one set as said wheels are rotated while the other set meshes to provide synchronized movement. As said wheels are rotated the blades are arcuately moved and gradually superimposed. The blades are in contact and pressure when in a position substantially parallel to the rotation shafts of the pairs of toothed wheels throughout the cut by shearing the previously folded strip of web-material payed between the said pairs of toothed wheels. The wheels are driven by manual pulling on the strip of web material projecting below from the unit.
Unfortunately with such a device, some premature tearing occurs and/or jamming of the cutting blades if the web material is tugged too gently. To overcome the jam it is frequently necessary to pull very forcefully thereby increasing the likelihood of a tear.
At the end of the pulling step, the pairs of toothed wheels return to their idle position after the cutting step. However, if the web material has been torn, the end of this web material be in the device and not readily accessible for the next pulling step.
SUMMARY OF THE INVENTION
In order to overcome these disadvantages, a pusher means is disclosed which operates when the two mentioned cutting blades come into contact. The pusher means is detailed to release energy which is retained when the pairs of toothed wheels rotate. This energy is imparted to of the set of pairs of wheels for further rotation;
According to a feature, the pusher consists of a two piece L-shaped lever operated upon by a cam keyed for rotation on one of the axle shafts of one of the pairs of toothed wheels. The cam is configured in order to firstly stress a spring connecting it to a fixed point on the surface of the oppositely disposed pair of toothed wheels. Thereby the spring is stressed as the cam is moved from an at rest position to a stressed position when the driven toothed wheels are rotated to bring into contact the cutting blades. Then the further rotation of the cam as the wheels rotate suddenly releases the lever while actuating the pair of toothed wheels opposite disposed to the wheels upon which the cam is journalled thereby imparting thereto rotational energy.
The rotational impetus is provided by the pusher rod which is connected to a spring central of the rod which has a hinged L-shaped configuration and a fixed point between the pairs of toothed wheels. The end of the pusher rod thereto meaningful against a suitably located projection on the drive wheel opposite to the one carrying the cam.
Furthermore, the device of the present invention is provided with means to vary to gap between the pairs of toothed wheels. This is accomplished by varying the position of one of the cutting blades by an adjustable means on one of the pairs of toothed wheels.
The latter may be accomplished by a blade holder which is hingedly mounted to one of the pair of toothed wheels. The said blade holder having an opening in which an eccentric can be turned with its axis on the said pair of wheels and thereby actuating the blade holder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating a unit according to the basic precepts for dispensing web wiping materials.
FIGS. 2, 3 and 4 are rear views of the interchangeable cassette fitted with the pusher means according to the invention.
FIG. 5 is a front view of the interchangeable cassette fitted with the position adjusting means of one of the cutting blades.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the main operating components of the device can be seen and as further illustrated and detailed in said copending patent and applications.
The device consists of a support base A which can be attached to any surface, a web material reel holder (B), an enclosure (D) therefore and a removable cassette (E). The latter is detailed to provide the mechanism necessary to propel and cut strips which have been previously folded longitudinally in accordion fashion or longitudinal corrugations. This has been accomplished by a series of interleaved spaced projections (G1-G2) defining a path between which the web material passes. One set of the projections is perpendicularly affixed to the support base (A) and the other set is perpendicularly affixed to the reel holder (B). The latter also supports a roller shaping means (H) over which the web material is payed from the reel and between the said projections to accomplish the corrugations. The cassette has means for sliding into the bottom opening of a housing defined by the base (A) and the enclosure (D) and is retained therein by suitable means not shown.
Between the front and rear faces of the cassette, there are two rotating pairs of cog-like wheels. The first pair consists of wheels 1 and 2 and the second pair consists of wheels 3 and 4. The wheels identified by reference numerals 1 and 3 are detailed to drivingly intermesh and engage. The wheels identified by reference numerals 2 and 4 have teeth that likewise intermesh but do not engage. The latter wheels have considerable greater width than the former and are detailed to permit the previously corrugatedly formed web material to pass between the cogs of wheels 2 and 4 as they rotate in opposite rotation to thereby impart to provide transverse corrugations to the web material.
The diameter therefore of the wheels 2 and 4, as they are in the nature of guide wheels are somewhat less than the diameter of wheels 1 and 3 which are in the nature of driving wheels. The latter are prone to backlash while the former are not, permitting the corrugated strip to pass therebetween without jamming.
The outside of cog wheels 2 and 4 have rounded edges thereby facilitating the insertion of the strip when loading the unit, whereas the inside of the teeth of the cog wheels 2 and 4 have a rough surface, particularly either side of the notches thereof to clear the cutting device in order to drive the separated strip after the cut without slipping.
The cutting device is made up of two metal blades (5 and 6) symbolized by the line of dashes in FIGS. 2, 3 and 4, being understood that they are mounted in compliance with the copending application and patent mentioned in the above.
Therefore, according to the features of the present improvement, in order to provide for a clean and reliable cut with the unit in any position and regardless of the manual pulling force and speed applied to the strip of folded and corrugated web material projecting outwardly underneath the unit, a pusher is provided which is associated with the driving and cutting mechanisms.
The improvement component consists of a lever (20) which is hinged at (21) at the top part of the rear wall of the cassette. It extends laterally towards the bottom externally of drive wheel (1). The lever (20) is hinged at (22) at one end portion with a horizontally position push rod (23) which thereby extends in the direction externally of the other drive wheel (3). At the axle of the drive wheel (1) the lever (20) has a projection (20a) having perpendicularly extending therefrom a freely rotating roller (24). It is detailed to abut against a cam (25) axially mounted to the same axle to which drive wheel (1) and cog wheel (3) are journalled.
The lever (20) carrying the so-mounted roller (24) are urged in abutment onto said cam (25) by spring (26) which is attached at one end to a fixed point between the pairs of wheels at the bottom of the cassette and at its other end to an end portion of push rod (23) proximate the hinged area (22), i.e. at a downwardly extending projection (23a) of the push rod.
As depicted in FIG. 2, when in the idle position, the lever (20) and rod (23) together are in abutment with projections (28 and 29) which act as stops and are mounted on the rear wall of the cassette (not shown).
In this idle position corresponding to FIG. 2, the cam (25) is orientated so that roller (24) is abutment against that part which is the nearest to the axle and spring (26) is under tension.
It is to be noted the triggering spring (14) is mounted between cam (25) and an eccentric lever (15) coaxially journalled and affixed to the other drive wheel (3) thereby providing a double eccentricities.
When the folded and corrugated strip projecting from the unit is pulled manually, thereby driving both pairs of toothed wheels and at the same time the cutting blades mounted thereon, the cam (25) urges through roller (24) the lever (20) arcuately away from the axle of drive wheel (1) thus pre-stressing the spring (26) which holds the push rod (23) against stop (29).
When the cutting blades (5 and 6) are opposite one another, as in FIG. 3, the roller (24) is at the highest point of the surface of the cam (25) and the roller is now the furtherest from the axle of drive wheel (1). At this juncture drive wheel (3) due to its having been rotated has been brought perpendicularly extending projection dowel (30) fixed the wheel (3) against the other end (23b) of the pusher rod (23), i.e. the end opposite to hinged end for lever (20). The said projection thereby deflects downwardly pusher rod (23) in the direction of the horizontally disposed spring (26).
With the further turning of the pairs of wheels (1 and 3) and (2 and 4), each in the direction depicted in FIGS. 2, 3 and 4, the cutting blades are operatively applied against one another, the cam (25), the notch (25a) is now opposite roller (24) into which it is then moved. Simultaneously, the projection (30) has been moved beyond the end of pusher rod (23) thereby releasing it to proceed to move into abutment with stop (29). Therefore, as illustrated in FIG. 4, with the release of ring (26) the pusher rod (23) thrusts against the project (30) until as a result of continued rotation of drive wheel (3) it escapes therefrom. This thrust is additional to that supplied as a result of triggering spring (14) is provided to avoid braking or jamming the cutting blades in contact even when the projecting strip is pulled too gently or unevenly.
Therefore, a clean cut can be made and any undue tearing of the material is avoided. The next strip portion is always ready and projects from the unit at the same length.
The said pusher arrangement is preferably mounted to actuate the pair of toothed wheels which support the blade which is above the other one when they come into contact in order to obtain the best results.
It is also to be noted that the cam (25) may have a retainer heel after the cut to ensure full separation of the web material pulled by reaction. It being understood that just like in the copending patent and application, the blade adjustment are a function of the type of web material dispensed.
According to another feature of the improved invention it is desired to easily and quickly change the position of the cutting blades, particularly the relative positions between one another.
With regard thereto attention is now directed to FIG. 5 which is taken from the other side of the said cassette as heretofore depicted by FIGS. 2, 3, and 4. Therein, one of the blades, preferably the one which is supported by the pair of toothed wheel (1) and (3), i.e. associated with the cam (25), is mounted so as to be adjusted by a blade-support (31) hinged at (32) with the said pair. Opposite the cam, there is an opening (31a)of the blade-support cross which extends an eccentric (33) with its axis at (34) of said pair. When the cutting device is in the at rest position, an opening (35) of the front wall of the cassette enables a screw driver to pass therethrough to loosen bolt (32) then the eccentric is turned through a slot (33a) with respect to the opening (31a) thereby making the cutting blade to tilt forwards or backwards which varies the gap with the other blade.
Finally, in order to improve the cut even more, cutting blades not only with a convex cutting edge and inclined as shown in the said copending patent and applications are provided, but also crowned in length as can be seen from FIG. 1.
The advantages are made well apparent from the description. The following is highlighted once again. the efficiency and reliability of the cut obtained with the pusher bar storing additional energy supplied at the time of the cut and the quick blade gap adjustment in the formation of the type of material.
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A folded corrugated discrete web material dispensing device. The device having corrugation and cutting oppositely rotating cog wheels. The cog wheels are connected to a spring to store kinetic energy when the device is operated to continue the rotation of the cog wheel even after manually pulling is ceased.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bistable flip-flop with reset control.
2. Discussion of the Related Art
D flip-flops produced by CMOS (complementary metal-oxide semiconductor technology customarily include a master stage and a slave stage which are clocked by offset clock signals. Each stage consists of a storage cell including two logic gates mounted in parallel, one of these two gates being feedback-mounted with respect to the other in order to provide for the storage function. In order to compensate for the leakage currents and thus provide for the stability of the stored information, the feedback-mounted logic gate is produced from resistive-channel MOS transistors, that is to say including a relatively long channel and a relatively long gate. These resistive-channel transistors occupy a sizeable area on an integrates circuit, and it is therefore generally sought to reduce their number in order to obtain the functionalities desired of a compact circuit.
The resetting of the D flip-flop must be performed simultaneously on the two stages on the basis of the same control signal. Conventionally, the master stage includes a NAND gate feedback-mounted with respect to an inverting gate, and the resetting of this master gate is provided for by one of the inputs of this NAND gate receiving the active reset control signal in the 0 state. This NAND gate requires four resistive-channel MOS transistors and is therefore relatively bulky in terms of integrated circuit area. Furthermore, this NAND gate must be supplemented with other logic elements intended to avoid write conflicts at the input of the inverting gate.
SUMMARY OF THE INVENTION
In view of the foregoing, the aim of the present invention is to propose a bistable flip-flop, in particular of the delay type, occupying a reduced area, so as to increase the density of layout of an integrated circuit comprising flip-flops of this type.
According to the present invention, this aim is achieved with a bistable flip-flop comprising at least one input terminal, one output terminal, one reset control terminal and one storage cell, in which the storage cell comprises a first inverter having an input capable of receiving a write signal dependent on an input signal delivered to the input terminal and an output, wherein the storage cell comprises a second inverter having an input connected to the output of the first inverter and an output connected to the input of the first inverter, and wherein the flip-flop furthermore comprises a first switch controlled by a reset signal for selectively connecting the input of the first inverter to a reference terminal of the flip-flop and thus enforcing a specified logic state at the input of the first inverter when the reset signal is in an active state, and a second switch controlled by the reset signal and arranged to prevent the input of the first inverter from being able to receive a write signal in a logic state inverse to said specified state when the reset signal is in its active state.
Thus, the feedback-mounted logic gate in the storage cell of the present invention is an inverter which typically requires just two resistive-channel transistors. The flip-flop therefore has a smaller surface area than that of conventional flip-flops. The reset function is carried out by the two switches, the first enforcing the resetting of the cell whilst the second prevents signal conflicts at the input of the first inverter.
BRIEF DESCRIPTION OF THE DRAWING
Other features and advantages of the present invention will emerge in the detailed description below of a preferred and non-limiting embodiment, read jointly with the attached drawing in which the single FIGURE represents an electrical diagram of a flip-flop according to the present invention.
DETAILED DESCRIPTION
The FIGURE illustrates a delay flip-flop (D flip-flop) with reset control produced according to the invention. The inputs and outputs of this flip-flop are as follows:
reference terminal 1 receiving the circuit's positive supply voltage VDD representative of the 1 logic state;
reference terminal 2 receiving the earth voltage VSS representative of the 0 logic state;
input terminal 3 receiving the binary input signal D of the flip-flop;
output terminal 4 delivering the binary output signal Q of the flip-flop;
reset control terminal 5 receiving an active binary reset signal NRESET in the 0 logic state;
master clock terminals 10a, 10b respectively receiving a master clock signal HM and the logic inverse NHM of this master clock signal; and
slave clock terminals 16a, 16b respectively receiving a slave clock signal HE and the logic inverse NHE of this slave clock signal.
The flip-flop comprises a master stage 6 and a slave stage 17 each consisting of a storage cell. The input of the master stage 6 is connected to the input terminal 3 of the flip-flop by way of a gate 9 and an interrupter 10. The output of the master stage 6 is connected to the input of the slave stage 17 by way of an interrupter 16. The output of the slave stage 17 is connected to the output terminal 4 of the flip-flop by way of an inverter 20.
The gate 9, whose structure will be detailed further on, produces a write signal which is the logic inverse of the input signal D and, under certain conditions, transmits this write signal to the interrupter 10. The interrupter 10 consists conventionally of an n-channel MOS transistor whose gate receives the master clock signal HM and of a p-channel MOS transistor whose gate receives the inverted master clock signal NHM, these two transistors being mounted with their channels in parallel. The interrupter 10 is therefore open when HM=0 and closed when HM=1.
The storage cell 6 forming the master stage comprises a first inverter 7 whose input is connected to the interrupter 10 and a second inverter 8 whose input is connected to the output of the first inverter 7 and whose output is connected to the input of the first inverter 7. As explained earlier, the feedback-mounted second inverter 8 consists conventionally of resistive-channel MOS transistors so as to compensate for the leakage currents in the cell 6.
The output of the first inverter 7 is furthermore connected to the interrupter 16 which is of the same type as the interrupter 10 with an n-channel MOS transistor whose gate receives the slave clock signal HE and a p-channel MOS transistor whose gate receives the inverted slave clock signal NHE. The interrupter 16 is therefore open when HE=0 and closed when HE=1.
The slave stage 17 consists of a storage cell comprising conventionally a NAND gate 18 having a first input connected to the interrupter 16, a second input connected to the reset control terminal 5 and an output connected to the output terminal 4 of the flip-flop by way of the inverter 20. The slave stage 17 furthermore comprises an inverter 19 feedback-mounted with respect to the NAND gate 18 with its input connected to the output of the NAND gate 18 and its output connected to the first input of the NAND gate 18. The inverter 19 consists of resistive-channel MOS transistors in order to compensate for the leakage currents in the slave stage 17.
The master and slave clock signals HM, HE are signals of like frequency, offset temporally in order to provide for the master/slave operation of the two stages 6, 17, and non-overlapping in the high state in order to avoid any problem of transparency of the flip-flop. Typically, the master clock signal HM can have a duty cycle of 0.5 and the slave clock signal HE can be the logic inverse of this signal HM.
The resetting of the slave stage 17 is carried out by way of the second input of the NAND gate 18. When the reset signal is active (NRESET=0), the slave stage 17 is in the 1 state on its output and the output signal Q is reset to the 0 state. This state of the slave stage 17 is maintained until the reset command disappears and a signal in the 1 state arrives at the first input of the NAND gate 18 by way of the interrupter 16.
For the simultaneous resetting of the master stage 6, the flip-flop comprises a first switch 14 consisting, in the example represented, of a p-channel MOS field-effect transistor 14 whose gate is connected to the reset control terminal 5. The channel of the transistor 14 is mounted between the reference terminal 1 at the voltage VDD and the input of the first inverter 7 of the master stage 6. When NRESET is in the active state, the switch 14 is closed and the 1 logic state is enforced at the input of the inverter 7, so that the output of the master stage 6 is reset to the 0 state.
The flip-flop furthermore comprises a second switch 13 arranged to prevent the input of the first inverter 7 from being able to receive a write signal in the 0 logic state inverse to that enforced by the first switch 14 when the reset signal NRESET is active. In the example represented, the second switch 13 is an n-channel MOS field-effect transistor included in the logic gate 9, the gate of the transistor being connected to the reset control terminal 5.
The logic gate 9 comprises, apart from the second switch 13, two MOS field-effect transistors of different polarities 11, 12 whose respective gates are connected to the input terminal 3 of the flip-flop. The p-channel MOS transistor 11 has its source connected to the reference terminal 1 at the voltage VDD and its drain connected to the interrupter 10. The n-channel MOS transistor 12 has its channel mounted in series with that of the transistor 13 forming the second switch between the reference terminal 2 at the voltage VSS and the interrupter 10. In the example represented, the n-channel transistor 12 has its drain connected to the reference terminal 2 and its source connected to the drain of the transistor-switch 13 whose source is connected to the interrupter 10. It is seen that apart from the switch 13, the gate 9 has the conventional structure of a CMOS inverter. The write signal which can be addressed to the input of the master stage 6 when the interrupter 10 is closed is the inverse of the input signal D. However, during a reset command, the switch 13 is open (NRESET=0), thus preventing the transmission of a write signal in the 0 state which could create a conflict of data at the input of the inverter 7 and occasion a short-circuit between the reference terminals 1, 2.
The delay flip-flop represented in the FIGURE has optimal compactness since it uses a minimum number of resistive-channel transistors which are bulky elementary components in terms of area. By comparison with a flip-flop without reset control, in the preferred example, the addition of this control requires just two extra transistors (the switches 13 and 14) which are not of resistive-channel type.
Although the invention has been described with regard to a preferred example, it will be understood that this example is not limiting and that diverse variants may be made thereto without departing from the scope of the invention.
Thus, a flip-flop with a single stage can incorporate the invention, which is not limited to a two-stage D flip-flop operating in master/slave mode. Moreover, the invention is clearly not limited to the particular configuration of the logic components represented in the FIGURE. For example, the write signal addressed to the input of the storage cell 6 may, as a variant, be equal to the non-inverted input signal D, the second switch 13 then being interposed simply to prevent the transmission of this signal D when the reset control signal is active.
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A bistable flip-flop with reset control is provided. The flip-flop includes a storage cell having a first inverter whose input can receive a write signal from an input signal delivered to the input terminal of the first inverter, and a second inverter which is feedback-mounted with respect to the first inverter. The flip-flop also includes a first switch controlled by a reset signal for enforcing a specified logic state at the input of the first inverter when the reset signal is active, and a second switch controlled by the reset signal so as to prevent the first inverter from receiving a write signal in a logic state opposite to the specified state when the reset signal is active.
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RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Application No. 60/668,189 filed Apr. 4, 2005, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
[0002] The invention relates to standardized mechanical interface (SMIF) substrate carriers used in semiconductor manufacturing and more particularly to transportable and shippable reticle/photomask carriers that include a filtration system to reduce chemical and particulate contaminants within the controlled environment of the carrier.
BACKGROUND OF THE INVENTION
[0003] The processing of silicon wafers for semiconductor applications typically includes photolithography as one of the process steps. In photolithography, a wafer surface with a deposit of silicon nitride is coated over with a light-sensitive liquid polymer or photoresist and then selectively exposed to a source of radiation using a template with a desired pattern. Typically, ultraviolet light is shone through or reflected off a surface of a mask or reticle to project the desired pattern onto the photoresist covered wafer. The portion of the photoresist exposed to the light is chemically modified and remains unaffected when the wafer is subsequently subjected to a chemical media that removes the unexposed photoresist leaving the modified photoresist on the wafer in the exact shape of the pattern on the mask. The wafer is subjected to an etch process that removes the exposed portion of the nitride layer leaving a nitride pattern on the wafer in the exact design of the mask.
[0004] The industry trend is towards the production of chips that are smaller and/or with a higher logic density necessitating even smaller line widths on larger wafers. Clearly, the degree of fineness to which the surface of the reticle can be patterned and the degree to which this pattern can be faithfully replicated onto the wafer surface are factors that impact the quality of the ultimate semiconductor product. The resolution with which the pattern can be reproduced on the wafer surface depends on the wavelength of ultraviolet light used to project the pattern onto the surface of the photoresist-coated wafer. State-of-the-art photolithography tools use deep ultraviolet light with wavelengths of 193 nm, which allow minimum feature sizes on the order of 100 nm. Tools currently being developed use 157 nm Extreme Ultraviolet (EUV) light to permit resolution of features at sizes below 70 nm. The reticle is a very flat glass plate that contains the patterns to be reproduced on the wafer. Typical reticle substrate material is quartz. Because of the tiny size of the critical elements of modern integrated circuits, it is essential that the operative surface of the reticle (i.e. the patterned surface) be kept free of contaminants that could either damage the surface or distort the image projected onto the photoresist layer during processing leading to a final product of unacceptable quality. Typically, the critical particle sizes are 0.1 μm and 0.03 μm for the non-patterned and patterned surfaces respectively when EUV is part of the photolithography process. Generally, the patterned surface of the reticle is coated with a thin, optically transparent film, preferably of nitrocellulose, attached to and supported by a frame, and attached to the reticle. Its purpose is to seal out contaminants and reduce printed defects potentially caused by such contamination in the image plane. However, extreme EUV utilizes reflection from the patterned surface as opposed to transmission through the reticle characteristic of deep ultraviolet light photolithography. At his time, the art does not provide pellicle materials that are transparent to EUV. Consequently, the reflective photomask (reticle) employed in EUV photolithography is susceptible to contamination and damage to a far greater degree than reticles used in conventional photolithography. This situation imposes heightened functional requirements on any reticle SMIF pod designed to store, transport and ship a reticle destined for EUV photolithography use.
[0005] It is well known in the art that unnecessary and unintended contact of the reticle with other surfaces during manufacturing, processing, shipping, handling, transport or storage will likely cause damage to the delicate features on the patterned surface of the reticle due to sliding friction and abrasion. Likewise, it is generally accepted by those skilled in the art that any particulate contamination of the surface of the reticle can potentially compromise the reticle to a degree sufficient -to seriously affect the end products of processes that use such a flawed reticle. In this regard, the art has developed innovative approaches to locate and support the reticle in reticle containers so as to reduce or eliminate sliding friction and consequent abrasion of the reticle and the resultant generation of contaminating particulates. In recognition of the need to maintain a controlled environment around the wafer during storage, processing and transport, the prior art has evolved approaches to isolation technology that allows for control of the environment in the immediate vicinity of a wafer by providing for a container so that it can be kept relatively free from incursion of particulate matter. Typically, containers are provided with standardized mechanical interfaces that allow automatic manipulation of the container by processing machinery. Such containers can hold photomasks of up to 200 mm and are designated standard mechanical interface pods, or SMIF-Pods. Even with such a controlled environment, migration of particulates that may be present inside the controlled environment is still possible due to pressure changes of the air trapped in the controlled environment or turbulence of the trapped air brought on by rapid movements of the container and/or by disturbing the trapped air volume. For example, thin walled SMIF pods may experience wall movement due to altitude related pressure changes causing the trapped air inside the controlled environment to be displaced. Temperature changes can set up convection currents within the container. Dimensional changes of the container and its components due to pressure fluctuations can lead to compromising the sealing between cover and door of the carrier and incursion of particulates within the carrier. Prior art approaches contemplate a breathing apparatus between the external environment and the internal controlled volume of air. The breathing apparatus provides a path for the air to flow. Prior art breathing apparatus may include a particulate filter to block the entry of particulates from the external environment into the controlled environment of the carrier.
[0006] Those skilled in the art will appreciate that particulate contaminants are but one half of the equation. Equally important are gas-phase contaminants or airborne molecular contaminants (AMC) due to ambient air venting or leaking into or getting trapped in a hermetically sealed system. For example, at a suitable dew point temperature, the moisture in the air will condense out of the air and some of it may get deposited onto the reticle. Even with a perfectly sealed container, there is the possibility of air entering into the system when the reticle is removed from and replaced within the container during processing. Water vapor condensing onto the patterned surface of the reticle can interfere with the optics just as a solid particulate would. Other sources of gas-phase or vapor contamination are solvent residues resulting from reticle/pod cleaning operations during the photomask lifecycle, chemical agents. generated by out-gassing from the structural components of the carrier and chemical agents that enter into the carrier from the ambient atmosphere by breaching the hermetic sealing arrangement between the carrier shell and the carrier door. Multiple contamination species are thought to be the largest contributors to gas-phase contamination. These include NH 3 (ammonia), SO 2 (sulphur dioxide), H 2 O (moisture) and condensable organics C6-C10. Depending on the photolithography system, a photomask can be exposed to a laser light source of a wavelength that can range from 436 nm to 157 nm. Currently, 193 nm lasers are quite common. The energy of the laser can initiate chemical reactions that precipitate defect formation and propagation on the surface of the reticle. For instance, some of the chemical species are altered to form highly reactive species such as SO 4 2− and NH 4 + . Some of these chemicals, such as acids for instance, are reactive with glass and can damage the reticle by etching it to create a haze on the patterned surface. The bases can create resist poisoning. The condensable organics can lead to SiC formation. In general, all of the contaminants can be considered to result in the same effect: crystal growth that degrades the functionality of the reticle. In this respect, the current thinking is that moisture or water is one of the key ingredients required for crystal growth. Essentially, water combines with some of the aforementioned contaminants to form the salts are generally clubbed together under the rubric of crystal growth. Prior art use of dessicants, for example, cannot ameliorate this problem because they cannot reduce the concentration of moisture to low enough levels to prevent salt (or crystal) formation. Likewise, purging a reticle carrier with clean dry air (CDA) or other dry gas may not reduce the moisture concentration to the levels required to avoid crystal growth. There is therefore a need for a contamination control mechanism at each stage of the reticle life cycle.
[0007] One of the approaches commonly employed in the art to ameliorate the effect of the chemical contaminants is periodic reticle/mask cleaning. The mean time between such cleans (MTBC) can approach, for example, approximately 8000 wafers in a 193 nm exposure tool. The threshold of the MTBC is set to prevent mean time between defects (MTBD) printed on the wafer using the reticle/mask. However, there is a limit to the number of such ‘cleans’ a reticle/mask can be subject to before resolution is degraded beyond functionality and the mask must be scrapped. In view of the above, one of skill in the art will recognize the need to ensure that the reticle environment within the carrier remains clean during storage, transportation, manipulation as well as during the standby condition when the carrier is empty of the reticle. While desirable, it is generally infeasible to construct a hermetically sealed environment that is absolutely impervious to incursion by AMCs or other contaminants. It is also infeasible to continuously purge the reticle carrier especially when the reticle and reticle carrier have to be transported or shipped.
[0008] What is needed is some type of structure or device for ensuring that the incursion, concentration and rate of accumulation of AMCs within the photomask carrier is controlled to levels that preclude or significantly reduce the formation of crystalline salts so that the useful life of the photomask can be significantly extended.
SUMMARY OF THE INVENTION
[0009] The present invention provides a reticle/mask carrier with a controlled environment within which to house a reticle during storage, transport, processing and shipping. According to a primary embodiment of the present invention, the reticle/mask carrier is equipped with means to control the ingress and build-up of particulate and gas-phase contaminants into the controlled environment.
[0010] According to one aspect of the invention, the reticle carrier is provided with a layered filter having specialized filter elements arranged to form a composite sandwich. Each filter element is associated with specialized media characterized by its ability to selectively capture at least one of the several trace impurities known to be present within or known to diffuse into the hermetically sealed space within the reticle carrier.
[0011] According to another aspect of the present invention, the filter media is selected to weakly bind to the contaminants so that the contaminants could be expelled from the filter by subjecting the filter to a flow of pressurized gas thereby regenerating the filter.
[0012] According to a related embodiment of the present invention, the filter is shaped, sized and located so as to present a surface on which particulates will preferentially settle instead of settling on the patterned surface of the reticle. Another aspect of the alternate embodiment contemplates a large filter, i.e. a filter with at least one major surface are that is preferably at least sixty percent of the surface area of the patterned surface, to take advantage of the diffusion length of the particulates within the container to cause the particulates to preferentially settle on the filter as opposed to settling on the patterned surface of the reticle. According to another aspect of the primary embodiment, the filter is preferably shaped and sized substantially proportionate to the reticle and preferably positioned substantially concentrically with respect to the reticle. One aspect of this embodiment at least one surface of the filter is disposed substantially to the carrier door portion with the reticle residing on the reticle supports.
[0013] According to a related embodiment, the present invention provides means for limiting the exposure of the filtration medium to the exterior of the reticle pod as compared to the interior of the hermetically sealed space within the reticle carrier. One aspect of the means involves providing a perforated tray to hold the filter wherein the perforations present a restricted area through which the filter communicates with the external environment. Another aspect of the means involves providing a filter with an additional fluid impermeable layer that is provided with one way slit valves to prevent the ambient air from communicating with the hermetically sealed space within the reticle carrier. Another aspect of the means involves the provision of check valves in the purge ports to keep contaminants from entering the hermetically sealed space.
[0014] According to yet another primary embodiment of the present invention, the reticle carrier is provided with a means to inject pressurized, extremely clean dry air, denominated XCDA, into the hermetically sealed space of the reticle carrier and a means to exhaust the XCDA from the sealed space. The purge gas is sufficiently pressurized to allow egress of the gas through both the filter and the exhaust means. Purging the hermetically sealed space in this manner serves to flush out contaminants as well as dehumidify the filter and the reticle carrier thereby regenerating the filter.
[0015] Additional objects, advantages, and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a bottom perspective view of an assembly of a reticle carrier according to a primary embodiment of the present invention.
[0017] FIG. 2 is an exploded perspective view of the assembly of the reticle carrier according to the primary embodiment of the present invention.
[0018] FIG. 3 is a perspective view of a base portion of the reticle carrier of FIG. 1 shown supporting a reticle.
[0019] FIG. 4 is a bottom perspective looking upward of the base portion of the reticle carrier of FIG. 3 .
[0020] FIG. 5 is a plan view of the base portion of FIG. 3 .
[0021] FIG. 6 is a side sectional view through section B-B of the base portion of FIG. 5 .
[0022] FIG. 7 is a detailed view showing the purge port of FIG. 6 .
[0023] FIG. 8 is a side sectional view through section A-A of the base portion of FIG. 5 .
[0024] FIG. 9 is still another detailed view showing the purge port of FIG. 8 .
[0025] FIG. 10 is a bottom perspective looking up of the cover portion showing the inside surface of the cover portion according to an alternate embodiment of the present invention.
[0026] FIG. 11 is perspective view of an exemplary filter according to the present invention.
[0027] FIG. 12 is a perspective view of a high surface area filter according to a secondary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The accompanying Figures depict embodiments of the reticle carrier of the present invention, and features and components thereof. Any references to front and back, right and left, top and bottom, upper and lower, and horizontal and vertical are intended for convenience of description, not to limit the present invention or its components to any one positional or spatial orientation. Any dimensions specified in the attached Figures and this specification may vary with a potential design and the intended use of an embodiment of the invention without departing from the scope of the invention.
[0029] In FIGS. 1-11 , there is shown a reticle carrier 100 equipped with a chemical filtration system according to a primary embodiment of the present invention. The reticle carrier 100 (alternatively referred to as a reticle container, a reticle pod, or a reticle box) generally comprises a door portion 106 (alternatively referred to as a base portion) which mates with a carrier shell 112 (alternatively referred to as a cover) to form an hermetically sealed space 118 which provides a sealed environment in which a reticle 124 may be stored and transferred. The term “reticle” in used in a broad sense to include quartz blanks, photo-masks, masks used in the semiconductor industry that are susceptible to damage from particulates and gas-phase chemical contaminants. Generally, the reticle 124 is square shaped with a first surface 126 opposite a second patterned surface 128 having a surface area 129 provided with the etched pattern as discussed above. A reticle lateral surface 130 separates the first surface 126 from the second patterned surface 128 and extends around a reticle perimeter 130 . It will be appreciated that the present invention is not limited by a particular shape of reticle 124 .
[0030] The door portion 106 , best shown in FIGS. 2, 4 and 5 includes an opposed upper door surface 136 and a lower door surface 142 separated by a lateral wall 148 . A plurality of reticle supports 154 , reticle side positioning members 160 and back positioning members 166 extend outwardly from and are disposed in spaced apart relationship adjacent an upper periphery 172 of and generally about a central portion 178 of the upper door surface 136 . The reticle supports 154 are configured to hold the reticle 124 at a predefined height 156 above upper door surface 136 . The reticle side positioning members 160 and the back positioning members 166 serve to guide manual positioning of the reticle 124 and ensure proper lateral and rearward placement of the reticle on the reticle supports 154 so that the reticle substantially occupies and its volume bounded by a reticle receiving region 168 associated with the door portion 106 and defined by the reticle supports 154 , the reticle side positioning members 160 and the back positioning members 166 as best depicted in FIG. 3 . A Gasket 184 loops along the upper periphery 172 on the door surface 136 . Preferably, the door portion 106 and the carrier shell 112 conform to the shape of reticle 124 .
[0031] Referring now to FIGS. 2, 3 and 4 , the door portion 106 is provided with a central hole 190 extending through the door portion 106 and defined by a first opening 196 on the upper door surface 136 , a second opening 202 on the lower door surface 142 and an inside peripheral wall 208 communicating the first opening 196 with the second opening 202 . In an exemplary embodiment, illustrated in FIGS. 2, 3 and 4 , the first and second openings 196 and 202 are substantially square shaped and are characterized by their respective first and second areas 212 and 214 . The inside peripheral wall 208 extends generally parallel to the lateral wall 148 of the door portion 106 between the first and the second Openings 196 and 202 . The inside peripheral wall 208 is configured with a peripheral shelf 220 suitable for securely supporting a filter frame 226 such that the filter frame 226 is substantially perpendicular to the first opening 196 and is located generally flush with the upper door surface 136 .
[0032] In one embodiment best illustrated in FIG. 2 , the filter frame 226 can be a semi-rigid, molded plastic receptacle in which a filter 232 in accordance with the present invention may be used. The filter frame 226 is substantially hat shaped with a peripheral flange 242 (alternatively identified as a lip) circumjacent an open end 248 , a filter frame side wall 258 depending from the open end 248 and terminating at a closed end 252 to define a cavity 262 adapted to receive the filter 232 . Closed end 252 has a structure defining a plurality of perforations 264 as best illustrated in FIG. 4 . Filter frame side wall 258 includes a shoulder 268 with a shape complementary to the peripheral shelf 220 on inside peripheral wall 208 . The filter frame is configured to be inserted through first opening 196 on upper door surface 136 and snug-fittingly received into central hole 190 for detachable mounting in door portion 106 with flange 242 resting on upper door surface 136 and shoulder 268 securely positioned on peripheral shelf 220 of inside peripheral wall 208 . In alternate embodiments, an elastomeric seal or gasket such as for example, the gasket 184 described above, can be interposed between the shoulder 268 and the peripheral shelf 220 to provide a hermetic seal between the filter frame 226 and the filter 232 .
[0033] Filter 232 will next be described with reference to the illustrations of FIGS. 2 and 12 . Filter 232 can have a variety of constructions each of which provide a fluid-permeable, clean, cost-effective, high efficiency, low-pressure drop, adsorptive composite filter such as the filters described in U.S. Pat. Nos. 7,014,693, 6,761,753, 6,610,128, and 6,447,584 the contents of which are incorporated herein by reference in their entirety. FIGS. 2 and 12 illustrate an exemplary embodiment of filter 232 . Filter 232 is desirably a fluid-permeable filter that can include several types of adsorptive and non-adsorptive media. Adsorptive media can include, for example, chemisorptive media and physisorptive media. Non-adsorptive media may include particulate impermeable media. One of skill in the art will appreciate that the adsorptive media can be engineered with pore sizes for removal of particulate materials. Such adsorptive media is also exemplary of particulate impermeable media according to the present embodiment. Each type of media can be in separate filter elements. The term, “physisorption,” refers to a reversible adsorption process in which the adsorbate is held by weak physical forces. In contrast, the term, “chemisorption”, refers to an irreversible chemical reaction process in which chemical bonds are formed between gas or liquid molecules and a solid surface. The term “particulate impermeable” refers to the attribute of substantially filtering particulates having a size greater than a threshold size from a fluid flowing through the fluid-permeable but particulate impermeable media. Typically, the particulates may be dislodged from respective particulate impermeable media by reversing the fluid flow thereby substantially restoring the particulate filtering capacity of the media. Referring to FIG. 2 , an exemplary filter 232 according to the present invention comprises a plurality of removable or replaceable filter elements (alternatively identified as layers, components, or laminas) arranged in parallel in a predefined series of layers. Exemplary Filter 232 includes a base layer 276 of a first particulate impermeable media, a first filter membrane 278 of a first adsorptive media, a second filter membrane 280 of a second adsorptive media and a cover layer 282 of a second particulate impermeable media with the absorptive media layers 278 and 280 being sandwiched between the particulate impermeable media base layer 276 and cover layer 282 . In the primary embodiment, the base layer 276 and the cover layer 282 may comprise, for instance, a filtering non-woven polyester, polyamide or polypropylene material or other similar materials configured for the removal of particulate materials in a fluid stream. Other particulate filter media, such as for instance, a high efficiency particulate air (HEPA) filter medium or an ultra low penetration air (ULPA) filter medium, may also be used singly or in combination without departing from the scope of the present invention. The base and cover layers 276 and 282 prevent particulate incursion into the hermetically sealed space 118 from the ambient atmosphere (from the clean room for example) as well as egress of particulates from the hermetically sealed space 118 to the ambient atmosphere. In the preferred embodiment of the present invention, the first absorptive media associated with the first filter membrane 278 is a first physisorptive media. The term, “untreated,” as used herein, means an activated carbon that has not been modified by chemical treatment to perform chemisorption; rather, untreated, active carbon remains as a physical, nonpolar, adsorbent. The first physisorptive filter element 278 , shown in FIGS. 2 and 12 can include untreated, activated carbon. The carbon is porous (the specific surface area can be on the order of 1000 m2/g) and can be provided in the form of fibers or particles incorporated into a mat of polymer fibers, either woven or nonwoven. The untreated, activated carbon can be formed from a variety of sources, including coconut shell, coal, wood, pitch, and other organic sources. Further still, a sulfonated copolymer coating can be attached to the untreated, activated carbon. The medium of filter membrane 278 may include other materials such as for instance, granulated activated carbon, bead activated carbon, chemically impregnated carbon, chemically impregnated activated carbon, zeolites, cation exchange resin, anion exchange resin, cation exchange fiber anion exchange fiber, activated carbon fiber, and chemically impregnated activated carbon fiber. Physisorptive media of layer 278 specifically removes acids, organic and inorganic condensable contaminants such as C6-C10 as well as SO 2 gas. Such media are sold, for example, under the trade name Purolyte® by Purolyte Corporation. The second filter membrane 280 is a strongly acidic ion-exchange resin of a second adsorptive medium such as for instance, sulfonated divinyl benzene styrene copolymer in the form of microporous beads. The second adsorptive medium is configured to specifically capture ammonia (NH 4 ) and moisture (H 2 O) both from within the hermetically sealed space 118 and from the ambient atmosphere of the clean room. Such media are sold under the trade name, AMBERLYST® 15DRY or AMBERLYST® 35DRY, by Rohm and Haas. Catalysts with physical properties outside the ranges described above can also be used. The base layer 276 and the cover layer 282 can also serve to retain the granular or particulate media in adsorptive layers 278 and 280 . One of skill in the art will recognize that various combinations of the number of layers, the arrangement of the layers relative to each other, and media types forming the layers may be advantageously used without departing from the scope of the present invention. For example, in an alternate embodiment of the present invention chemisorptive and a physisorptive filter elements can be used. The relative thicknesses of the chemisorptive filter element and the physisorptive filter element being engineered so that the useful life of the two filter elements will be exhausted at approximately the same time in a given environment. Accordingly, a chemisorptive filter element formed of sulfonated polymer can be made thinner than a physisorptive filter element formed of untreated carbon since the physisorptive properties of the carbon will typically be exhausted more quickly than the chemisorptive properties of the acidic, sulfonated polymer. In a different embodiment, the chemisorptive and physisorptive media may be present within a single filter layer. In yet another embodiment, the multiplicity of filter elements may be sequentially supported in a frame container (not shown) to provide a multi-stage filter through which air can pass in a direction perpendicular to each of the layers. Such a multi-stage filter can be replaced as a whole after its filtration capacity is exhausted. Alternatively, filter elements having a high-surface area 338 may be formulated by forming each medium as a packed array of three dimensional cells in FIG. 13 as disclosed in the prior art. Such a high-surface area 338 filter may be formed by pleating the medium into an accordion-like structure. A prefilter layer (not shown) of hydrophilic medium, which may be separately removable from the filter 232 , may be incorporated above the base layer 276 of the cover layer 282 .
[0034] Still referring to FIG. 2 , layers 276 , 278 , 280 and 282 preferably have the same shape 287 . All the layers have the same surface area 288 bounded by the perimeter 289 of the shape 287 but may have different thicknesses. In assembled condition, the several layers 276 , 278 , 280 and 282 are sequentially disposed within the cavity 262 of the filter frame 226 to form a multi-stage filter having a composite sandwich structure of a thickness 290 . The filter frame 226 is inserted through the first opening 196 on the upper door surface 136 and is detachably mounted into the central hole 190 with the flange 242 resting on the upper door surface 136 with the shoulder 268 being supported on the peripheral shelf 220 . In a related embodiment, the filter frame 226 and the filter 232 comprise a cartridge 270 which may be inserted into and removed from the central hole 190 on the upper door surface 136 of the door portion 106 as described in U.S. Pat. No. 6,319,297, the entire contents of which is incorporated herein by reference in its entirety.
[0035] In the primary embodiment of the present invention best explained with reference to FIGS. 2, 3 and 5 , the first area 212 of the first opening 196 is configured to be substantially proportional to the surface area 129 of the second patterned surface 128 of the reticle 124 . According to one aspect of the particular embodiment, the first area 212 is at least 50% of the surface area and in a further embodiment the surface area is at least sixty percent (60%) of the surface area 129 and preferably in the range of seventy-five percent (75%) to one hundred percent (100%) of the surface area 129 . In the preferred embodiment of the present invention, the first area 212 is substantially concentric with reticle receiving region 168 . Furthermore, the first opening 196 and the location of reticle supports 154 are arranged so that in a assembled configuration, i.e. when the carrier shell 112 is mated to the door portion 106 and the reticle 124 is supported on the reticle supports 154 , the filter 232 is located with the surface area 288 disposed opposite at least a portion of second patterned surface 128 within the hermetically sealed space 118 such that reticle perimeter 130 overlies perimeter 289 of surface area 288 . One of skill in the art will recognize that other operative configurations of surface area 288 and second patterned surface 128 are possible without departing from the scope of the present invention. All of the aforementioned operative configurations are selected to maximize the extent of the surface area 288 relative to the second patterned surface 128 based in part upon the dimensions of the hermetically sealed space 118 , the diffusion length generated during reticle carrier purging, reticle processing, transport, shipping and storage and other conditions the reticle 124 might encounter during its residency within the reticle carrier 100 . The surface area 288 is disposed proximate the second patterned surface 128 . By selecting the extent and location of surface area 288 in the manner of the present invention, the probability, that a particulate present within or entering the hermetically sealed space 118 will preferentially encounter and settle upon the surface 288 instead of diffusing onto the secondary patterned surface 128 , is maximized. To those skilled in the art, the extent of surface area 288 is representative of the total number of fluid passages available for entry of a fluid into the filter 232 . The term “high-surface area” associated with reference numeral 338 , on the other hand, refers to the effective surface area of the total filter media available for filtration as the fluid flows through the entire thickness 290 of the filter 232 . The effective surface area controls adsorption of gases and chemical reactions. In this regard, the filter 232 differs from the prior art SMIF pod filters in that the filter 232 of the present invention is structurally a significant component of the door portion 106 because surface 288 can extend over a substantial portion of the upper door surface 136 . Furthermore, in the assembled configuration, base layer 276 is positioned on closed end 252 so that filter 232 places the hermetically sealed space 118 in fluid communication with the ambient atmosphere outside the reticle pod 100 through the plurality of perforations 264 as best seen in FIG. 4 .
[0036] The primary embodiment of the present invention provides means for limiting the exposure of the filter media 276 , 278 , 280 , 282 and other media that the filter 232 may comprise of, to the ambient atmosphere external to the reticle carrier 100 . One such means is exemplified in the illustration of FIGS. 2 and 4 . One skilled in the art will appreciate that the extent of surface 288 of the filter 232 in fluid communication with the hermetically sealed space 118 within the reticle carrier 100 is generally maximized as explained above. However, the extent of the base layer 276 of the filter 232 in direct communication with the ambient atmosphere is much smaller due to the limited number of perforations 264 and the limited area 266 of each perforation. Another means provided in the present invention include a fluid impermeable membrane 360 adjacent closed end 252 below base layer 276 . Angularly cut criss-crossed slits (not illustrated) in the fluid impermeable membrane 360 , the slits being preferably located opposite perforations 264 , allow the fluid impermeable membrane slit portions to extend axially thus opening when the interior of the pod is pressurized in the purge mode. Generally the pod will not be subjected to a vaccum thus the slit portions will not open inwardly only outwardly effectively operating as a multiplicity of one-way valve which would open during the flow of fluid out of the reticle carrier 100 . Similar valves are described in U.S. Pat. No. 5,482,161, the entire contents of which is incorporated herein by reference. Additionally, the outer membrane 360 can be a hydrophobic membrane to prevent incursion of moisture from the ambient atmosphere into the reticle carrier 100 through the filter 232 . When the SMIF pod is pressurized providing a significant outward flow through the filter the hydrophobic characteristic may be overwhelmed and allow the exit of air or purge gas with some moisture being carried therewith. Under static minimal in and out flow through the filter, the hydrophobic effect is expected to effectively reduce the flow of moisture laden air from the exterior to the interior.
[0037] According to the primary embodiment of the present invention, the concentration of moisture within the hermetically sealed space 118 is preferably maintained at concentration levels approaching a few parts per billion (ppb). Using prior art approaches, such as dessicants for example, moisture concentrations within the hermetically sealed space 118 can be controlled only to within a few parts per million (ppm). The level of humidity control achieved by coupling reticle pod 100 to a purging system which periodically flows a very dry gas, such as for example dry nitrogen gas or dry argon, through the hermetically sealed space 118 . Referring now to FIGS. 2 , 6 - 9 there is illustrated the construction of a reticle structure 100 equipped for coupling to a purging system (not shown) according to a primary embodiment of the present invention. As seen in FIG. 2 , upper periphery 172 of door portion 106 is configured with injector and extractor ports 306 and 312 extending through door portion 106 between upper door surface 136 and lower door surface 142 in a direction generally parallel to lateral wall 148 of door portion 106 . Injector port 306 and extractor port 312 are configured to coaxially receive an injector fitting 318 and extractor fitting 324 . Injector and extractor fittings 318 , 324 may be threadably coupled to injector and extractor ports 306 and 312 respectively. Other connection means may also be used without departing from the scope of the invention. Injector fitting 318 is detachably coupled to gas inlet line (not illustrated). Extractor fitting 324 is detachably coupled to a gas removal line (not illustrated) which may in turn be connected to a gas evacuation means (not illustrated). Each of the injector fitting 318 and extractor fitting 32 is equipped with a check valve 330 configured to allow a unidirectional flow past and prevent ingress or egress of gaseous or particulate contaminants into the hermetically sealed space 118 when the system is not in use. Diaphragm valves with slits such as those described in U.S. Pat. No. 5,482,161 referenced above may also be employed in conjunction with or without the check valves 330 . This is a mechanical means for limiting the exposure of the filter media 276 , 278 , 280 , 282 and other media that the filter 232 may comprise of, to the ambient atmosphere external to the reticle carrier 100 . One of skill in the art will recognize that injecting a very dry purge gas, for example dry nitrogen gas and dry argon gas, under pressure into the hermetically sealed space 118 will cause at least a portion of the purge gas to egress through the filter 232 and out into the ambient atmosphere through the closed end 252 . An apparatus and method of purging the reticle carrier 100 is described in U.S. Pat. No. 5,988,233 and U.S. Pat. No. 5,810,062, the entire contents of the two patents being incorporated herein by reference in their entirety. In an alternate embodiment, the extractor fitting 324 is replaced by an injector fitting 318 coupled to the gas inlet. In this configuration, the hermetically sealed space 118 is pressurized by the purge gas flowing into it through the injector fittings 318 . The purge gas exits the hermetically sealed space 118 through the filter 232 . Generally, purging the hermetically sealed space 118 removes trace contaminants by entraining them in the gas flow. Purging with dry gas also dehumidifies the filter 232 . Purging under pressure may dislodge and thus remove particulates and other contaminants that may be weakly bonded to the physisorptive media filter elements and the filter elements that specifically filter particulates. In effect, purging regenerates filter 232 by replenishing its capacity to adsorb contaminants. One of skill in the art will appreciate that the capacity of the filter 232 of the present invention may also be replenished by replacing the depleted filter 232 .
[0038] Of course, many alternative embodiments of the present environmental control for a SMIF reticle pod are possible and are within the scope of the invention, as will be appreciated by those of skill in the art. Such embodiments would include, but are not limited to, varying the numbers and locations of the layers comprising the filter, varying the location of the filter, varying the area of the filter, using several smaller filters and using a plurality of purge ports.
[0039] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of the invention. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples described herein.
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The present invention provides a standardized mechanical interface (SMIF) reticle pod that is configured to provide a controlled environment for supporting a reticle wherein the controlled environment is maintained substantially free of crystal growth causing contaminants. Accordingly, there is provided a layered filter with filter elements capable of filtering particulates and adsorbing gaseous contaminants. The filter has an inwardly facing face generally planar shaped with a surface area that is substantially half or more of the area of the reticle face. The inwardly facing face is placed in close proximity to the reticle patterned surface and has an area that is a significant fraction of the reticle patterned surface area. The SMIF pod is also provided with a purge system configured to inject a very dry gas within the controlled environment to flush the controlled environment of contaminants as well as to regenerate the filter.
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BACKGROUND
[0001] 1. Technical Field
[0002] Embodiments of the invention relate to the field of warping looms in textile weaving and manufacturing.
[0003] 2. Description of the Related Art
[0004] Since before the industrial revolution, the heddles used on handlooms have been similar in design. Heddles generally have a closed loop in the center through which the ends of warp threads are threaded. The top and bottom of the heddles have loops through which the heddles are attached to the harness or shaft frame. Heddles are typically made of polyester, twisted wire, or are pressed from sheet metal. Warp threads extend from a beam on one end of the loom, through a heddle, and attach to another beam at the other end of the loom.
[0005] One disadvantage of a closed loop heddle is that, once it is attached to the frame, it cannot be removed from the frame. Nor can the warp threads be removed from the heddles, once warping begins, since the warp threads are threaded through the heddle's center. Advanced weavers create complex weaving patterns using shaft switching. Shaft switching is the changing of the harness on which a single warp thread is moved. When switched to another harness, those warp threads can then change the pattern being woven. Shaft switching is not easily accomplished with conventional closed loop heddles. If a mistake is made during the warping process, all of the ends of the warp threads must be unthreaded back to the point at which the mistake was made to correct the problem. While some complex assemblies have been designed that open and close the eyelet of the heddle, the complex assemblies consist of several moving parts and are not readily adaptable to existing looms.
[0006] The warp beams or tie rods used on most handlooms are similar in design. The beams consist of a metal rod or wooden stick onto which the ends of the warp threads are tied. The traditional warp beams, and looms, do not provide any means to measure out the length of the warp threads. The warp beams are not meant to be used when removed from the loom. They also do not have means for maintaining a fixed distance between warp threads. The warp beams are seldom, if ever, removed from the loom. Clamps have been developed to attach warp thread to a beam without tying knots. However, the clamps have several disadvantages including multiple warp threads bunched together without separation, requiring drilling many holes into existing warp beams, having multiple parts, and using a series of springs with inconsistent tension on the warp threads across the beam.
[0007] Groups of 8 or more warp threads are typically tied to a warp beam in a single knot, which causes the threads to fan out from the knot to the heddles. The fan-out of the warp threads causes a scalloped edge at the beginning portion of a warp, and is referred to as the draw-in effect. For this reason, several inches of cloth must be woven before the scallops even out and the actual project may be started. This consumes time, adds to the amount of wasted material, and increases the overall length of the required warp.
[0008] An alternate means of attaching warp threads to a loom is to wind individual warp threads over a strip of adhesive on the beam and around the circumference of the beam. The disadvantages of this method include the potential for adhesive residue on the warp threads, potential release of the adhesive on one or more warp threads and attendant variations of tension, and a lack of positive and consistent control of the separation between warp threads. In addition, the method is not conducive to removal and replacement of the entire warp due to an inability to replicate the initial tension. This method also does not allow loading or removing the warp without removing all heddles from their frame.
[0009] Attaching the warp threads to the warp beams, also referred to as warping, in the traditional manner is very tedious. Traditional weavers usually install yards and yards of warp thread at one time. This permits the weaver to weave many projects before re-warping the loom. Unfortunately this means waiting until the entire warp is used before the individual projects can be removed from the loom. This can be especially frustrating for beginning weavers.
SUMMARY
[0010] It is therefore desirable to provide quick threading, openable heddles and a warp beam that provides even spacing of warp thread, even tension on the warp thread, and rapid set-up.
[0011] In some embodiments, a heddle for a weaving loom includes an eyelet with a break in the circumference of the eyelet. The break allows insertion and removal of a warp thread in the eyelet while both ends of the warp thread are attached to the weaving loom.
[0012] In other embodiments, a method of warping a loom includes positioning the warp thread against the periphery of an eyelet in the heddle; and moving the warp thread through a break in the periphery of the eyelet.
[0013] In still other embodiments, a warp beam includes a deck and a plurality of retaining members configured in spaced relationship to one another on the deck. Each retaining member retains a strand of warp thread that is substantially parallel to lines of warp thread retained by the other retaining members.
[0014] In further embodiments, a kit for retrofitting a loom includes a first warp beam and a second warp beam. The first and second warp beams include retaining members for retaining portions of warp thread in spaced apart substantially parallel relation, and the first and second warp beams are attachable to existing warp beams on the loom.
[0015] The foregoing has outlined rather broadly the features and technical advantages of embodiments of the present invention so that those skilled in the art may better understand the detailed description of embodiments of the invention that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Embodiments of the present invention may be better understood, and their numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings. The use of the same reference symbols in different drawings indicates similar or identical items.
[0017] FIG. 1A is a front view of an embodiment of a heddle for threading warp thread in a loom.
[0018] FIG. 1B shows detail of the eyelet portion of the heddle of FIG. 1A .
[0019] FIGS. 1C and 1D show how a warp thread can be inserted in the eyelet of the heddle of FIGS. 1A and 1B without removing either end of a warp thread from a warp beam.
[0020] FIG. 2A is a front view of another embodiment of a heddle that can be threaded without removing either end of a warp thread from a warp beam.
[0021] FIG. 2B shows detail of the eyelet portion of the embodiment of the heddle shown in FIG. 2A .
[0022] FIG. 3A shows another embodiment of a heddle that can be threaded without removing either end of a warp thread from a warp beam.
[0023] FIG. 3B shows a side view of the heddle of FIG. 3A .
[0024] FIG. 4 shows a perspective view of another embodiment of a heddle that can be threaded without removing either end of a warp thread from a warp beam.
[0025] FIG. 5A shows another embodiment of a portion of a heddle that can be threaded without removing either end of a warp thread from a warp beam.
[0026] FIG. 5B shows the apparatus in FIG. 5A in the open position.
[0027] FIG. 5C is a cross-sectional view of a finger portion engaged in a channel portion of the heddle of FIGS. 5A and 5B .
[0028] FIG. 6 is a perspective view of a series of heddles installed on a frame.
[0029] FIG. 7 is a side view of loom components including frames and warp beams.
[0030] FIG. 8 is a perspective view of an embodiment of a warp beam.
[0031] FIG. 9 is a top view of a conceptual diagram of a warp utilizing the warp beams of FIG. 8 .
[0032] FIG. 10 is a top view of a loom utilizing the warp beams of FIG. 8 .
[0033] FIG. 11 is a side view of loom components including frames and the warp beams of FIG. 8 .
DETAILED DESCRIPTION
[0034] Embodiments of heddles and warp beams are disclosed that facilitate warping a loom by allowing the beams to be warped before being attached to the loom. Additionally, the warp threads can be threaded through an opening in the eyelets of the heddles while both ends of the warp thread remain attached to the warp beams.
[0035] Referring to FIGS. 1A and 1B , an embodiment of heddle 100 is shown with eyelet 110 that includes opening 112 in the circumference of eyelet 110 . Opening 112 allows warp thread to be inserted and removed without removing either end of the warp thread from a warp beam. In the embodiment shown, eyelet 110 is formed from a spiral loop 120 of material, such as plastic, metal, or other suitable material capable of substantially retaining its shape. In one embodiment, spiral 120 includes approximately one and one-half turns (coils) of material. Ends 122 of heddle 100 can include J-hooks or other fastening means to allow heddle 100 to be attached to, and detached from, a frame (not shown).
[0036] As shown in FIGS. 1C and 1D , heddle 100 can be threaded by raising one end 122 of heddle 100 to be substantially parallel to warp thread 124 . Warp thread 124 is positioned through opening 112 of spiral 120 and captured within eyelet 110 when end 122 of heddle 100 is lowered. The end 122 of heddle 100 can then be reattached to a frame.
[0037] FIGS. 2A and 2B depict another embodiment of a heddle 200 comprising an interlocking closure 202 in the circumference of eyelet 204 . The circumference of eyelet 204 is constructed from a flexible material, such as plastic, that allows bending of the ends of interlocking closure 202 in opposite directions to create an opening between adjacent portions of interlocking closure 202 . When interlocking closure 202 is open, warp thread 124 ( FIG. 1C ) can be inserted into eyelet 204 without removing either end of the warp thread from a warp beam, as well as without detaching either end 122 of heddle 200 from a frame (not shown).
[0038] FIGS. 3A and 3B depict an embodiment of a portion of another heddle 300 including a V-shaped break 302 in the circumference of eyelet 304 . As shown in FIG. 3B , one end of break 302 includes an inner V-shaped portion that engages an outer V-shaped portion of the other end of break 302 . The V-shapes retains the ends of break 302 in alignment during use of the loom. In some embodiments, a gap between the ends of break 302 allows a warp thread 124 ( FIG. 1C ) to be inserted into eyelet 304 without removing either end of the warp thread from a warp beam and without removing heddle 300 from a frame (not shown). A user simply raises the warp thread to the gap in break 302 , and exerts a slight inward pressure against break 302 to force the ends of break 302 apart. A slight upward and downward movement, or vice versa depending on the orientation of the V-Shape of break 302 , may be required, depending on the height of the vertex of the V-shape. In some embodiments, the circumference of eyelet 304 is fabricated with a flexible material that allows the ends of break 302 to bend open to insert or remove warp thread 124 . The material is sufficiently elastic to return the ends of break 302 to a substantially closed position when released.
[0039] FIG. 4 depicts an embodiment of a portion of another heddle 400 with a break 402 that can be configured in the circumference of an eyelet (not shown) to allow warp thread 124 ( FIG. 1C ) to be inserted and removed from the eyelet while the heddle remains attached to a frame, and the ends of warp thread 124 remain attached to the loom.
[0040] In the embodiment shown, break 402 includes two overlapping portions 404 , 406 formed or cut in the sidewall of the circumference of the eyelet. Overlapping portions 404 , 406 are fabricated from rigid material with flexible properties that allows overlapping portions 404 , 406 to be separated to insert and remove warp thread 124 from the eyelet, and return to their original position when released. In some embodiments, overlapping portions 404 , 406 can include a fastener to retain overlapping portions 404 , 406 in a closed position to retain warp thread 124 in the eyelet. The fastener can be disengaged to move overlapping portions 404 , 406 apart to remove warp thread 124 from the eyelet. An example of a fastener than can be used on overlapping portions 404 , 406 includes one or more protuberances 408 that are sized and shaped to snap into and out of corresponding indentation(s) (not shown) in overlapping portion 404 . Other suitable fasteners for opening and closing overlapping portions 404 , 406 can be utilized, in addition to, or instead of, protuberances 408 and corresponding indentations.
[0041] FIGS. 5A and 5B depict another embodiment of a heddle 500 that includes a finger portion 502 and channel portion 504 . Finger portion 502 is movable to engage channel portion 504 in a closed position, and to disengage channel portion 504 in an open position. Finger portion 502 can be moved to open or closed positions by exerting lateral force on the outer periphery of finger portion 502 . Any suitable angle can be utilized between finger portion 502 and channel portion 504 to help discourage warp threads 124 ( FIG. 1C ) from snagging in the eyelet. FIG. 5C is a cross sectional view of finger portion 502 engaged in channel portion 504 . Finger portion 502 and channel portion 504 can be formed by any suitable means such as extrusion, injection molding, or other fabrication process.
[0042] Referring now to FIG. 6 , heddles 100 , 200 , 300 , 400 , 500 , collectively referred to herein as heddles 600 , can replace closed heddles in most looms. Most frames 602 include a flat thin steel bar or rod 604 at the top and bottom of frame 602 . A series of heddles 600 are suspended onto rods 604 . The end portions of heddles 600 can be shaped to accommodate various frames 602 .
[0043] Referring now to FIG. 7 , loom 700 is shown with a plurality of frames 602 . Warp threads 124 are inserted through heddle eyelets (not shown) mounted in frames 602 . Warp threads 124 extend from front beam 702 through heddles in frames 602 to back beam 704 . During operation, frames 602 alternately raise and lower warp thread 124 . Typically, half of the frames 602 alternate with adjacent frames 602 between up and down positions. Back roller 706 is unwound to allow unwoven warp thread stored on it to move through the heddles, and front roller 708 winds up woven cloth.
[0044] Referring now to FIG. 8 , warp beam 800 includes a plurality of retaining members 802 protruding from a rounded edge 804 of deck 806 . Retaining members 802 retain parallel strands of warp thread 124 ( FIG. 1C ) in a spaced relationship to one another, typically evenly spaced at intervals depending on the desired tightness of the weave. Alternatively, retaining members 802 can be relatively closely spaced, and a user can skip one or more alternating retaining members 802 to achieve the desired weave density. One advantage of warp beam 800 over known configurations is that retaining members 802 evenly space warp thread 124 over the width of the loom. The even spacing provides consistent warp tension, and produces more evenly woven material. A common spacing of retaining members 802 is five retaining members 802 per inch. Other spacing intervals can be used, however. Some embodiments of warp beam 800 include a plurality of attachment points 810 connected to deck 806 . Attachment points 810 can be eyebolts, snap hooks, hooks or other means for attaching warp beam 800 to various portions of loom 700 , either directly or by means of rope, hooks or other fastening material.
[0045] Referring to FIGS. 7, 8 and 9 , a top view of a conceptual diagram of warp 900 includes parallel lines of warp thread 124 created by the consecutive back and forth winding of a single length of warp thread 124 between two spaced warp beams 800 . Warp beams 800 are typically used in pairs, and can be positioned the desired distance apart on a table or other surface, and “warped” by winding warp thread 124 between retaining members 802 . The warp beams 800 can be held in place during the warping process with C-clamps or other suitable attachment, with retaining members 802 facing outward. Warp 900 can then be fastened to existing front and back beams 702 , 704 on loom 700 . Alternatively, warp beams 800 can be fastened to loom 700 before installing warp thread 124 on retaining members 802 . Once warp 900 is completed, each parallel line of warp thread 124 can be inserted through a corresponding heddle 600 ( FIG. 6 ).
[0046] Warp beams 800 can include warp thread attachment points to retain the ends of warp thread 124 . The ends of warp thread 124 can be tied or otherwise fastened to retaining members 802 , or other suitable structure. In one embodiment, a knot is tied in warp thread 124 to fasten the end of warp thread 124 to one of retaining members 802 , or other suitable structural component on warp beam 800 or loom 700 . In alternate embodiments, the ends of warp thread 124 can be adhesively attached, positioned in a notch, or clamped to warp beam 800 . In some situations, for example in the production of multi-colored or striped material, more than two attachments for the ends of warp threads 124 may be required. In such embodiments, different warp threads 124 can be wound on warp beam 800 , with each end of warp thread 124 being attached to an intermediate retaining member 802 , or other suitable structural component, on warp beam 800 .
[0047] A single length of warp thread 124 can be used to warp loom 700 by winding warp thread 124 in consecutive parallel lines between two spaced apart warp beams 800 . Accordingly, parallel lines of warp thread 124 are evenly spaced over their entire length between warp beams 800 , and very few knots or other means for attaching warp threads 124 are required. The even spacing between parallel lines of warp thread 124 over their entire length eliminates the “draw-in effect” found on conventional looms, which is caused by attaching multiple warp threads 124 to one location on a warp beam.
[0048] In some embodiments, warp thread 124 is attached to warp beam 800 by inserting a portion of warp thread 124 between retaining members 802 and retention strip 808 . Retention strip 808 can be fabricated with elastic material capable of deflecting when warp threads 124 are inserted around portions of the retaining members 802 . Retention strip 808 substantially maintains to its original shape to provide compressive force on warp thread 124 against retaining members 802 . Retention strip 808 can be positioned adjacent retaining members 802 to keep warp thread 124 in place by providing compression against the portion of warp thread 124 positioned between retaining members 802 and retention strip 808 .
[0049] Sufficient tightness of retention strip 808 is typically developed to hold the warp thread in place if warp thread 124 breaks. Alternatively, a strip of adhesive tape or other retention mechanism placed under and over the ends of warp thread 124 , adjacent to retention strip 808 , can retain warp thread 124 in the event of a break.
[0050] In some embodiments of warp beam 800 , retaining members 802 comprise snap hooks or other suitable fasteners that grasp a portion of warp thread 124 . Such embodiments may not require retention strip 808 . Retaining members 802 can be spring-mounted to create consistent tension between parallel lines of warp thread 124 . Further, certain types of fasteners such as snap hooks can be used as retaining members 802 to reduce or even eliminate the need to tie knots in warp thread 124 to attach the ends of warp threads 124 to retaining members 802 . The snap hooks, or other fasteners, can be installed at any desired spacing along warp beam 800 .
[0051] Warp beams 800 can be attached to loom 700 ( FIG. 7 ) using large metal snap hooks or other suitable fasteners. Fasteners may be attached to the loom's original warp beam or to ropes used to secure the original warp beams 702 , 704 to loom 700 . Warp beams 800 can be strapped or tied to existing warp beams 702 , 704 , or attached with a variety of mating interlocking mechanisms, such as hooks and eyes, and dovetails. Other suitable attachment means may also be used to attach warp beams 800 to loom 700 .
[0052] Referring now to FIGS. 7, 8 , 9 , 10 and 11 , alternate embodiments of warp beams 800 can be attached to loom 700 using attachment points 810 . (In FIG. 10 , front beam 702 and back beam 704 have been removed for clarity.) In one embodiment, attachment point 810 comprises an eyebolt through which attachment media 1010 is threaded. Attachment media 1010 is typically comprised of nylon rope when it is used to attach a tie rod in traditional looms. However, attachment media 1010 could be made of other suitable material, such as rope, chain, or twine. One section of attachment media 1010 attaches a first warp beam 800 to roller 706 , and another section of attachment media 1010 attaches the other warp beam 800 to roller 708 . In some embodiments, many yards of warp thread 124 are suspended between two warp beams 800 . Excess warp thread 124 can then be wound around back roller 706 , together with one warp beam 800 at the beginning of weaving, and then unwound as needed in the weaving process. Later, the completed cloth would follow the first section of attachment media 1010 and the front warp beam 800 as they are all wound onto front roller 708 .
[0053] A loom assembly that includes warp beams 800 and heddles 600 can be warped in much less time than conventional looms. The various alternate embodiments of heddles 600 described herein enable warp threads 124 to be threaded through heddles 100 after the entire warp 900 is attached to loom 700 . Additionally, warp beams 800 and heddles 600 enable different warps 900 to be easily interchanged to switch weaving projects before the projects are finished. The various embodiments of heddles 600 also allow warp thread 124 to be removed without removing either end of warp thread 124 from loom 700 . Once unthreaded, individual heddles 600 can be removed from frame 602 while the rest of warp 900 remains intact on loom 700 . Heddles 600 also allow shaft switches to be easily made to create complex weaving patterns.
[0054] Unlike conventional closed loop heddles, embodiments of heddles 600 can easily be inserted or removed from frame 602 . Instead of threading ends of warp thread 124 through eyelets with closed circumferences, the weaver can lift warp thread 124 that has already been warped on the loom, and insert it through an opening in heddle 600 . Warp threads 124 can be reinserted in heddles 600 while warp thread 124 remains attached to front and back warp beams 800 (or 702 , 704 ) on loom 700 .
[0055] While the invention has been described with respect to the embodiments and variations set forth above, these embodiments and variations are illustrative and the invention is not to be considered limited in scope to these embodiments and variations. Accordingly, various other embodiments and modifications and improvements not described herein may be within the scope of the present invention, as defined by the following claims.
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An apparatus and method for warping a loom includes a heddle with an open or openable break in the circumference of its eyelet that allows insertion and removal of warp thread with simple motions through the break while both ends of the warp threads are fastened to the loom. A warp beam includes a plurality of retaining members that retain parallel strands of warp thread in a spaced relationship to one another. A length of warp thread is wound in consecutive parallel lines between two spaced apart warp beams. The combination of openable heddles and warp beams with warp thread retaining members allow a loom or knitting device to be rapidly set-up, allow for easy correction of mistakes, and for the removal and reloading of the heddles or a weaving project in mid-production.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a controlled method for an energy-saving and energy-releasing air conditioning system. The energy-saving and energy-releasing actions are performed by the two adjoined heat exchangers of the storage means. The feature of this design is to meet refrigerating and heat-produced requirements by using the controlled method of the present invention. Automatically adjusting the refrigerant flow rates of the first and the second circular refrigerant loops can place it into the optimum operational condition while central air conditioner is either under high loading or under low loading condition.
2. Description of the Related Art
According to the general central air conditioner's operation capacity (compressor and heating system) and following to the design rule of which QL (the environmental loading during peak period)<Qe (the cooling-produced ability of evaporator)<Qc (compressor and heating systems' abilities), the central air conditioner (compressor and heating system) can surely provide enough operation capacity for the refrigerating air conditioning system during peak loading. However, the peak period is a small portion of the whole operation. Therefore, the operational control of central air conditioner (compressor and heating system) situates in a huge energy-releasing condition for long-term, which causes energy waste. Moreover, the operational control of general central air conditioner (compressor and heating system) uses on/off to control energy supply. However, the actions of on and off cause central air conditioner on and off frequently and which decrease the central air conditioner's life cycle. As a result, the various-speed controlling mode is the latest method to actuate the central air conditioner to perform partial loading operation, which use frequency converter to control frequency and to keep the total refrigerant flow rate of central air conditioner (compressor and heating system) in a certain range during under various loadings. The central air conditioner is under low loading operation in long-term performance, and which can cause energy waste. Moreover, oil-return problem in partial loading operations will increasingly damage mechanical components and causes serious break-up and damage.
In order to overcome the shortage of over-operations in prior central air conditioners, the present invention is completed by multiple improvements. The energy-saving and energy-releasing actions are performed by the two heat exchangers of the storage means as shown in the present invention. Automatically adjusting the refrigerant flow rates of the first and the second circular refrigerant loops can place air conditioner into the optimum operational condition while central air conditioner is either under high loading or under low loading condition. This invention can achieve energy-saving purpose and efficiently solve the shortage of the prior art.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a controlled method for an energy-saving and energy-releasing refrigerating air conditioning system. In order to meet the refrigerating and heating-produced requirements, automatically adjusting the refrigerant flow rates of the first and the second circular refrigerant loops can place central air conditioner into the optimum operational condition while central air conditioner is either under high loading or under low loading condition. This design can achieve energy-saving purpose.
It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawing is included to provide a further understanding of the invention, and is incorporated in and constitutes a part of this specification. The drawing illustrates an embodiment of the invention and, together with the description, serves to explain the principles of the invention. In the drawing,
FIG. 1 is the preferred embodiment of the present invention showing the system of the first refrigerant circular loop;
FIG. 2 is the preferred embodiment of the present invention showing the system of the second refrigerant circular loop operation;
FIG. 3 is the controlled flow chart 1 of the present invention;
FIG. 4 is the controlled flow chart 2 of the present invention; and
FIG. 5 is the controlled flow chart 3 of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
FIG. 1 and FIG. 2 are the preferred embodiments of the present invention showing a refrigerating air conditioning system, which comprises one central air conditioner ( 11 ) at least, one heating-produced machine ( 12 ), one storage means ( 13 ), and one refrigerating machine ( 14 ) and one controller ( 15 ). Besides, the first refrigerant circular loop (L 1 ) and the second refrigerant circular loop (L 2 ) are also included in the system for connecting to the above components, in which;
The first refrigerant circular loop (L 1 ) performs circulation through the central air conditioner ( 11 ), the heating-produced machine ( 12 , the refrigerant in the system is acting cooling process here), the first refrigerant flow controller (V 1 , the first temperature sensor T 1 is set here to measure the first refrigerant back-flow temperature (TA1), and the first heat exchanger ( 131 ) of the storage means ( 13 ) in order. Finally, it will return to the central air conditioner ( 11 ) for constructing a circular loop.
The second refrigerant circular loop (L 2 ) performs circulation through the central air conditioner ( 11 ), the heating-produced machine ( 12 , the refrigerant in the system is acting cooling process here), the second refrigerant flow controller (V 2 , the second temperature sensor T 2 is set here to measure the second refrigerant back-flow temperature TA2), and the refrigerating machine ( 14 , the refrigerant in the system is acting steam absorption) in order. Finally, it will return to the central air conditioner ( 11 ) for constructing a circular loop.
The storage means ( 13 ) comprises with a phase-changeable cooling medium (W) (such as water and glycol liquid), the first heat exchanger ( 131 ), and the second heat exchanger ( 132 ), and the third temperature sensor (T 3 , which is to detect the temperature Ti of the storage means 13 ). Both of the heat exchangers ( 131 and 132 ) are adjoined but cannot penetrate. The first heat exchanger ( 131 ) is one section of the first refrigerant circulation loop (L 1 ), and the second heat exchanger ( 132 ) is one section of the 2 nd refrigerant circular loop (L 2 ). The refrigerant circular loop, and the first and the second refrigerant flow controllers (V 1 and V 2 ) control the refrigerant flow rates (m1 and m2), and the refrigerant temperature difference (temperature range) between heating exchangers makes one of the heat exchanger perform energy-releasing action (cooling releasing or heating-releasing) and the other heat exchanger performs energy-saving action (cooling-saving or heating-saving).
The heating produced machine ( 12 ) comprises with the forth temperature sensor (T 4 ) for detecting heating-produced temperature Th of the heating-produced machine. This can control the heat supply of a heat-required system H while cooling-produced requirement is greater than heating-produced requirement, and also the extra heat can be removed. Similarly, the refrigerating machine ( 14 ) comprises with the fifth temperature sensor (T 5 ) and which can detect refrigerating temperature (Tc) of the refrigerating machine ( 14 ) for controlling cooling supply in required-cooling system (C). Besides, the required-cooling system is with heat-absorption capacity while the heating-produced requirement is greater than refrigerating requirement.
By comprising above components, the controller ( 15 ) measures the temperatures (TA1, TA2, Ti, Th, Tc) from each temperature sensor (T 1 , T 2 , T 3 , T 4 , and T 5 ), and the results are compared with the setting temperatures (TAS1, TAS2, Tics, Tihs, Ths, Tcs). The first and the 2 nd refrigerant flow controllers (V 1 and V 2 ) control the temperature flow rates (m1 and m2), and which can make refrigerant do well adjustment in circular loop according to different loadings while meeting refrigerating or heating-produced requirements. The relationship can be seen as the following;
1. The refrigerant flow rate m (a fixed value), the required refrigerant flow rate (m1) of the 1 st refrigerant circular loop (L 1 ), and the required refrigerant flow rate (m2) of the 2 nd refrigerant circular loop (L 2 ) have the following relationship, which is m=m1+m2. Because of the refrigerant flow rate is fixed, m2 is smaller while m1 is greater, and vice versa.
2. The refrigerating flow rate m1 (m2) of the first (the second) refrigerant circular loop L 1 (L 2 ) is controlled by the 1 st (the second) refrigerant flow controller V 1 (V 2 ) measures the first (the second) refrigerant back-flow temperature TA1 (TA2) of the first (the second) temperature sensor T 1 (T 2 ), and then performs a comparison to with setting temperature TAS1 (TAS2) to control its flow rate.
Manual operation or automatic control is to meet different requirements of refrigerating and heat-produced needs in the whole operation of the refrigerating air conditioning system, the controlled method of the refrigerant circular loop can refer to FIG. 3 .
1. While cooling-produced requirement is greater than heating-produced requirement and the refrigerating temperature Tc is greater than setting cooling-produced temperature Tcs (which is Tc≦Tcs), the refrigerating air conditioning system forces it to perform refrigerating circulation. The steps of the controlled method as the following (please referring to FIG. 3 and FIG. 4 );
(1) In the cases where the second refrigerant back-flow temperature (TA2) is greater than the 2 nd setting temperature (TAS2) with pulsing setting temperature range (X). and where the first refrigerant back-flow temperature (TA1) is greater than the first setting temperature (TAS1) with pulsing setting temperature range X (TA2>TAS2+X and TA1>TAS1+X), the refrigerating air conditioning system ( 1 ) automatically chooses the second refrigerant circular loop (L 2 ) as circulation. In the meanstime, the second refrigerant flow controller (V 2 ) is opened. The flow rate of m2 is at maximum flow rate but the flow rate (m2) of the first refrigerant flow controller (V 2 ) is at the minimum flow rate. The storage means ( 13 ) is performing heating-releasing action.
(2) In the cases where the second refrigerant back-flow temperature (TA2) is less than or equal to the second setting temperature (TAS2) with plusing setting temperature range (X), and where the second refrigerant back-flow temperature (TA2) is greater than or equal to the second setting temperature (TAS2, which is TAS2+X≧TA2≧TAS2), the first and the second refrigerant circular loops are acting at the same time. The refrigerant flow rate (m2) of the second refrigerant flow controller (V 2 ) has a direct ratio relationship to the second refrigerant back-flow temperature (TA2). While the second refrigerant back-flow temperature (TA2) is smaller, the refrigerant flow rate (m2) of the second refrigerant flow controller (V 2 ) is smaller. Since the equation of m1=m-m2 in the system performs automatically adjustment, the refrigerant flow rate of first refrigerant flow controller (V 1 ) is relatively great. The storage means ( 13 ) automatically performs cooling-saving and cooling-releasing actions, and it makes the cooling-releasing action to the cooling-saving action.
(3) In the cases where the second refrigerant back-flow temperature (TA2) is less than the second setting temperature (TAS2), and where the first refrigerant back-flow temperature (TA1) is greater than or equal to the first setting temperature (TAS1, which TA2<TAS2, and TA1≧TAS1), the refrigerating air conditioning system makes the cooling-releasing action to the cooling-saving action, and automatically chooses the first refrigerant circular loop (L 1 ) as circulation. The refrigerant flow rate (m2) of the second refrigerant flow controller V 2 is at the minimum flow rate here. However, the refrigerant flow rate (m1) of the first refrigerant flow controller V 1 is at the maximum flow rate. The storage means ( 13 ) is performing cooling-saving action.
(4) While the temperature (Ti) of the storage means ( 13 ) is less than or equal to the setting temperature (Tics, and which Ti≧Tics), the central air conditioner ( 11 ) will be off operation, and complete cooling-saving operation.
While heating-produced requirement is greater than refrigerant requirement and the heating-produced refrigerating temperature (The) is less than setting heating-produced temperature Ths (which is Tc≦Tcs), the refrigerating air conditioning system forces it to perform heating-produced circulation. The steps of the controlled method as following (please referring to FIG. 3 and FIG. 5 );
(1) In the cases where the first refrigerant back-flow temperature (TA1) is less than the 2 nd setting temperature TAS2 (which is TA1<TAS1 and TA2<TAS2). The refrigerating air conditioning system ( 1 ) automatically chooses the first refrigerant circular loop (L 1 ) as circulation. In the meanstime, the first refrigerant flow controller (V 1 ) is opened. The flow rate of m1 is at maximum flow rate but the flow rate m2 of the 2 nd refrigerant flow controller (V 2 ) is at the minimum flow rate. The storage means ( 13 ) is performing heating-releasing action.
(2) In the cases where the first refrigerant back-flow temperature (TA1) is less than or equal to the setting temperature (TAS1) with the setting temperature range (X), and where the first refrigerant back-flow temperature (TA1) is greater than or equal to the first setting temperature (TAS1, which is TAS1+X≧TA1≧TAS1), the 1 st and the 2 nd refrigerant circular loops (L 1 and L 2 ) are acting at the same time. The refrigerant flow rate (m1) of the first refrigerant flow controller (V 1 ) has an inverse ratio relationship to the first refrigerant back-flow temperature (TA1). The first refrigerant back-flow temperature (TA1) is greater while the refrigerant flow rate (m1) of the first refrigerant flow controller (V 1 ) is smaller. The equation of m2=m-m1 is for automatically adjusting refrigerant flow rate, and the refrigerant flow rate (m2) of the 2 nd refrigerant flow controller (V 2 ) is relatively large. The storage means ( 13 ) automatically performs partial heating-saving and heating-releasing actions, which makes heating-releasing action to heating-saving action.
(3) In the cases where the first refrigerant back-flow temperature (TA1) is greater than the first setting temperature (TAS1) with adding setting temperature range (X), and where the second refrigerant back-flow temperature (TA2) is greater than or equal to the second setting temperature (TAS2, which TA1>TAS1+X, and TA2≧TAS2), the refrigerating air conditioning system makes the heating-releasing action to the heating-saving action, and automatically chooses the second refrigerant circular loop (L 2 ) as circulation. The refrigerant flow rate (m1) of the first refrigerant flow controller V 1 is at the minimum flow rate here. However, the refrigerant flow rate (m1) of the second refrigerant flow controller V 2 is at the maximum flow rate. The storage means ( 13 ) is performing heating-saving action.
(4) While the temperature (Ti) of the storage means ( 13 ) is greater than or equal to the setting temperature (Tihs, and which Ti≧Tihs), the central air conditioner will be off operation, and complete heating-saving operation.
According to the above description, the present invention uses the storage means with the controlled method of the first and the second refrigerant circular loops to achieve energy-saving and energy-releasing actions. This invention can efficiently achieve energy-saving purpose.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A controlled method for an energy-saving and energy-releasing air conditioning discloses the energy-saving and energy-releasing actions performed by the two adjoined heat exchangers of the storage means. The feature of this design is to meet refrigerating and heat-produced requirements by using the controlled method of the present invention. Automatically adjusting the refrigerant flow rates of the first and the second circular refrigerant loops can place it into the optimum operational condition while central air conditioner is either under high loading or under low loading condition.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority from co-pending U.S. application Ser. No. 11/269,139 filed Nov. 8, 2005, which is based on and claims priority from U.S. application Ser. No. 10/863,580, filed on Jun. 7, 2004, now U.S. Pat. No. 6,993,573, which claims priority from then co-pending U.S. Provisional Application Ser. No. 60/476,496, which was filed on Jun. 6, 2003, which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to wireless access of Internet content, in particular to the use of a portable camera/cell phone device for scanning bar codes and automatically downloading associated web content that is linked to the scanned bar code.
[0003] Systems exist in the prior art that allow a user to scan a bar code such as a product UPC code (or other machine-readable indicia), decode the bar code data, and send the decoded bar code data to an offsite server computer, where the server computer looks up a URL associated with that bar code in a database and sends the retrieved URL back to the user's computer. A browser at the user's computer then uses the URL to retrieve web content associated with the URL. This type of system, for example disclosed in U.S. Pat. Nos. 5,978,773 and 6,199,048 (owned by the assignee of the present invention, NeoMedia Technologies, Inc.), allows a user to automatically link to web content by simply scanning a bar code with a scanner attached to the user's PC. In another type of system, disclosed in U.S. Pat. No. 6,542,933, also owned by NeoMedia Technologies, Inc., a special bar code known as a PaperClick code is scanned, and the decoded data in parsed into two portions (a server ID and an item ID), with the server ID used to retrieve a URL template that is sent back to the user's PC, which then assembles a full URL by inserting the item ID from the bar code into the URL template, which is then used to retrieve the linked web content.
[0004] It is desired to be able to utilize this type of automatic web content retrieval system with portable devices that are not tethered to the user's PC. Such a portable device would allow a user to automatically access linked web content at any location, and not just when using his desktop PC. However, portable devices that can scan barcodes are not widely deployed. In addition, it is most convenient for the person scanning a PaperClick code or UPC code to be able to see the results immediately, even if they are not at their computer. A desired application for a portable device under this invention is for a user to enter a Barnes & Noble store, see a book he likes, scan the barcode on the back, and see what Amazon.com's price is, all without involving anything that one would normally consider a computer.
SUMMARY OF THE INVENTION
[0005] The present invention is a cellular telephone having an embedded or attachable camera and wireless Internet access capabilities, adapted to image a bar code symbol and retrieve related web content automatically, without the user being tethered to a desktop PC as in the prior art. The invention uses a camera phone adapted to perform the desired functions described herein. By adapting a camera phone in accordance with the invention, a consumer having such a camera phone can be provided with the value-added functionality of taking a picture of a bar code on a product, and having the camera phone automatically obtain information on the product, which may be for example prices from a search engine or sponsored web content.
[0006] The present invention utilizes a client program that operates a cell phone with a built-in camera and web browser. When the user activates the client on the camera phone, it provides a real-time on-screen display of what the camera is imaging. When the user presses the trigger, the camera phone grabs the image, uses an image-based decode algorithm to locate and decode a barcode, then invokes the built-in web browser, pointing it at a resolution server on the Internet with the barcode value it decoded. The resolution server takes the data sent from the camera phone and resolves the data into a URL in one of several ways, depending on the application (to be described later).
[0007] Thus, the present invention is a method for accessing content from an information server computer on a computer network such as the Internet using a camera-enabled cell phone. First, an image of a machine-readable code such as a bar code symbol is captured with the camera-enabled cell phone. The captured bar code image is processed to decode the bar code into a file identifier, and a request URL is formed that includes the file identifier. The request URL is then transmitted to a resolution server computer on the computer network. At the resolution server computer, an information URL is determined as a function of the request URL. The information URL is then returned to the camera-enabled cell phone, which in turn transmits the information URL to an information server computer designated by the information URL. The information server computer receives the information URL and returns content to the camera-enabled cell phone as a function of the information URL.
[0008] The request URL sent by the camera-enabled cell phone may optionally include a device identifier that serves to identify certain operating characteristics of the camera-enabled cell phone, such as the browser capabilities. In this case, the information URL will be determined as a function of the device identifier. This allows different information URLs to be returned for different devices, based on their display capabilities, so that each device will retrieve content that is optimized for display on that particular device.
[0009] The information URL may also be determined at the resolution server by extracting the file identifier from the request URL; and then querying a database with the file identifier. The resolution server database will have a plurality of mappings of file identifiers to associated information URLs.
[0010] In a further embodiment, the camera-enabled cell phone will capture an image of a machine-readable code with a camera-enabled cell phone and then process the captured image to decode the machine-readable code into a file identifier that contains a server ID and an item ID. A request URL is formed that includes the file identifier. The request URL is transmitted to a predetermined gateway server on the computer network, which analyzes the server ID to determine an associated resolution server on the computer network. The gateway server sends the item ID to the resolution server that is associated with the server ID to obtain an information URL as a function of the server ID and the item ID. The resolution server returns the information URL to the gateway server, and the gateway server interacts with the camera-enabled cell phone to send the information URL to an information server computer designated by the information URL and receive content from the information server computer as a function of the information URL.
[0011] In this embodiment, the gateway server interacts with the camera-enabled cell phone to send the information URL to an information server computer designated by the information URL and receive content from the information server computer as a function of the information URL in either of two ways. First, the gateway server may send the information URL to the information server computer designated by the information URL. The gateway server would then receive content from the information server computer as a function of the information URL and send the content received from the information server to the camera-enabled cell phone. Alternatively, the gateway server may send the information URL to the camera-enabled cell phone, and the camera-enabled cell phone then sends the information URL to the information server computer designated by the information URL. The camera-enabled cell phone then receives content from the information server computer as a function of the information URL.
[0012] In order to carry out this invention, the camera-enabled cell phone of the present invention includes a housing with a cellular telephone transceiver, a digital camera module having a camera lens, a display screen, and processing circuitry that interoperates with these components. In particular, the processing circuitry is adapted or programmed to cause the cellular telephone transceiver to selectively communicate with a cellular telephone network to place and receive cellular telephone calls, and to communicate with server computers via a browser program on a global computer network. The processing circuitry is also adapted to capture, via the digital camera module, an image of a machine-readable code, to process the captured image to decode the machine-readable code into a file identifier, to form a request URL comprising the file identifier and to transmit, via the cellular telephone transceiver, the request URL to a resolution server computer on the global computer network. The processing circuitry is also adapted to receive from the resolution server an information URL determined by the resolution server as a function of the request URL, interoperate with the browser program to transmit the information URL received from the resolution server to an information server computer designated by the information URL, receive content from the information server computer as a function of the information URL, and to display the received content on the display screen.
BRIEF DESCRIPTION OF THE DRAWING
[0013] FIG. 1 shows a basic block diagram of the operation of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 shows a basic block diagram of the operation of the present invention. A camera-enabled cell phone 2 (also referred to herein as a camera phone) includes, in one housing, a digital camera module 4 , a display screen 10 , a cellular telephone transceiver 8 , processing circuitry 6 , and various user input devices (such as keys, buttons, microphone, touch screen display) as well as output devices (such as a speaker) not shown for the purpose of clarity but well known in the art of cell phones. It is noted that although the preferred embodiment described herein utilizes an integrated camera phone (i.e. a cell phone with a built-in camera), the present invention is also intended to operate with a cell phone having an attachable camera, e.g. via an input/output port, as well. Likewise, any device that utilizes the functionality of a cellular or wireless phone and an imaging device such as a digital camera is covered by this invention as well.
[0015] A user invokes the appropriate client application on the phone (described below), and then images (takes a picture of), with the camera 4 , the target bar code symbol 12 or other machine readable code. The processing circuitry 6 decodes the bar code image obtained by the camera 4 and generates a request, typically in the form of a request URL having all or part of the decoded bar code integrated therewith, for sending out via the cell phone's wireless transceiver 8 . This is typically done via a wireless Internet connection as known in the art.
[0016] The request URL is sent wirelessly via a local antenna 14 , through the cellular network 16 and the Internet 18 , to the destination server, which is referred to as a resolution server 20 . The resolution server 20 accepts the request URL and parses out the bar code data from it. The resolution server 20 then looks up the bar code data on a mapping database 27 and retrieves an associated information URL, which is then sent back to the camera phone 2 and handed to a web browser program, which is then redirected by the information URL to the appropriate information server 22 on the Internet. The content requested by the information URL is sent from the information server 22 to the browser on the camera phone 2 and displayed thereon for the user. Thus, by invoking the appropriate client software on the phone 2 as described herein, the user can image or take a picture of a bar code and have content driven to his display 10 that is associated with that bar code 12 .
[0017] Various methodologies are known in the art that control how the bar code symbol is used to retrieve content from the Internet. In the basic case mentioned above, there is a simple mapping function carried out by the resolution server 20 , which takes the decoded bar code data and looks up a preprogrammed information URL in its database 27 . This is shown, for example, in U.S. Pat. No. 5,978,773, which is incorporated by reference herein. In an alternative embodiment, the bar code may be parsed into a server ID and an item ID, as taught in U.S. Pat. No. 6,542,933, which is incorporated by reference herein. Moreover, the content returned to the camera phone 2 may be specifically tailored for display on the small display of that device. This may be accomplished by using a methodology referred to as device-specific profiled routing, in which the request URL is assembled by the camera phone based on an additional parameter that is a device identification code, which designates if that client device is a wireless device that supports, for example, WML content, or XHTML content. By signaling to the resolution server 20 that the requesting device is WAP compliant, then the information URL sent to the camera phone will redirect its browser to an appropriate web site with WML content (wherein if the same bar code were used to request content via a full screen monitor on a desktop, the full HTML page would be returned). This device based profile routing is fully described in U.S. application Ser. No. 09/821,535, DEVICE-BASED ROUTING FOR WEB CONTENT RETRIEVAL, owned by the assignee of the present invention, the specification of which is incorporated by reference herein.
[0018] In an alternative embodiment, another server computer referred to as a gateway server 23 is utilized. The gateway server 23 acts essentially as a proxy server that receives request URLs from the camera phone, processes these requests, and returns either the information URL in a redirect to the camera phone browser or the information server content directly to the browser without requiring a redirect at the camera phone. In this embodiment, the bar code symbol is a file identifier that includes a server ID and an item ID as previously mentioned. The server ID will identify which resolution server will contain the specific mapping of item IDs to information URLs. In this scenario, there will be more than one (and likely many) resolution servers employed so as they distribute the database and computing requirements amongst many computers. This also has the advantage of allowing multiple parties to have control over various resolution servers instead of one party controlling one large resolution server.
[0019] In this embodiment, the request URL contains the server ID and the item ID, and is sent to a gateway server computer 23 . Each and every request URL sent by the camera phone will be sent to the same gateway server computer 23 (the address is essentially hard coded into the client application running on the camera phone). The gateway server 23 receives the request URL from the camera phone and parses out or extracts the server ID. The gateway server 23 then analyzes the server ID to determine which resolution server on the computer network is identified thereby (e.g. by reference to a database 25 ). The gateway server then sends the item ID to the resolution server 20 identified by the server ID. The resolution server 20 receives the item ID and performs a lookup of the item ID to retrieve an associated information URL from memory. That is, the resolution server will prepare and an information URL that indicates where the requested information may be found. The resolution server then returns the information URL to the gateway server 23 .
[0020] The gateway server then interoperates with the camera phone in one of two ways, depending on how the system is configured, to provide the information content at the camera phone. In one embodiment, the gateway server sends the information URL to the information server, receives the content from the information server computer as a function of the information URL, and sends the content received from the information server to the camera-enabled cell phone.
[0021] In an alternative embodiment, the gateway server hands off the information URL to the camera phone, the camera phone sends the information URL to the information server computer, and then the camera phone receives the content directly from the information server computer as a function of the information URL.
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A camera-enabled cell phone that is adapted to image a machine readable code such as a bar code, decode the bar code, send the bar code data over the Internet to a resolution server that will return an associated URL that will link the camera phone to content on an information server. Thus, by taking a picture of a bar code symbol, the camera phone will automatically retrieve content from the Internet that has been linked to that bar code.
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