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FIELD OF THE INVENTION
The present invention relates to pizza pans and systems, pizza preparation and cooking, and methods for facilitating pizza preparation and cooking.
BACKGROUND
Conventional pizza pans generally produce flat pizza pies. In order to prevent pizza toppings from oozing over the edge of the crust (and thereby dirtying the pan and oven, as well as harming the flavor and appearance of the pizza), a toppingless section of crust is typically maintained. This toppingless crust area is considered unpalatable by many consumers, and is often uneaten and discarded.
Storage of pans of uncooked dough is also a problem in conventional pizza pan systems, resulting in a requirement for large areas of counter, refrigerator and/or freezer space devoted to pan storage, or else necessitating the use of additional devices such as metal racks to stack the pans. In addition, in conventional pizza pan systems pans of uncooked dough are either left uncovered, resulting in accelerated drying out and crusting of the dough, or else must be covered by the use of kitchen foils and films, plastic trays/containers and lids, or make-shift devices.
SUMMARY
According to an aspect of the invention, a pizza pan comprises a bottom wall; a side wall circumferentially about the bottom wall such that the bottom wall and side wall cooperate to define an area for containing pizza dough; and a seal area for cooperating with a lid-like member to form a seal about the perimeter of the pan.
According to an aspect of the invention a pizza pan comprises a bottom wall; a side wall circumferentially about the bottom wall such that the bottom wall and side wall cooperate to define an area for containing pizza dough; and a trimming means to trim the dough to the desired shape about the perimeter of the pan.
According to an aspect of the invention, a pizza pan system comprises a pizza pan including a bottom wall; a side wall circumferentially about the bottom wall such that the bottom wall and side wall cooperate to define an area for containing pizza dough; and a rim circumferentially about the outer edge of the side wall; and a lid-like member mating with said rim enabling pizza dough to be compressed between said lid-like member and said rim to produce single crust, fold-over or double-crusted pizzas.
According to an aspect of the invention, a pizza pan system comprises a pizza pan including a bottom wall; a side wall circumferentially about the bottom wall such that the bottom wall and side wall cooperate to define an area for containing pizza dough; and a rim circumferentially about the outer edge of the side wall; and a lid-like member mating with said rim and having a wall cooperative with the pizza pan for stacking plural systems.
According to an aspect of the invention, a pizza pan comprises a bottom wall; a side wall circumferentially about the bottom wall such that the bottom wall and side wall cooperate to define an area for containing pizza dough; and a means to restrain the dough from drying, crusting and/or over-rising.
According to an aspect of the invention, a pizza pan comprises a bottom wall; and a side wall circumferentially about the bottom wall and cooperative with the bottom wall for containing pizza dough, the side wall having an upturned portion to prevent spillage of the pizza toppings/juices during cooking.
According to an aspect of the invention, a pizza pan comprises a bottom wall; a side wall circumferentially about the bottom wall such that the bottom wall and side wall cooperate to define an area for containing pizza dough; a rim circumferentially about the outer edge of the side wall; and a lid-like member attached to the underside of the bottom wall, cooperative with another pan for stacking plural pans.
According to an aspect of the invention, a method of preparing pizza comprises rolling dough, placing the dough in a pizza pan, and placing a lid over the pizza pan to compress dough about a rim area of the pizza pan and lid.
To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed.
Although the invention is shown and described with respect to certain preferred embodiments, it is obvious that equivalents and modifications will occur to others skilled in the art upon the reading and understanding of the specification. The present invention includes all such equivalents and modifications, and is limited only by the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top exploded perspective view of one embodiment of the pizza pan system of the present invention;
FIG. 2 is a side sectional view of the pizza pan system of FIG. 1;
FIG. 3 is a side sectional view of the side wall and rim of a pizza pan useful in the system of FIG. 1;
FIG. 4 is a side sectional view of the seal area formed by the mating of the pan and the lid-like member of the system of FIG. 1;
FIG. 5 is a side sectional view of a plurality of stacked pan/lid combinations;
FIG. 6 is a side sectional view of an attached pan/lid combination embodiment of the present invention;
FIG. 7 is a side sectional view of a plurality of nested pan/lid combinations;
FIG. 8 is a side sectional view of a modified, "traditionally-styled" pie pan embodiment of the present invention.
FIG. 9 is a side sectional view of a modified, "deep dish" pan embodiment of the present invention.
DESCRIPTION
Referring in detail to the drawings, wherein like reference numerals designate like parts in the several figures, and initially to FIG. 1, a pizza pan system 10, comprising a pan 11 and lid 12, is shown. The pan 11 has a bottom wall 13, which may be solid or perforated, and which may or may not be substantially flat, which cooperates with a side wall 14, about its perimeter, to define an area upon which pizza dough is placed for spreading, preparing, e.g., applying toppings, etc., and/or cooking. The side wall is shown as curved, although it could be sloped or even a more complex shape. The upturned side wall 14 provides a dam against spillage of pizza contents during cooking. Preferably, though not necessarily, the pan 11 has a rim 15 at the top of side wall 14; such a rim may provide a mating surface for the sealing flange 16 of lid 12, as well as providing a convenient means for trimming away excess pizza dough.
The lid 12 has a top wall 20 to which a handle 21 (or other means of manipulating the lid) may be attached. The handle 21 may be optional; it may be removable. Along the perimeter of top wall 20 a side wall 22 is attached. Top wall 20 and side wall 22 of lid 12, in conjunction with bottom wall 13 and side wall 14 of pan 11, combine to define a cooking volume 23 (FIG. 2) in which the pizza is cooked. When no handle is secured to the lid, the lid has a shape with a flat wall 20 and side wall 22; inverting the lid, then, enables the lid to be used as a pizza pan itself. This use can be advantageous particularly when all other pans 11 already are in use, or, when the user requires a pan of shallower depth.
If the lid 12 does not have a handle sticking up from the top 20, then the top 20 is a generally flat surface. The lid then may be used to support a pizza pan 11 on a table where the pizza is to be served. For example, the lid 12 may be placed on the table with the flange 16 against the top surface of the table. The pizza pan 11 may be placed with the bottom wall 13 thereof against the wall 20 of the lid 12 for support therefrom. Since the flange 16 is spaced away from the wall 20 of the lid 12 by the side wall 22, a volume or dead air space is provided between the wall 20 and the surface of the table. Such space provides thermal insulation that tends to resist the transfer of heat from the pizza and pizza pan to the table. Additionally, the relatively wide area of the flange 16 allows it to be supported on the surface of a table without presenting a sharp edge that could scratch or otherwise damage the table surface. Pan 11 may be spot-welded to lid 12 as a permanent assembly.
The rim 15 of pan 11 comprises a stepped wall with a seat 24 and a rim wall 25 (FIG. 3). The seat 24 mates with sealing flange 16 of lid 12 (FIG. 4), allowing compression of pizza dough between seat 24 and sealing flange 16 for the purposes of providing steady, uniform pressure for crimping and shaping the crimp of the dough/crusts of any pizza, and especially double-crusted or fold-over pizzas or pizza-like products such as focaccias, calzones, neapolitans, and rusticas. The rim wall 25 keeps the lid 12 centered over pan 11, and acts, in a knifing action, to trim excess dough.
When making a pizza, the dough may be spread along the bottom wall 13 of the pan 11 and up along the side wall 14. Additionally, some of the dough also may be spread onto the seat 24 of the rim 15. The flange 16 of the lid 12 may be pressed against the dough in the area of the seat 24. Such pressing may cause the cutting of the dough so that some of the dough is squeezed out above the rim 15 wall 25, and/or so that some of the dough may be urged back into the cooking volume 23, for example, along the side wall 14. The cooperation between the flange 16, seat 24, and rim wall 25 provides a substantially accurately-shaped pizza in the shape of the circular (or other) outline of the pan, for example, the outline at the top of the side wall 14. Additionally, the flange 16 of the lid 11 and the seat 24 and/or rim wall 25 may cooperate with some of the dough therebetween to provide a seal that is substantially air tight. Extra dough hanging over the rim wall 25 may be trimmed after such seal has been formed to provide the circular shape mentioned above. The seal helps to prevent air from entering the cooking volume 23 and causing drying, crusting, and/or other effects when the dough is stored or cooked. Thus, the seal may tend to prevent moisture loss from the pizza dough when it is being stored.
The pizza dough tends to expand while it is baked. The curvature of the side wall 14 of the pan 11 and the distance between the top of that side wall and the bottom wall 13 of the pan 11 allows pizza dough to be pressed against the side wall and to form a wall of dough which tends to retain cheese and/or other toppings or other ingredients on the pizza that is flat against the bottom wall 13 and in any event away from the side wall 14. During cooking, the cheese and possibly other ingredients may release a liquid-like grease, juice or oil, or excess moisture. In the past, such oil/moisture might burn when contacting the hot wall of a pizza pan. By providing the upstanding wall of dough mentioned, the liquid-like grease/juice/oil or excess moisture is kept away from the side wall and the bottom wall, too, of the pizza pan. Furthermore, as the pizza dough shrinks during cooling, for example, leaving a gap between the upstanding dough wall and the side wall 14, grease, juice tends not to spill into that gap area due to the containment provided by the upstanding dough wall.
The aforementioned trimming by the flange 16, seat 24 and rim wall 25 helps assure the pizza will have an aesthetically pleasing shape conforming thereto, e.g., circular or some other shape. The curvature of the side wall guides and supports the pizza crust during baking so such shape tends to be maintained. Also, since juices tend to be blocked from engaging the hot pan, burning of the pizza crust where juices interface between the dough and pan is avoided, thus further enhancing the pleasant aesthetics of appearance and odor of the pizza.
The upstanding rim wall 25 provides a still further barrier to prevent grease, juice and/or other material, such as dough or other ingredients or toppings on the pizza, from overflowing or spilling beyond the pan 11 onto a surface of the cooking oven, conveyer belt carrying the pizza pan through a pizza oven, etc. Such spillage in the past would tend to burn on the oven surface, for example, and by preventing such spillage and, thus, burning, the cleanliness of the oven equipment can be maintained relatively easily.
A plurality of combinations of pans 11 and handleless lids 12 can be stacked (FIG. 5). This stacking minimizes the space required (such as countertop, refrigerator, or freezer space) when multiple pans are used to prepare pizzas prior to cooking, storing panned dough in a refrigerator or freezer, or to store pizzas after cooking.
In another embodiment of the invention (FIG. 6) a pan/lid combination 210 comprises a lid 212 attached to the underside of a pan 211. The pan 211 has a side wall 214. The lid 212 has a side wall 222, preferably but not necessarily of a different shape than side wall 214. When the lid/pan combination 210 is inverted, the lid 212 can function as a separate pan, thus increasing the variety of pizza sizes and shapes available (if the lid 212 and the pan 211 are of different shape), and increasing the useful life of the pan before cleaning is required, since two cooking surfaces are available instead of one. Also, the attached lid 212 at the bottom of the pan 211 may serve as a stand to support the pan above the surface of a table. The side wall 222 of the lid supports the pan 211 above the table providing a dead air space below the pan bottom wall which provides a thermal insulating effect from the table to help keep the pizza warm with the pan 211 and lid 212 so secured, the pan and pizza cannot slide off the support.
Pan 211 has a rim 215 attached to the top of side wall 214, for mating with a lid (such as lid 12 shown in FIG. 1). Lid 212 could have an identical rim, enabling both pans of the pan/lid combination 210 to mate with the same lid. However, in the preferred embodiment lid 212 has a sealing flange 216, which allows a plurality of pan/lid combinations 210 to be stacked to facilitate storage when a plurality of pans are being used to prepare pizzas (FIG. 7). A stack of pan/lid combinations 210 is topped with a lid (such as lid 12 shown in FIG. 1).
An additional embodiment of the invention is a modified traditionally shaped (pie) pan 311 (FIG. 8), comprising a bottom wall 313 and side wall 314, wherein the side wall 314 includes a curved portion 325 (which could also be sloped or of a more complex shape) and an substantially straight portion 326.
An additional embodiment of the invention is a deep dish pan 411 (FIG. 9), comprising a bottom wall 413 and side wall 414, wherein the side wall 414 includes a curved portion 425 (which could also be sloped or of a more complex shape) and an substantially straight portion 426.
A number of advantages inure to the pizza pan system 10 of the present invention. Some of these advantages are with respect to storage, use, and resulting product, such as the pizza itself.
For example, the relationship of the flat bottom wall 13 and sloped side wall 13 facilitates stacking of plural pans 11 for storage. Stacking reduces the amount of space required for storage, and facilitates organization during pizza preparation. Also, a pizza pan system 10 having a flat bottom wall 13 on the pan 11 and a flat top wall 20 on the lid 12 enables a plurality of such assembled systems to be stacked for storage, for example, as is depicted schematically in FIG. 5. If a system 10 includes uncooked pizza dough or already cooked pizza, the closed system depicted in FIG. 5, for example, can be used for relatively long term storage providing protection of the dough or pizza from dirt, damage, etc. Also, with the pan 11 and lid 12 assembled in the manner shown in FIG. 5, for example, the two may form a relatively effective seal tending to prevent air from entering the interior volume where pizza dough or pizza is contained and also to tend to prevent drying of that material, for example, due to storage in a frost-free type refrigerator or freezer. Further, the confined space within the pan system 10 including an assembled pan 11 and lid 12, for example, as is shown in FIG. 5, may help to prevent undesired rising of the dough while it is stored either at room temperature or in a cooled environment. Being able to store the dough in the relatively isolated interior of a pan system 10 facilitates storage, including relatively long term storage, while the dough is ready for preparation and cooking relatively conveniently. This capability tends to minimize the time required to prepare a pizza because the dough can be prepared in advance and maintained in a controlled environment ready for use.
The pizza pan system 10 is strong and durable. It can be made, for example, of hard aluminum alloy, stainless steel, or of another suitable material able to withstand the temperatures at which pizza is baked, for example. Preferably the material of which the pan is made can be cleaned relatively easily. Also, preferably there are no small areas in the surface of the pan, such as folded, bent, cast, molded, etc. metal parts that would facilitate food becoming stuck and difficult to clean.
The various parts of the pizza pan system 10, etc., of the several embodiments disclosed herein may be interchangeable. In particular, the lid 12 may be used with a regular crust or "deluxe" pan, such as that shown in FIG. 1, or with a modified, "traditional style" pan, such as that shown in FIG. 8 or a deep dish pan, such as that shown in FIG. 9. The trimming, shaping, cutting and crimping actions of the pizza pan system may be employed in the various embodiments and combinations of the pizza pan system hereof.
In using the pizza pan system 10 or one of the other systems disclosed herein, for example, pizza dough is prepared and placed on the bottom wall 13 of the pan 11. The pan may be first rubbed or brushed with olive oil or the like applied to the inner surface against which the dough is to be placed. The dough preliminarily may be rolled out on a rolling sheet and it then is placed in the center concavity of the baking pan 11. The edges of the dough preferably will droop over the top of the rim wall 25. Preferably the dough is drawn up evenly over that rim wall 25 and air is let out so that it is not trapped between the dough and the pan. The dough will tend to conform to the shape of the pan. The lid 12 then is placed over the pan 11 and is aligned so the flange 16 will fit in the area of the step 24 and rim wall 25. The lid 12 is pressed against the ledge 24 to crimp the dough, shaping it and trimming it. After the lid has been seated on the pan in the above manner, a hand or a tool can be used to peel any excess dough away from the edge of the pan, removing that dough for later use.
Inside the pizza pan 10, then, is a "panned" portion of dough. It is ready for prepping by adding sauce, cheese, toppings, etc. for immediate baking or at a later time in the same day. Alternatively, the dough can be refrigerated or frozen by placing it still in the pan into a refrigerator or freezer, respectively. In a refrigerator the dough will keep for a few days, although some rising may occur depending on the dough recipe and how cold is the ambient temperature of the refrigerator is. In a freezer, rising would not occur, other than possibly for a short initial time until freezing has been completed. With the lid 12 in place on the pan 11 to form the pizza pan system 10, the dough is maintained in the volume 23 in a relatively sealed, air-tight relation away from the external environment.
If the dough has been frozen, it can be defrosted while still in the pan, proofed, topped with sauce, cheese, toppings, etc., and then baked.
During the baking the walled effect provided by the pizza dough along the side wall 14 of the pan 11 tends to prevent grease, juices and the like from dripping into the pan, and such pizza dough wall and the ledge 24 and rim wall 25 also may cooperate to prevent such oozing or dripping into the oven, etc., as was mentioned above.
In instances where a double-crusted (multi-layer) pizza style dough is used, the cooperative relation of the lid 12 and pan 11, especially of the lid flange 16 and the ledge 24 and rim wall 25 may be used to press the layers of dough together in effect tending to seal, crimp and combine them as a unitary material. Also, it will be appreciated that although the illustrated embodiment of the invention employs a pizza pan system having circular plan shape, other shapes may be used, such as rectangular, other polygon or some other plan shape, as may be desired.
The pizza pan and method described may be used to prepare, to store, to bake, to re-heat, to serve, and to re-store pizza or other product.
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A pizza pan system includes a pizza pan including a bottom wall, a side wall circumferentially about the bottom wall such that the bottom wall and side wall cooperate to define an area for containing pizza dough, and a rim circumferentially about the outer edge of the side wall; and a lid-like member mating with said rim enabling pizza dough to be compressed between said lid-like member and said rim to produce single-crusted, fold-over or double-crusted pizzas. The system allows storage of panned pizza dough within a substantially air tight chamber. The pans of the system can be stacked to economize on countertop or storage space. The area for confining pizza dough allows, in conjunction with a trimming means, consistent reproduction of aesthetically pleasing pizza shapes. A method of preparing pizza includes rolling dough, placing the dough in a pizza pan, and placing a lid over the pizza pan to compress, shape, conform and trim dough about a rim area of the pizza pan and lid.
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TECHNICAL FIELD
This invention relates to a vehicle compartment latch and more particularly to a vehicle compartment latch for latching a vehicle compartment closure, such as a trunk deck lid in the closed position to secure the vehicle compartment.
BACKGROUND OF THE INVENTION
Passenger vehicles are normally equipped with a rear vehicle compartment for storing a spare tire and transporting items such as groceries and luggage. The compartment, conventionally known as a trunk is closed by a deck lid that is hinged to the vehicle body and swings open to provide access to the compartment. The closure or deck lid is equipped with a compartment latch that cooperates with a striker attached to the vehicle body to latch the closure in the closed position automatically when the deck lid is closed.
In order to open the deck lid, the compartment latch is usually designed to be unlatched or opened from a position outside the compartment because the compartment is not designed to hold passengers. This compartment latch characteristic results in a possibility of a child (or older person) being trapped inside the trunk without any way for the trapped child to unlatch and open the deck lid.
SUMMARY OF THE INVENTION
The object of the invention is to provide a vehicle compartment latch that does not automatically latch when deck lid is closed against the striker.
A feature of the invention is that the vehicle compartment latch is equipped with a safety device that disables the detent lever when the compartment latch is unlatched thus preventing an inadvertent automatic latching of the vehicle compartment latch when the deck lid is closed subsequently.
Another feature of the invention is that the vehicle compartment latch is equipped with a safety device that must be reset manually after the compartment latch is unlatched in order to arm the compartment latch for a subsequent latching operation.
Another feature of the invention is that the vehicle compartment latch is equipped with a safety device that is automatically engaged but difficult to reset.
Still another feature of the invention is that the vehicle compartment latch is equipped with a safety device that disables the latch detent in response to an unlatching operation.
These and other objects, features and advantages of the invention will become more apparent from the following description of a preferred embodiment taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The presently preferred embodiment of the invention is disclosed in the following description and in the accompanying drawings, wherein:
FIG. 1 is a fragmentary rear view of a vehicle compartment latch of the invention showing internal parts of the vehicle compartment latch in the open or unlatched position and armed (i.e. with the safety device reset);
FIG. 2 is a fragmentary rear view of the vehicle compartment latch of FIG. 1 showing the internal parts of the vehicle compartment latch in the latched position;
FIG. 3 is a fragmentary rear view of the vehicle compartment latch shown of FIG. 1 showing the internal parts of the vehicle compartment latch in the open or unlatched position and disarmed (i.e. with the safety device engaged);
FIG. 4 is fragmentary rear view of the vehicle compartment latch of FIG. 1 showing the internal parts of the vehicle compartment latch in the open or unlatched position and partially rearmed (i.e. with the safety device partially reset in response to a first disengagement manipulation).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Vehicle compartment latch 10 comprises a housing or support 11 that is adapted for fastening to a vehicle compartment closure, such as a trunk compartment deck lid 50 and a fork bolt 12 . Fork bolt 12 pivots on support 11 about pivot pin 13 between an open or unlatched position shown in FIG. 1 and a closed or latched position shown in FIG. 2 . Vehicle compartment latch 10 is attached to the deck lid 50 so that fork bolt 12 is moved from the open position shown in FIG. 1 to the closed position shown in FIG. 2 when deck lid 50 is closed and fork bolt 12 engages a striker 52 that is attached to the vehicle body 54 at the deck lid opening. The cooperation of a fork bolt and striker is well known and need not be described in detail.
Vehicle compartment latch 10 further comprises a pawl lever 14 that pivots on support 11 about pivot pin 15 and cooperates with fork bolt 12 in a well known manner to retain fork bolt 12 in the closed position shown in FIG. 2 or release the fork bolt 12 for return to the open position shown in FIG. 1 . That is, pawl lever 14 pivots between a detent position shown in FIG. 2 and a release position shown in FIG. 1 . Pawl lever 14 also pivots to two successive disarmed positions as explained below.
Fork bolt 12 is spring biased counterclockwise to the open position shown in FIG. 1 by a coil spring 17 that surrounds pivot pin 13 with an extension at one end engaging ear 19 of fork bolt 12 . An extension at the other end of coil spring 17 engages an abutment of support 11 . Pawl lever 14 is spring biased clockwise by a second coil spring 21 that surrounds pivot pin 15 with an extension at one end engaging pawl lever 14 and an extension at the other end engaging another abutment of support 11 . Coil spring 21 biases pawl lever 14 clockwise to the detent position shown in FIG. 2 where pawl lever 14 engages a release lever 56 . Release lever 56 is pivotally mounted on pivot pin 15 behind pawl lever 14 and is spring biased by a third coil spring 58 counterclockwise against a stop 60 of support 11 . Thus pawl lever 14 rides on portion 22 of fork bolt 12 and then pivots clockwise with respect to release lever 56 to engage latch shoulder 23 of fork bolt 12 when fork bolt 12 is moved to the closed position by the closing deck lid 50 .
Pawl lever 14 has an arm 25 at one end that has a plastic end cap 26 secured to it. End cap 26 engages release lever 56 when pawl lever 14 is in the detent position shown in FIG. 2 . Pawl lever 14 is moved from the detent position shown in FIG. 2 to a release position shown in FIG. 1 by pivoting release lever 56 counterclockwise so that pawl lever 14 is pivoted counterclockwise to the release position. Release lever 56 is pivoted by a pull cable that is attached to an upper end of release lever 56 and that is operated by a conventional key lock cylinder (not shown) to move pawl lever 14 o the release position allowing the deck lid 50 to open. Alternatively release lever 56 can be pivoted by an electrically driven cam lever (not shown) that is remotely controlled.
Pawl lever 14 has a second arm 27 at the opposite end that is equipped with a stop pin 20 and a cable attachment 28 . Stop pin 20 and cable attachment 28 are part of a safety device 29 that disarms or disables vehicle compartment latch 10 . Safety device 29 further comprises a rotary cam 16 that is attached to support 11 by a pivot pin 30 . Cam 16 is spring biased to the armed position shown in FIG. 1 by a spring centering arrangement indicated generally at 32 . This arrangement comprises a coil spring 34 that surrounds pivot pin 30 with radial end extensions 35 that engage opposite sides of a stop tab 36 of support 11 . Cam 16 has a projection 38 on one end portion that fits between the two radial end extensions 35 so that cam 16 is always spring biased to the armed position of FIG. 1 whether cam 16 is pivoted from this position in the clockwise direction or in the counterclockwise direction.
Cam 16 has circumferentially spaced abutments 40 and 42 , an upper guard rib 44 and a cam surface 46 on the opposite end portion that cooperate with stop pin 20 to prevent inadvertent latching of vehicle closure latch 10 .
Vehicle compartment latch 10 operates in the following manner. When the deck lid 50 is closed, striker 52 engages fork bolt 12 pivoting fork bolt 12 clockwise from the open or unlatched position shown in FIG. 1 to the closed or latched position and trapping striker 52 in the compartment latch 10 as shown in FIG. 2 . As fork bolt 12 pivots to the closed position of FIG. 2, pawl lever 14 being spring biased clockwise, rides on portion 22 of fork bolt 12 and then pivots clockwise to engage latch shoulder 23 as shown in FIG. 2 .
As pawl lever 14 pivots clockwise, stop pin 20 pivots rotary cam 16 clockwise slightly via cam surface 45 and moves to a position engaging cam surface 46 on the bottom of cam 16 as shown in FIG. 2 . Deck lid 50 is now latched closed securely by vehicle compartment latch 10 which is now cocked for automatic actuation of safety device 29 when fork bolt 12 of vehicle compartment latch 10 is released and deck lid 10 is opened.
Fork bolt 12 is released by pivoting release lever 56 counterclockwise which pivots pawl lever 14 counterclockwise raising arm 27 away from latch shoulder 23 . As pawl lever 14 pivots counterclockwise, stop pin 20 pivots rotary cam 16 counterclockwise until stop pin 20 engages the first abutment 40 of cam 16 as shown in FIG. 3 . For such engagement cam 16 returns clockwise a small distance under the bias of coil spring 34 . Vehicle compartment latch 10 is now disarmed or disabled and cannot be latched. When deck lid 50 is subsequently closed, fork bolt 12 pivots to the latched position as shown in dashed line in FIG. 3 . However pawl lever 14 does not engage latch shoulder 23 and hence striker 52 can be withdrawn freely. Thus whenever deck lid 50 is closed with safety device 29 engaged, the deck lid 50 can be reopened from the interior of the trunk or other closure simply by lifting the deck lid.
In order to latch the deck lid 50 in the closed position, safety device 29 must be disengaged or reset before the deck lid 50 is closed. Safety device 29 is disengaged or reset in two stages by moving pawl lever 14 counterclockwise against the bias of coil spring 21 twice. This can be done by lifting cable attachment 28 up twice which returns cam 16 to the disengaged or reset position shown in FIG. 1 . In response to the double lift, cam 16 is pivoted clockwise with respect to support 11 from the engaged position shown in FIG. 3 to the interim, partially reset position shown in FIG. 4 to the reset position shown in FIG. 1 under the bias of spring 34 .
To move cam 16 clockwise to the interim partially reset position of FIG. 4, cable attachment 28 is lifted until stop pin 20 clears the first abutment 40 whereupon cam 16 pivots clockwise under the bias of spring 34 until stop pin 20 engages abutment 42 as shown in FIG. 4 . Cam 16 preferably includes guard rib 44 to prevent stop pin 20 being lifted long enough to overshoot the second abutment 42 .
Cam 16 is then fully reset by lifting cable attachment 28 a second time so that stop pin 20 clears the second abutment 42 whereupon cam 16 pivots clockwise to the fully reset position shown in FIG. 1 where stop pin 20 engages cam surface 45 of cam 16 . Vehicle closure latch 20 is now fully reset for latching engagement with striker 52 when deck lid 50 is subsequently closed.
It should be noted that the disengagement or resetting operation of safety device 29 requires two distinct manipulations of the pawl lever 14 . The resetting operation is purposely made difficult in order to further avoid inadvertent resetting of the safety device 29 particularly by a child who must be able to Figure out the requirement for the repeated manipulation of pawl lever 14 .
While the compartment latch of our invention has been described in connection with deck lid 50 , the compartment latch 10 can be used with other compartment closures where unintentional latching is not desirable. Moreover, the pawl lever 14 can be manipulated by a pull cable or other suitable device rather than lifted directly. In other words, many modifications and variations of the present invention in light of the above teachings may be made. It is, therefore, to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A vehicle closure has a compartment latch that includes a safety device that is automatically engaged to disable the compartment latch when the compartment latch is unlatched. The safety device must be reset manually to restore normal operation of the compartment latch. Manual resetting requires repeated manipulation of a pawl lever to avoid inadvertent disengagement of the safety device, particularly by children.
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TECHNICAL FIELD
The present invention relates to the inhibition of oxidation in functional fluids such as lubricants or hydraulic fluids, and more particularly to the inhibition of oxidation in cyclophosphazene fluids.
BACKGROUND OF THE INVENTION
Cyclophosphazene fluids are known to be useful as lubricants, hydraulic fluids, fuel additives, flame retardants, and for a variety of other purposes as well. The polyfluoro-substituted cyclophosphazenes, especially the polyfluoro-substituted cyclotriphosphazenes, appear to be a particularly useful group of cyclophosphazenes. As a class, the cyclophosphazenes appear to have significant potential as high temperature lubricants or hydraulic fluids, that is, at service temperatures in excess of 250° C. Applications at these high temperatures include use in jet aircraft, turbine and diesel engines.
Unfortunately, when employed at high temperatures in ambient atmospheres, the cyclophosphazenes can oxidize, and their utility thereby suffer. Oxidation of the cyclophosphazenes can cause the formation of solid deposits in them, can change their viscosities or lubricities, and can increase their corrosivity (that is, increase their acid number). U.S. Pat. No. 4,724,264 (Feb. 9, 1988, Nakacho et al.) discloses an attempt to avoid the problem of oxidation by employing particular substituents on the cyclophosphazene which render it less subject to oxidation. However, the selection of these particular substituents defines and therefore limits the circumstances under which the substituted cyclophosphazene fluid may be used.
At least one attempt has been made to protect cyclophosphazene fluids from oxidation by adding an antioxidant to them. More particularly, U.S. Pat. No. 3,313,731 (Apr. 11, 1967, Dolle, Jr. et al) discloses the use of perfluorinated aryltin compounds as antioxidants in cyclic triphosphonitriles (cyclotriphosphazenes) and polyfluoroalkoxy-substituted triazines. Of course, the triaryltin compounds are now known to be among the leading high temperature antioxidant additives for other conventional fluids, such as the polyphenyl ether fluids.
The '731 patent discloses good utility for the perfluorinated aryltins in the triazine fluids. However, the data given in the patent also disclose that less success was enjoyed when the aryltins were employed in the cyclotriphosphazenes. Comparative Sample A disclosed in Example below further demonstrates that the perfluorinated triaryltins are less than satisfactory as antioxidants in cyclophosphazenes, because the protection they provide is inadequate for high temperature uses of the cyclophosphazenes. Indeed, the use of aryltin compounds has often been found to be detrimental to the properties of the cyclophosphazenes.
Other antioxidant materials are of course known to be useful in other fluids. For example, it has long been known to employ triarylphosphines and phosphine oxides as antioxidant or anticorrosive additives in perfluorinated aliphatic polyether or polyol ester lubricants. The triarylphosphines and other known antioxidants, however, would be expected to lack utility in cyclophosphazene fluids for a variety of reasons. The known antioxidants are often immiscible with cyclophosphazene fluids. Known antioxidants often have a high volatility, such that they do not remain in cyclophosphazene fluids very long when employed at high temperatures. Many known antioxidants also possess low thermal stability, again, rendering them less than useful for high temperature applications. Some antioxidants have unacceptable decomposition products, interfering with the desired function of cyclophosphazene fluids. Similarly, some known antioxidants have an unacceptable coefficient of viscosity at high temperatures, that is, they interfere with the viscosity or lubricity of cyclophosphazene fluids. Indeed, many known antioxidants have narrow liquid ranges, that is, they have a high pour point and a low boiling point.
Perhaps the most significant reason why the antioxidants useful in other fluids are not expected to be useful in cyclophosphazene fluids is that cyclophosphazene fluids have an oxidative degradation mechanism which is substantially different from those of conventional fluids or lubricants, such as the polyphenyl ethers, the polyol esters and the perfluorinated aliphatic polyethers. Put simply, if the known antioxidants work by interfering with one step or another in the oxidative pathway associated with the oxidation of a conventional fluid, and if the oxidative pathway for cyclophosphazenes lacks such a step, the conventional antioxidants couldn't be expected to interfere in the oxidative pathway for the cyclophosphazenes.
As a more particular example, it is known that antioxidants for polyphenyl ether fluids function by the formation of a free radical, which reacts in a series of reactions with compounds such as the phenols, in order to form more stable radicals. As explained in more detail in "High-Temperature Stabilization of Polyphenyl Ethers By Inorganic Salts," Ravner et al., 15 ASLE Transactions 45-53 (1971), the antioxidants act as electron sinks during the free radical reaction, and the overall oxidation rate of the base fluid is thus curtailed by the antioxidants. The paragraph bridging pages 50 and 51 of the article notes a variety of potential reaction pathways in the neat ether fluids. The article, and in particular that paragraph, are expressly incorporated by reference herein.
In contrast, oxidation of cyclophosphazene fluids does not entail a free radical reaction. Rather, it appears that cyclophosphazenes oxidize by a cationic mechanism, such that the major oxidation products are arylphosphate esters, arylphosphate ester acids, arylphosphate ester amides, and arylphosphate ester nitriles. The complete oxidation mechanism of the cyclophosphazenes is not yet understood, and research into the mechanism is continuing. However, the cationic mechanism for oxidation of cyclophosphazenes may proceed as follows: ##STR2##
Whatever the details of the true mechanism may be, it is clear that conventional antioxidants such as organometallic salts (for example, triaryltins), being electron sinks, could not reasonably be expected to interfere in the oxidation of the cyclophosphazenes, since their oxidation entails a cationic mechanism. Despite the resulting expectation that conventional antioxidants are not useful in cyclophosphazenes, it would still be highly desirable to find materials which could successfully function as antioxidants in cyclophosphazenes.
It is therefore an object of the present invention to provide a cyclophosphazene fluid with an effective antioxidant, so as to stabilize the cyclophosphazene fluid against oxidation when used in ambient air at the high operating temperatures encountered in jet aircraft, turbine and diesel engines.
It is another object of the present invention to provide cyclophosphazene fluids with antioxidants having relatively low volatility, high thermal stability, tolerable decomposition products and a wide liquid range, that is, a low pour point and a high boiling point.
SUMMARY OF THE INVENTION
The present Applicant has discovered, contrary to the expectation one skilled in the art would have from the unsatisfactory results obtained with aryltin and other conventional antioxidants, that a defined group of aryl phosphines and phosphine oxides function very well as antioxidants in cyclophosphazene fluids, particularly in the polyfluoro-substituted cyclotriphosphazenes. The present Applicant has tested a number of other aryl phosphines and phosphine oxides, and found them to be unacceptable for many of the reasons noted above, with respect to other antioxidants. The apparent lack of any homologous structure between the useful phosphines, in comparison to those found not to be useful, serves as further proof that the utility of the defined phosphines and phosphine oxides is unexpected.
Thus, in a first aspect, the present invention is directed to an oxidation-resistant cyclophosphazene fluid composition, comprising: a cyclophosphazene fluid component; and an oxidation inhibiting amount of an aryl phosphine or phosphine oxide selected from the group consisting of: (a) symmetric triarylphosphines of formula R 3 P, wherein R is selected from the group consisting of 4-trifluoromethyl phenyl, 3-trifluoromethyl phenyl, 3-trifluoromethoxy phenyl, 3-(3-trifluoromethylphenoxy) phenyl, 3-(perfluoro-2, 5-dimethyl-3, 6-dioxanonyl) phenyl, and 1-naphthyl; (b) oxides of these symmetric triarylphosphines; and (c) 1, 3-bis(diphenylphosphino) benzene. The cyclophosphazene fluid composition enjoys its greatest utility as a hydraulic fluid or as a lubricant for metal parts at service temperatures in excess of 250° C., and the invention is also directed to a method of lubrication comprising supplying to such metal parts the oxidation-resistant cyclophosphazene fluid composition defined above.
In a related aspect, the oxidation-resistant fluid composition includes about 0.01 to about 5 percent by weight of the defined aryl phosphine or phosphine oxide.
In another related aspect, the cyclophosphazene fluid component of the composition is of the general formula (I): ##STR3## wherein n is 3 to 7, inclusive; wherein R is individually in each occurrence fluorinated phenoxy or 3-perfluoroalkylphenoxy; and wherein the ratio of fluorinated phenoxy to 3-perfluoroalkylphenoxy is about 1:5 to 1:1, inclusive.
The present invention is particularly advantageous in that the defined group of aryl phosphines and phosphine oxides provide superior oxidation resistance to cyclophosphazene fluids, in comparison to the only other antioxidant (triaryltin) known to have some utility in cyclophosphazenes. The present invention thus allows the cyclophosphazenes to be employed at temperatures above 250° C., in accordance with their previously-unrealized potential.
DETAILED DESCRIPTION OF THE INVENTION
As indicated above, the oxidation-resistant cyclophosphazene fluid composition of the present invention comprises a cyclophosphazene fluid component and an oxidation-inhibiting amount of a defined aryl phosphine or phosphine oxide. It is expected that the cyclophosphazene fluid component may be any cyclophosphazene which is liquid under the intended temperatures and the pressures of use, without regard to the nature of the substituents on it. Of course, a cyclophosphazene useful as the cyclophosphazene fluid component of the present invention must be of a type such that its oxidation is inhibited by the defined aryl phosphines or phosphine oxides of the present invention. Any cyclophosphazene undergoing oxidation via a cationic mechanism should find its oxidation inhibited by the defined aryl phosphines or phosphine oxides, and accordingly should be useful in the practice of the present invention. The easiest way to determine the suitability in any particular cyclophosphazene as a cyclophosphazene fluid component of the present invention is simply to add one of the defined aryl phosphine or phosphine oxides to it, and compare its oxidation resistance to a sample of it lacking the aryl phosphine or phosphine oxide. A variety of tests are well known for determining oxidation resistance; two preferred tests are described in the Examples below.
Cyclophosphazenes preferred as the cyclophosphazene fluid component in the present invention are trimeric oligomers, that is, containing three --N═P--units (the cyclotriphosphazenes). However, as a practical matter, the presently known methods of producing cyclophosphazenes typically yield materials containing at least minor amounts of higher oligomers. Thus, more preferably, cyclophosphazenes useful as the cyclophosphazene fluid component in the present invention contain at least about 90 percent or more of trimeric oligomers, and may contain up to about 10 percent of tetrameric and higher oligomers. Cyclophosphazenes containing greater proportions of tetrameric and higher ogliomers are still contemplated as useful in the practice of the present invention, however.
Cyclophosphazenes preferred for use as the cyclophosphazene fluid component in the present invention possess fluorinated aliphatic and/or fluorinated alkyl aliphatic substituent groups, particularly groups containing oxygen. The particularly preferred cyclophosphazenes correspond to the general formula (I): ##STR4## wherein n is 3 through 7 and R is individually in each occurrence fluorinated phenoxy or 3-perfluoroalkylphenoxy, with the proviso that the ratio of fluorinated phenoxy to 3-perfluoralkylphenoxy ranges from about 1:5 to about 1:1.
The fluorinated phenoxy moieties can contain from one to five fluorine atoms. It is preferred that the fluorinated phenoxy moiety contains one fluorine atom and that the fluorine atom is ortho-, meta-, or para- to the oxygen atom of the phenoxy moiety. The perfluoroalkyl group of the meta-perfluoroalkylphenoxy is preferably a lower perfluoroalkyl group having from one to about five carbon atoms and is most preferably a trifluoromethyl group. The preferred fluorinated phenoxy moiety is selected from the group consisting of 3-(3-trifluoromethylphenoxy)phenol and bis(3-phenoxyphenol).
The ratio of fluorinated phenoxy to perfluoroalkylphenoxy substituents ranges from about 1:5 to about 1:1. It is preferred that the ratio ranges from about 1:2 to about 1:1. It is more preferred that the ratio is about 1:2. While the cyclophosphazene compounds are described as single molecules having specified substituents present in a stated ratio, it will be realized by one skilled in the art that the compounds actually exist as statistical mixtures of molecules. Some of these molecules will have higher or lower ratios. However, the phosphazines will, within these statistical mixtures, have substituents present at the specified ratios.
The following are non-limiting examples of the cyclophosphazenes wherein the m-perfluoroalkyl phenoxy substituent is a 3-fluoromethyl phenoxy moiety. These examples include 2,2,4,4,6,6-di(4-fluorophenoxy)tetra(3-trifluoromethylphenoxy)-1,3,5-triaza-2,4,6-triphosphorine, 2,2,4,4,6,6-di(3-fluorophenoxy)tetra(3trifluoromethylphenoxy-1,3,5-triaza-2,4,6-triphosphorine, 2,2,4,4,6,6-di(2-fluorophenoxy)tetra(3-trifluoromethylphenoxy)-1,3,5-triaza-2,4,6triphosphorine, 2,2,4,4,6,6-tri(2-fluorophenoxy)tri(3-trifluoromethylphenoxy)-1,3,5-triaza-2,4,6triphosphorine, 2,2,4,4,6,6-tri(3-fluorophenoxy)tri(3-trifluoromethylphenoxy)-1,3,5-triaza-2,4,6-triphosphorine, 2,2,4,4,6,6-tri(4-fluorophenoxy)tri(3-trifluoromethylphenoxy)-1,3,5-triaza-2,4,6-triphosphorine, 2,2,4,4,6,6,8,8-tri(4fluorophenoxy)penta(3-trifluoromethylphenoxy)-1,3,5,7-tetraza-2,4,6,8-tetraphosphorine, 2,2,4,4,6,6,8,8-tri(3fluorophenoxy)penta(3-trifluoromethylphenoxy)-1,3,5,7-tetraza-2,4,6,8-tetraphosphorine, 2,2,4,4,6,6,8,8tetra(4-fluorophenoxy)tetra(3-trifluoromethylphenoxy)1,3,5,7-tetra-2,4,6,8-tetraphosphorine, 2,2,4,4,6,6,8,8-2.57(3-fluorophenoxy)-5.43(3-trifluoromethylphenoxy)-1,3,5,7-tetraza-2,4,6,8-tetraphosphorine, 2,2,4,4,6,6,8,8-2.57(3-fluorophenoxy) -5.43(3-trifluoromethylphenoxy)-1,3,5,7-tetraza-2,4,6,8tetraphorine, 2,2,4,4,6,6,8,8-2.57(4-fluorophenoxy)-5.43(3-trifluoromethylphenoxy)-1,3,5,7-tetraza-2,4,6,8-tetraphorine, and mixtures thereof. In a preferred embodiment, the cyclophosphazene is either 2,2,4,4,6,6-di(3-fluorophenoxy)tetra(3-trifluoromethylphenoxy)-1,3,5-triaza-2,4,6-triphosphorine, 2,2,4,4,6,6-di(4fluorophenoxy)tetra(3-trifluoromethylphenoxy)-1,3,5-triaza-2,4,6-triphosphorine, or mixtures thereof.
The cyclophosphazene fluids may be prepared in a one-pot, two-stage reaction. As an example, in the first stage, a fluorinated phenol and a perfluoroalkylphenol are placed into a flask with a solvent. An alkali metal hydroxide is added and the mixture is allowed to reflux followed by the waters of reaction being removed. The mixture is then allowed to cool, a halogenated cyclophosphazene is added, and then the new mixture is again refluxed. The product is recovered using conventional recovery techniques. The fluorinated phenol, perfluoroalkylphenol and halogenated cyclophosphazene starting materials are commercially available or may be prepared using conventional techniques.
In the preparation of the cyclophosphazene fluids, the fluorinated phenol, the perfluoroalkylphenol and the halogenated phosphazine reactants are used in amounts sufficient to insure that the fluorinated phenol and perfluoroalkylphenol are present in a ratio of from about 1:1 to about 1:2 and the fluorinated phenol and perfluoroalkylphenol substantially replace the halogens on the phosphazine ring. For example, when the cyclophosphazene is predominantly a trimer such as 2,2,4,4,6,6-hexachloro-1,3,5-triaza-2,4,6-triphosphorine, it is preferred to use at least about two moles of fluorinated phenol and at least about four moles of perfluoroalkylphenol per mole of 2,2,4,4,6,6-hexachloro-1,3,5-triaza-2,4,6-triphosphorine. When the phosphazine is a tetramer, it is preferred to use at least about 2.6 moles of fluorinated phenol and at least about 5.4 moles of perfluoroalkylphenol per mole of 2,2,4,4,6,6,8,8-octachloro-1,3,5,7-tetraza-2,4,6,8-tetraphosphorine. It is preferred to use a slight stoichiometric excess each of fluorinated phenol and perfluoroalkylphenol to insure complete reaction.
The particularly preferred cyclophosphazenes described above, and their methods of preparation, are disclosed in more detail in U.S. Pat. No. 5,015,405 (March, 1991, Kar et al.), which is expressly incorporated by reference herein in its entirety. Particular reference is made to Examples 1 through 3, at column 4, line 12 through column 5, line 12 of the patent specification.
Again, as indicated above, these preferred cyclophosphazenes are employed in combination with an oxidation-inhibiting amount of a defined aryl phosphine or phosphine oxide. The aryl phosphines and phosphine oxides useful in the practice of the present invention include 1,3-bis(diphenylphosphino)benzene and certain symmetrical triarylphosphines and their oxides. The symmetric trarylphosphines are of the general formula R 3 P, wherein R is 4-trifluoromethyl phenyl, 3-trifluoromethyl phenyl, 3-trifluoromethoxy phenyl, 3-(3-trifluoromethylphenoxy) phenyl, 3-(perfluoro-2,5-dimethyl-3,6-dioxanonyl) phenyl, or 1-naphthyl.
There does not appear to be any specific structure which could be considered to be generic to these materials which by itself would define them as a group. This fact by itself is good evidence that the utility of these materials in the present invention is unsuggested by the prior utility of a variety of triarylphosphines as antioxidants in other fluids. However, the aryl phosphines or phosphine oxides useful in the present invention are either unsubstituted, or have substituents such as perfluoroalkyl, perfluoroalkoxy, or perfluoroalkyl polyether, which are known to be thermally and oxidatively stable. Their substitution patterns are meta- and para-, rather than ortho-.
The fluid composition of the present invention preferably includes about 0.1 to about 5 percent by weight of the defined aryl phosphine or phosphine oxide. Advantageously, the aryl phosphine or phosphine oxide is introduced into the cyclophosphazene fluid component by the use of a compatible solvent, such as methylene chloride. More particularly, the defined aryl phosphine or phosphine oxide can first be suspended or, preferably, dissolved in appropriate quantity of the solvent. The resulting suspension or solution is then mixed with the cyclophosphazene fluid component, and the solvent driven from the resulting mixture. While heat can be employed to remove the solvent, the solvent is preferably removed under vacuum. Any other convenient method of mixing which achieves a uniform dispersion of the aryl phosphine or phosphine oxide in the cyclophosphazene fluid component may also be employed.
Some of the defined aryl phosphines possess only moderate stability in air, and may be subject to a degree of oxidation if allowed to stand in solution for significant time under an ambient atmosphere. Accordingly, it is preferred that the defined aryl phosphines and phosphine oxides be stored neat (that is, without a solvent) under an inert atmosphere, such as nitrogen, after their production and before they are admixed with the cyclophosphazene fluid component.
While all of the defined aryl phosphines and phosphine oxides have an antioxidizing effect in combination with the preferred cyclophosphazene fluid components, the defined aryl phosphines and phosphine oxides do not have identical utility in the practice of the present invention. Most notably, the symmetrical triarylphosphines in which R is 4-trifluoromethyl phenyl, 3-trifluoromethyl phenyl, and 3-trifluoromethoxy phenyl have relatively low molecular weights. These three materials therefore possess a moderate degree of volatility at temperatures on the order of 250° C or above, limiting their utility at higher temperatures. However, these materials still protect the preferred cyclophosphazene fluid components from oxidation at lower temperatures and are expected to extend the life of the preferred cyclophosphazene fluid components. Accordingly, their use still falls within the scope of the present invention.
The aryl phosphines and phosphine oxides useful in the practice of the present invention can be obtained from commercial sources or can be synthesized specifically for the practice of the present invention. For example, commercial tri(l-naphthyl)phosphine (that is, the symmetric triarylphosphine in which R is 1-naphthyl) is useful in the practice of the present invention. If not available on a commercial basis, the aryl phosphines can be synthesized by generating an aryllithium intermediate via metal-halogen exchange of an arylhalide with n-butyllithium, followed by nucleophilic reaction on a phosphorous-halogen bond. It should be noted, however, that this general method usually meets with varying degrees of success. Since the preparation of most of the defined aryl phosphines entails triple displacement on the same phosphorous center (phosphorous trichloride), the method becomes increasingly slow as the displacement reaction progresses, due to a build-up of steric hindrance. The slower the reaction, the more side-products that are obtained. Accordingly, alternative approaches may be desirable for some of the compounds. For example, the aryl phosphine in which R is 3-(3-trifluoromethylphenoxy) phenyl can be synthesized by first generating an aryl Grignard, again followed by nucleophilic displacement on phosphorous trichloride.
The aryl phosphine 1,3-bis(diphenylphosphino) benzene can be prepared by the dilithiation of 1,3-dibromobenzene, followed by reaction with commercially available chlorodiphenylphosphine. However, such a method has been found to give only low yields of product. An alternative approach has been described in the chemical literature which involves the preparation of 1-bromo-3-diphenylphosphinobenzene as an intermediate, followed by lithium-halogen exchange of the intermediate with n-butyllithium, followed by reaction with chlorodiphenylphosphine. The present Applicant has found that, while the 1-bromo-3-diphenylphosphinobenzene can be obtained in quantitative yields, the likelihood of its subsequent conversion to 1,3-bis(diphenylphosphino) benzene may be quite low, and not to be considered successful, presumably due to competitive oxidation to various phosphine oxide side-products.
PREPARATION OF ARYL PHOSPHINES AND PHOSPHINE OXIDES
The preparation of the defined aryl phosphines or phosphine oxides sometimes entailed reactions requiring anhydrous conditions. All reactions requiring anhydrous conditions were therefore performed in oven-dried glassware, which had been cooled under nitrogen. When performed, thin layer chromotography was performed on glass plates precoated with a 0.25 millimeter thickness of silica gel (type GHLF from Analtech, Inc.). Flash chromotography was performed on 230-400 mesh silica gel 60. All reported melting points were determined in open capillary tubes, and are uncorrected. 1 H-NMR spectra at 300 MHz and uC-NMR spectra at 75.4 MHz were recorded by a Varian VXR300. Tetramethylsilane was employed as an internal standard. Infrared spectra were obtained by use of a Perkin-Elemer 1310 Spectrophotometer. An elemental analysis, when performed, was performed according to standard analytical technique.
PREPARATION OF TRIS(4-TRIFLUOROMETHYLPHENYL)PHOSPHINE (R═4-trifluomethylphenyl)
8 grams of 4-bromobenzotrifluoride were dissolved in 45 milliliters of anhydrous diethylether at 0° C. under a nitrogen atmosphere. 14 milliliters of a 2.5 M solution of n-butyllithium in hexane were then added to the solution via syringe, with stirring, over a 10 minute period. The solution was stirred for 30 minutes at 0° C., and then a solution of 1 milliliter of phosphorous trichloride in 15 milliliters of diethylether was added to the solution dropwise over a 50 minute period. The resulting mixture was warmed to room temperature and stirred for 21/2 hours, then quenched with 50 milliliters of a 5 percent solution of hydrochloric acid. The organic phase of the mixture was washed with 50 milliliters of water, followed by 50 milliliters of aqueous sodium chloride solution. The organic phase was then dried over magnesium sulfate, filtered, and concentrated on a rotavap (rotary evaporator). The resulting product was a red-orange oil, yield 5.31 grams. The product included a triarylphosphine oxide side-product. The side-product was removed by precipitation by the addition of hexane, followed by filtration of the side product. The hexane solvent was removed on a rotavap, and the final product was an orange oil which crystallized upon standing. The triarylphosphine product was purified by recrystallization from methanol. The final yield of the triarylphosphine product was 1.95 grams (yield 35%).
The melting point of the triarylphosphine product was 74° to 75° C. The primary mass spectrum peak had an m/z ratio of 466. Infrared (potassium bromide disk) and NMR spectra were consistent with the disclosed structure of the product. The expected elemental analysis of the product was 54.09 carbon and 2.59 percent hydrogen, and 53.99 percent carbon and 2.74 hydrogen were found upon elemental analysis.
The corresponding triarylphosphine oxide had a melting point of 177° to 178° C. and a primary mass spectrum peak of m/z 481. The infrared (potassium bromide disk) and NMR spectra were consistent with the expected structure.
PREPARATION OF TRIS(3(TRIFLUORMETHYLPHENYL)PHOSPHINE (R═3-trifluoromethylphenyl)
10 grams of m-bromobenzotrifluoride were dissolved in anhydrous diethylether under nitrogen at 0° C. 17.8 milliliters of a 2.5 M solution of n-butyllithium in hexane were slowly added to the ether solution via syringe over a 10 minute period, with stirring. The resulting mixture was stirred for an additional 50 minutes at 0° C. 1.29 milliliters of phosphorous trichloride in 20 milliliters of diethylether were then added dropwise to the mixture over a 25 minute period, with stirring. The resulting mixture was stirred for 2 hours at room temperature, and the reaction then quenched with 50 milliliters of a 5 percent aqueous hydrochloric acid solution. 75 milliliters of diethylether were then added, and the organic layer washed with 50 milliliters of water followed by 50 milliliters of aqueous sodium chloride solution. The organic layer was then dried over magnesium sulfate and filtered. The solvent was removed on a rotavap to yield 6.66 grams of a crude product oil. The oil was purified by flash chromatography on a 6 inch by 1 inch inside diameter column packed with flash-grade silica gel. The eluting solvent was hexane. The purified oil was obtained at a 79 percent yield (5.45 grams). The mass spectrum of the product possessed a primary m/z peak at 466. The infrared (neat film) and NMR spectrum of the product were consistent with the expected structure.
PREPARATION OF TRIS(3-TRIFLUOROMETHOXYPHENYL)PHOSPHINE (R=3-trifluoromethoxyphenyl)
5.15 grams of m-bromophenyltrifluoromethyl ether were dissolved in 40 milliliters of anhydrous diethylether under nitrogen at 0° C. 8.5 milliliters of a 2.5 M solution of n-butyllithium were then added dropwise to the ether solution via a syringe, with stirring. The mixture was stirred for an additional 50 minutes at 0° C. 0.62 milliliters of phosphorous trichloride in 10 milliliters of diethylether were then added dropwise to the mixture by syringe over a 10 minute period. The mixture was allowed to warm to room temperature and stirred for 2 hours, after which the reaction was quenched by the addition of 25 milliliters of a 5 percent aqueous solution of hydrochloric acid. 50 milliliters of diethylether were then added to the mixture and the resulting organic layer washed with 25 milliliters of water, then 50 milliliters of aqueous sodium chloride solution. The organic layer was then dried over magnesium sulfate and filtered. The solvent was then removed from the product on a rotavap to leave 2.73 grams of an oil. The product oil was then purified by flash chromotography with hexane on a 6 inch by 1 inch inside diameter column packed with flash-grade silica gel. The resultant product was obtained as a viscous yellow oil at a 38 percent yield (1.41 grams). The product possessed a primary mass spectrum peak at m/z 514, and infrared (neat film) and NMR spectra were consistent with the disclosed structure for the product.
PREPARATION OF TRIS[3-(3-TRIFLUOROMETHYLPHENOXY) PHENYL] phosphine (R═3-(3-trifluoromethylphenoxy) phenyl)
A 1 liter, 3-necked flask was prepared by providing it with a mechanical stirrer, a Dean-Stark trap topped with a condenser and a nitrogen bubbler, and a stopper. The flask was flushed with nitrogen and then charged with 22.4 grams of potassium hydroxide, 64.8 grams of α,α,α-trifluoro-m-cresol and 500 milliliters of toluene. The mixture was stirred and heated at reflux for 2 hours, during which time it was observed that about 6 milliliters of water collected in the trap. 50 milliliters of 3-dibromobenzene and 39.6 grams of cuprous chloride were then added to the reaction mixture, and the mixture heated at reflux for another 18 hours. Analysis of the reaction mixture by capillary gas chromotography disclosed it to contain about 44 percent of 1-bromo-3-(3-trifluoromethyl)phenoxybenzene (determined with reference to a previously prepared and purified sample of verified identity). The crude mixture also contained about 12.5 percent of a product resulting from dialkylation, the rest of the material being the starting materials.
200 milliliters of diethylether were added to the crude reaction mixture, and the mixture then washed successively with two 100 milliliter portions of 5 percent aqueous hydrochloric acid solution, water, and aqueous sodium chloride solution. (The hydrochloric acid was employed to remove any residual copper impurities from the reaction mixture.) The organic mixture was then dried with magnesium sulfate and concentrated on a rotavap to a red, oily residue. The 1-bromo-3-(3-trifluoromethyl)phenoxybenzene was separated from the crude product by fractional distillation. Distillation at 1 millimeter Hg pressure and at 113° to 117° C. provided 47 grams of the product, a 38 percent yield. The desired product was contained in other fractions from the distillation, but no further effort was made to isolate it. The infrared (neat film) and NMR spectra of the product were consistent with the structure 1-bromo-3-(3-trifluoromethyl)phenoxybenzene.
3.2 grams of 1-bromo-3-(3-trifluoromethyl)phenoxybenzene, 0.25 grams of magnesium turnings and 40 milliliters of anhydrous tetrahydrofuran (THF) were stirred under nitrogen and heated at reflux for 6 hours. The mixture was then cooled to 0° C., and 0.29 milliliters of phosphorous trichloride in 10 milliliters of THF added dropwise to the mixture through an addition funnel. The resulting mixture was heated at reflux for 18 hours, then quenched with 20 milliliters of water. 100 milliliters of diethylether were added to the mixture, and the organic layer washed with two 50 milliliter portions of water and a 50 milliliter portion of aqueous sodium chloride solution. The organic layer was then dried over magnesium sulfate, filtered, and concentrated on a rotavap. The procedure yielded a crude oil weighing 2.22 grams. The oil was partially purified by eluting first with hexane, and then with 3 percent ethyl acetate in hexane, via flash chromotography on a 6 inch by 1 inch inside diameter column packed with flash-grade silica gel. The desired product was an oil; although only a crude product, it was determined via high pressure liquid chromotography analysis on a C-18 reverse-phase column to be greater than 70 percent pure. The crude product was further purified by placing the oil on a Kugelrohr apparatus, and heating at 100° to 120° C. under a vacuum of about 1 millimeter Hg for 6 hours. Some 3-(3-trifluoromethyl)phenoxybenzene was found to distill over during heating, which increased the purity of the desired product to about 78 percent, again determined by HPLC analysis. The mass spectrum of the product possessed a primary m/z peak at 742, and the infrared (neat film) and NMR spectra of the product were consistent with the disclosed structure.
PREPARATION OF TRIS[3; -(PEFLUORO-2,5-DIMETHYL-3, 6-DIOXANONYL) PHENYL]PHOSPHINE (R═3-(PERFLUORO-2, 5-DIMETHYL-3,6-DIOXANONYL) PHENYL)
26.3 grams of I-bromo-3(perfluoro-2,5-dimethyl-3,6-dioxanonyl) benzene were dissolved in 50 milliliters of diethyl ether at 0° C. under nitrogen. 16 milliliters of a 2.5 M solution of n-butyllithium in hexane were then added to the solution dropwise by a syringe over a 10 minute period, with stirring. The mixture was stirred for an additional 25 minutes at 0° C., then 1.16 milliliters of phosphorous trichloride in 15 milliliters of diethyl ether were added to the solution dropwise over a 15 minute period at 0° C. The resulting mixture was then stirred at room temperature for 16 hours, and quenched with 50 milliliters of a 5 percent aqueous hydrochloric acid solution. 100 milliliters of diethyl ether were then added to the mixture, and the organic layer washed with two 50 milliliter portions of water and 50 milliliters of aqueous sodium chloride solution. The organic layer was then dried over magnesium sulfate and filtered. The solvent was removed on a rotavap to leave 21.2 grams of a dark yellow, oily residue. The product was purified by flash chromotography using hexane as an eluent on a 6 inch by 1 inch inside diameter column packed with flash-grade silica gel. 17.1 grams of a yellow oil were obtained. This yellow oil was purified by distillation on a Kugelrohr apparatus. The desired product was contained in the fraction distilling between 195° and 230° C. at about 1 millimeter Hg pressure. 8.6 grams of the purified oil were obtained, a 37 percent yield. HPLC analysis on a C-18 reverse-phase column disclosed the product to be about 86 percent pure. The infrared (neat film) spectrum of the product was consistent with the disclosed structure.
The product oil was oxidized to the corresponding phosphine oxide by first dissolving 1 gram of the product oil in 20 milliliters of hexane at room temperature, and then adding 0.1 grams of 3-chloroperoxybenzoic acid in 10 milliliters of hexane dropwise over a 40 minute period, with stirring. The mixture was stirred for an additional 18 hours, and a white precipitate formed in the mixture during stirring. The precipitate was removed by filtration, and the filtrate washed with I00 milliliters of a saturated aqueous sodium carbonate solution, to remove any m-chlorobenzoic acid. The organic phase was then dried over magnesium sulfate, filtered, and concentrated on the rotavap. 0.46 grams of a colorless oil were obtained, a 46 percent yield. The infrared (neat film) spectrum of the oil was consistent with the structure of tris[3-(perfluoro-2,5-dimethyl-3,6-dioxanonyl) phenyl] phosphine oxide.
PREPARATION OF 1,3-BIS(DIPHENYLPHOSPHINO)BENZENE
A solution of 15 grams of 1,3-dibromobenzene in 155 milliliters of THF was prepared under nitrogen at -78° C. 93 milliliters of a 2.5 M solution of n-butyllithium in hexane were added to the solution by syringe over a 30 minute period, with stirring. The resulting mixture was then stirred for two hours at -78° C., and 41.7 milliliters of chlorodiphenylphosphine in 150 milliliters of THF added to the mixture over a 30 minute period. The mixture was allowed to warm to room temperature with stirring, and was stirred for 20 hours. The reaction mixture was then quenched with I25 milliliters of a 5 percent aqueous hydrochloric acid solution. 200 milliliters of diethylether were then added, and the organic layer washed with 150 milliliters of water and 100 milliliters of an aqueous sodium chloride solution. The organic layer was then dried over magnesium sulfate, filtered, and concentrated on a rotavap. 45.2 grams of a yellow oil were obtained. The oil was then heated on a Kugelrohr apparatus at 1 millimeter Hg pressure for 12 hours at 150° to 170° C. Gas chromotography-mass spectrometry analysis disclosed the distillate to contain several components, including butyldiphenyl phosphine and 1,3-dibutylbenzene. The pot residue was collected and eluted with hexane by flash chromotography on a 10 inch by 2 inch inside diameter column packed with flash-grade silica gel. 7.48 grams of the desired product were obtained as a yellowish oil, a 26 percent yield. The product was disclosed by HPLC analysis on a C-18 reverse-phase column to be about 86 percent pure. The product possessed a primary mass spectrum peak at m/z of 446, and the infrared (neat film) and NMR spectra of the product were consistent with the disclosed structure.
EXAMPLES
The following examples demonstrate the effectiveness of some of the defined aryl phosphines against oxidation of a particularly preferred cyclophosphazene fluid component, primarily comprising 2,2,4,4,6,6,-d i(4-fluorophenoxy)tetra(3-trifluoromethylphenoxy)-1,3,5-triaza-2,4,6-triphosphorine (hereinafter, the "cyclotriphosphazene").
Example 1
20 milliliter samples of the cyclotriphosphazene containing 0.5 percent by weight commercial tri(1-naphthyl) phosphine (Sample 1) or 1 percent tri(3-trifluoromethyl phenyl) tin (Comparative Sample A), as well as a 20 milliliter sample of the cyclotriphosphazene itself (Comparative Sample B), were tested for oxidative stability by a microoxidation/corrosion/acid number test. The test procedure is an adaptation of Federal Test Method Standard 79lb, Method 5307.1, "Corrosiveness and Oxidation Stability of Aircraft Turbine-Engine Lubricants." The test was conducted at 290° C. in the absence of metals, with an air flow rate of 1 liter per hour for 24 hours. At the conclusion of the run, each sample was removed from the test tube, and its acid number determined. The following total acid numbers were obtained:
TABLE 1______________________________________ Total Acid NumberSample before after net change______________________________________1 0.191 0.178 -0.013Comparative A 0.081 5.590 +5.460Comparative B 0.096 2.456 +2.360______________________________________
These data show that the mixture of the triarylphosphine with the cyclotriphosphazene (Sample possesses a significantly reduced acid number, in comparison to that of the cyclotriphosphazene itself (Comparative Sample B). This demonstrates that oxidative degradation of the cyclotriphosphazene is effectively inhibited by the triarylphosphine. The data also show, in contrast, that the triaryl tin compound (Comparative Sample A) was not merely ineffective as an antioxidant, but appears to have worsened oxidative degradation of the cyclotriphosphazene.
Example 2
Small quantities of Sample 1, Comparative Sample B and a sample containing 0.5 percent of 1,3-bis(diphenylphosphino)benzene in the cyclotriphosphazene (Sample 2) were tested for oxidative stability by differential scanning calorimetry. The test was carried out under 200 psi oxygen pressure. The test instrument rapidly heated each sample in a cell at a rate of 25° C. per minute up to 354° C., and then maintained each sample at that temperature. The heat flow in the cell containing each sample was monitored until a major oxidation exotherm was observed. The time for evolution of the exotherm relates to the oxidative stability of the sample, a shorter time corresponding to a less stable sample, and a longer time corresponding to a more stable sample.
Comparative Sample B required 47.7 minutes until the major oxidation exotherm was evolved, while Sample 1 required 51.4 minutes until the major oxidation exotherm was evolved, and Sample 2 required 55.4 minutes until the major oxidation exotherm was evolved. These data reflect a 7.7 percent improvement in the oxidative stability of Sample 1 over Comparative Sample B, and a 16 percent improvement in the oxidative stability of Sample 2 over Comparative Sample B.
It is clear from Examples 1 and 2 that certain aryl phosphines can provide good oxidation protection to cyclophosphazenes. The particular mechanism by which oxidation is inhibited is not presently known, and the useful aryl phosphines and phosphine oxides do not appear to contain any common structure which would give them their utility in this regard. A number of other aryl phosphines are not suitable for this purpose, however, so the prior use of the triarylphosphines as antioxidants in other fluids cannot be considered to suggest the use of the defined aryl phosphines and phosphine oxides with cyclophosphazene fluids in particular. The substantial differences between the oxidative degradation pathways for the cyclophosphazenes, and those of other fluids in which the aryl phosphines have previously been employed, make it clear that this utility of the defined aryl phosphines and phosphine oxides is unexpected.
Thus, the present invention provides an oxidation-resistant cyclophosphazene fluid composition, one which is particularly adapted for high temperature lubrication and hydraulic applications.
While the invention has been described in terms of specific embodiments, however, it should be appreciated that other embodiments could readily be adapted by those skilled in the art. Accordingly, the scope of the invention is to be considered limited only by the following claims.
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The oxidation resistance of a cyclophosphazene-based fluid (such as a lubricant or a hydraulic fluid) can be improved by the addition to the fluid of an oxidation-inhibiting amount of an aryl phosphine or phosphine oxide. The aryl phosphine or phosphine oxide is preferably present in an amount of about 0.01 to about 5 percent by weight. The aryl phosphine or phosphine oxide can be (a) a symmetric triarylphosphine of formula R 3 P, wherein R is 4-trifluoromethyl phenyl, 3-trifluoromethyl phenyl, 3-trifluoromethoxy phenyl, 3-(3-trifluoromethylphenoxy) phenyl, 3-(perfluoro-2, 5-dimethyl-3, 6-dioxanonyl) phenyl or 1-naphthyl; (b) an oxide of any of these symmetric triarylphosphines; or (c) 1, 3-bis(diphenylphosphino) benzene. The cyclophosphazene fluid component is preferably a (fluorinated phenoxy) (3-perfluoroalkylphenoxy)-cyclic phosphazene of the general formula (I): ##STR1## wherein n is 3 to 7, inclusive; wherein R is individually in each occurrence fluorinated phenoxy or 3-perfluoroalkylphenoxy; and wherein the ratio of fluorinated phenoxy to 3-perfluoroalkylphenoxy is about 1:5 to 1:1 inclusive. Although useful as antioxidants in other fluids such as polyphenyl ethers, perfluorinated aliphatic polyethers and polyol esters, the antioxidant activity of the defined aryl phosphines and phosphine oxides in cyclophosphazene fluids is unexpected because of the significant difference in the pathways of oxidative degradation between the cyclophosphazenes and these other fluids.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a division of U.S. application Ser. No. 10/710,067, filed Jun. 16, 2004 now U.S. Pat. No. 7,402,734, which claims the benefit of U.S. Provisional application 60/320,278 filed on Jun. 16, 2003, each of the disclosure of which are hereby incorporated by reference in their entirety.
BACKGROUND OF INVENTION
The present invention relates to plant cell transformation in which genetic material is inserted into plant cells to modify resulting plants, and in particular, the invention relates to an apparatus for collecting embryonic tissue from seeds that may be used for such transformation.
The genetic transformation of plants may be used to develop crops with improved yield, insect and disease resistance, herbicide tolerance, and increased nutritional value. In such transformation, new genes are introduced into the chromosomal material of existing plant cells. Various methods have been developed for transferring genes into plant tissue including high velocity microprojection, microinjection, electroporation, direct DNA uptake and, Agrobacterium-mediated gene transformation.
Once the gene is successfully introduced into the chromosomal material of the plant cells, new inheritable germ line tissue must be developed (e.g., seeds) so that the new plant may be propagated. One way this may be done is by selecting only cells that have accepted the new gene and culturing the callus of these cells into a new viable plant. The time required to develop a plant from a single cell is lengthy.
Shortened development times may be obtained by directly treating meristematic tissue of a preformed plant embryo. The meristematic tissue is formative plant tissue of cells that will differentiate to produce different plant structures including the seeds or germ line tissue. A number of plant embryos may be treated and selection or screening techniques used later to determine which of those plants have incorporated the new genetic information into their germ line tissue.
U.S. Pat. No. 6,384,301 assigned to the assignee of the present invention and hereby incorporated by reference describes a method of genetically transforming soybeans ( Glycine max ) using Agrobacterium mediated gene transfer directly on the meristematic cells of soybean embryos. In this procedure, the seeds are soaked to initiate germination. After germination has begun, the embryo is excised from the seed and the primary leaf tissue removed to expose the meristem of the soybean embryo. The meristem is formative plant tissue that will differentiate to give rise to different parts of the plant.
Although seeds are inexpensive, the considerable labor involved in excising the embryos, transferring the genetic material into the embryos, and cultivating the embryos makes it desirable to reduce damage to the embryo that could result in this effort being applied to tissue that is ultimately non-viable. For this reason, the excision of plant embryos is performed by hand.
In the manual process, surface sterilized seeds are aseptically handled one at a time with gloved hands. They are oriented in a manner as to eject the seed coat with applied force. Then the cotyledons are separated and removed leaving the seed embryo. The embryonic leaves are removed near the area of the primary meristem. Recovery of viable embryos for genetic transfer is less than 100% even with this hand method and may be as little as 70% with high quality seeds.
Bacterial contamination of the embryos after excision is a significant concern. Manual excision of the embryos allows early separation of the seed coat from the remainder of the seed to prevent contamination of the embryo with bacteria found on the seed coat, which normally protects the embryo.
Skilled personnel performing manual excision can often recognize abnormal embryos at the time of excision and discard them, substantially improving downstream yields.
Despite the advantages of manual excision, individual separation of each plant embryo from its seed is extremely labor intensive and stands as a barrier to a scaling up of the transformation process in which, typically, many plants must be treated to yield a successful few transformations.
What is needed is a process that can significantly increase the availability of transformable embryos without unacceptably increasing total costs of transformation, the latter which will rise if damage to embryos or bacterial contamination of the embryos causes fruitless cultivation of large numbers of non-viable embryos.
SUMMARY OF INVENTION
The present inventors have developed an automated technique for excision of transformable tissue from seeds that sufficiently reduces embryo damage and bacterial contamination such as might render mechanical separation impractical. A mechanical excision machine is combined with optional seed culling, improved hydration of the seeds, and automated separation of the embryos to make automatic excision practical. Additional techniques to reduce bacterial contamination incident to such automation, particularly between the seed coat and the embryo, are provided.
Specifically then, the present invention provides for automated preparation of transformable plant tissue by hydrating plant seeds to soften the seed tissue and then passing the hydrated seeds through a mechanical separator that divides the seeds into separate cotyledon, seed coat and embryo. Genetic material is then introduced into the cells of the separated embryo.
It is one object of the invention to provide for the high volume automated excision of transformable plant tissue.
The mechanical separator may provide opposed moving surfaces applying a shear force to the hydrated seeds.
It is another object of the invention to provide for a simple mechanical separator that separates the seed components without undue damage to the embryo. The shear force on the hydrated seeds coaxes the seeds apart along their natural separation points.
The opposed moving surfaces may be rollers having different rolling speeds.
Thus it is another object of the invention provide for shear surfaces that are easily manufactured.
The rollers may be co-rotating.
It is another object of the invention to provide a mechanism that is adaptable to a continuous or semi-continuous batch process.
The rollers may have serpentine roller faces.
It is another object of the invention to provide a surface that envelops the outer surface of the seeds to separate them and distribute the shearing force evenly to reduce damage to the embryos.
The rollers may have an outer elastomeric surface.
Thus, it is another object of the invention to provide for improved grip and reduced pressure on the seed coat.
The moving surfaces may comprise at least two successive sets of opposed rollers.
Thus, it is another object of the invention to provide for a series of graduated separations of the seed coats to increase yield.
The separation of the moving surfaces may be adjusted according to the type of seeds. The amount of shear between the moving surfaces may also be adjusted according to the type of seed.
Thus, it is another object of the invention to provide a machine suitable for the processing of a variety of different seed types.
The seeds may be sprayed with liquid as they pass through the mechanical separator.
It is another object of the invention to reduce bacterial contamination incident to such mechanical separations by a constant dilution or disinfecting of such contamination with sterile liquid or a disinfectant solution.
Liquid may be sprayed against the rollers to strike the rollers in a direction opposite rotation of the rollers.
It is another object of the invention to provide for a cleaning of the rollers that minimizes damage to attached embryos.
The volume or mass flow of seeds into the mechanical separator may be controlled to a predetermined constant value.
It is thus another object of the invention to minimize damage to the embryos that may be caused by an excessive number of seeds entering the rollers.
The seeds may be culled based on predetermined seed characteristics such as color, size, moisture, germplasm or density prior to their mechanical separation.
Thus it is another object of the invention to compensate for the lack of human visual inspection in mechanical excision by a tight control of seed type at a stage where rejection of seeds is relatively inexpensive.
The step of hydrating the seeds may include rinsing the seeds and then holding them for at least one hour followed by a soaking of the seeds.
It is thus another object of the invention to provide for a hydration in a manner that reduces cracking of the cotyledons such as may promote damage to the embryo.
The rinsing, holding, and soaking may be performed in a container in which seeds are introduced, the container having a drain and an inlet, the inlet communicating with the first rinse liquid reservoir, and a second soak liquid reservoir different from the rinse liquid reservoir and including a valve position between the inlet and the rinse liquid reservoir and the inlet and the soak liquid reservoir and the drain, the valve communicating with an electronic timer for controlling the rinse, holding, and soaking automatically.
Thus it is another object of the invention to allow more complex schedules for hydrating the seeds without undue seed handling. It is another object of the invention to allow the use of reservoirs into which different additives may be introduced permitting different rinse and soak materials to be used in hydrating the seeds.
The rinse may include an antimicrobial such as a bleach or other disinfecting solution.
Thus it is another object of the invention to reduce the bacterial load upstream of their mechanical excision, the latter which may cause contamination of the embryos.
After the mechanical separation, the cotyledons, seed coats, and embryos may be passed into a separating machine to separate the embryos from the seed coats and the cotyledons.
Thus it is another object of the invention to eliminate the need to manually sort through separated seed material such as would reduce the benefit of mechanical excision.
The separating machine may include a weir allowing the seed coats to wash over the top of the weir and the embryos and cotyledons to pass to the bottom of the weir.
Thus it is another object of the invention to provide a separation system that works naturally with the mixture of liquid and seed parts exiting the separation machine. It is another object of the invention to separate the dirty seed coats from the embryos early in the separation process to reduce the risk of contamination.
The separating machine may include a screen separating the cotyledons from the embryos.
Thus it is another object of the invention to reduce manual effort necessary to extract the embryos from the cotyledons.
The method may include, after the mechanical separation, a step of culturing the embryos for a predetermined period in a liquid medium to cull nonviable embryos.
It is thus another object of the invention to provide a mechanism that may, if necessary, accommodate a higher rate of nonviable embryos in mechanical separation without incurring excessive cultivation costs.
These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a flow chart showing principal steps of the present invention such as may include: culling, hydration, excision, separation, and a viability test;
FIG. 2 is a schematic diagram of an apparatus used in the hydration step of FIG. 1 allowing automatic control of seed hydration;
FIG. 3 is a simplified representation of an apparatus used in the excision step of FIG. 1 providing a series of opposed rollers which separate the seed parts by a sheering action;
FIG. 4 is a perspective view of one roller of the device on FIG. 3 ;
FIG. 5 is a cross-section through a pair of rollers of FIG. 3 taken along line 5 - 5 of FIG. 4 showing a setting of the separation of the rollers using a gauge;
FIG. 6 is a fragmentary enlarged view of one pair of opposed rollers of FIG. 3 showing liquid sprays directed to prevent the rollers from clogging and to direct process flow;
FIG. 7 is an elevational cross-sectional view of a weir in a collection vessel after the final rollers of FIG. 3 such as separates the seed coats from the cotyledons and embryos;
FIG. 8 is an elevational cross-section through a separation device that may follow the weir of FIG. 7 employing a screen to separate the cotyledons and remaining seed coats from the embryos;
FIG. 9 is a figure similar to FIG. 8 of an alternative embodiment of the separation device using a reciprocating sifting platform;
FIG. 10 is a figure similar to that of FIGS. 8 and 9 showing an alternative separation device employing a rotating drum having an outer peripheral screen;
FIG. 11 is an elevational cross-section of a sucrose separation system in which a predetermined density of sucrose solution separates embryos from the remaining portions of the seed;
FIG. 12 is a flow diagram of an inoculation step in which the embryos are treated with Agrobacterium and processed in a viability test in a liquid media prior to culturing;
FIGS. 13 a and 13 b are simplified elevational views of the path of seeds from an auger feeder into the apparatus of FIG. 3 , the elevational views superimposed on plots of seed distribution with and without a spreader bar used to provide a more uniform seed distribution;
FIG. 14 is an alternative embodiment of the separation devices of FIGS. 8-10 using air agitation;
FIG. 15 is a first embodiment of a nozzle assembly for the air agitation of the device of FIG. 14 ; and
FIG. 16 is a second embodiment of a nozzle assembly for the air agitation of the device of FIG. 14 .
DETAILED DESCRIPTION
Referring now to FIG. 1 , generally the mechanized method 10 of the present invention receives harvested soybeans or other seeds 12 from which transformable plant tissue will be extracted. The seeds 12 are ideally harvested at a predetermined internal moisture suitable for isolating transformable material therefrom, e.g., 8-14% internal moisture for soybeans, and held in stable storage conditions prior to use.
The seeds 12 may be subject to an optional culling step 14 intended to remove seeds 12 a with a high degree of bacterial or fungal contamination and also seeds 12 a that may for any reason statistically fail to produce viable embryonic tissue with the present invention. These latter reasons may include parameters such as the size of the seed or other physical characteristics that in other contexts would be unobjectionable and may be adjusted empirically by variation of the parameters and measurement of ultimate yields of the viable tissue.
Preferably, the culling step 14 is performed mechanically and may include a size culling using standard seed sorting techniques eliminating the seeds 12 above and below a predetermined size, optical sorting using high speed sorting equipment readily available on the market such as employs a camera and vision system to reject seeds 12 that are selected from one or more of the following criteria, color, size, shape or density. Examples of culling methods may include the use of an automatic scale after size sorting, or an optical sorter suitable for this purpose is the Satake Scan Master II manufactured by Satake USA Inc., of Houston, Tex. Other culling techniques may also be employed including culling by moisture content. Culling may also occur after hydration, as it has been determined that seeds with seed coats that have been damaged become imbibed faster than seeds with intact seed coats.
The culling step 14 is intended in part to replace the unconscious selecting of seeds by technicians performing the manual excision of the prior art, and to reduce bacterial and fungal load on the seeds 12 that may, in the mechanical process, create greater potential for contamination of the embryos. The optional culling step 14 may be quite aggressive because the seeds 12 prior to the excision are inexpensive.
Referring now to FIG. 2 , the seeds 12 b that pass the optional culling step 14 move to an optional hydration step 16 in which liquid may be introduced into the seeds 12 to soften the cotyledons and the seed coats reducing the possibility of damage of the embryo during the following excision step 18 . The hydration step 16 is preferably performed automatically, but may be performed manually. Referring again to FIG. 2 , in a preferred embodiment hydration is performed through the use of a sterilized hydration container 20 having a four-liter capacity and a false bottom 22 perforated by a series of holes 24 smaller than the size of the seeds 12 b . The holes 24 lead to a drain chamber 26 communicating via an outlet hose 28 and valve 30 to a drain 32 .
The seeds 12 are placed on top of the false bottom 22 and a retainer plate 34 having holes 36 , also smaller than the average seed 12 b , is placed to rest lightly on top of the seeds 12 b to prevent them from floating. An upper, removable lid 38 of the container 20 provides two inlets 40 and 42 . The first inlet 40 communicates via valve 44 to a rinse reservoir 46 containing a solution of sterile liquid and 200 ppm of Clorox. The second inlet 42 communicates via valve 48 to a tissue culture solution reservoir 50 containing a suitable plant tissue culture medium, such as bean germination medium (BGM) as described in U.S. Pat. No. 6,384,301. The tissue culture medium may also contain antimicrobials such as cefotaxime, Bravo, Benlate, Captan, and Carbenicillin. Other fungicides, disinfectants, plant hormones, antibiotics, and hydrogen peroxide may optionally be used in the tissue culture solution reservoir 50 . The liquid in both reservoirs 46 and 50 is held at room temperature.
An electronic timer 52 communicates with each of the valves 44 , 30 , and 48 and is programmed so to initially, at a predetermined time before the excision process, to close valve 30 and open valve 44 for a predetermined time to fill the container 20 with the rinse solution from the rinse reservoir 46 after which valve 44 is closed. The rinse solution is held in place for three to ten minutes as valve 30 is opened to drain the container 20 through outlet hose 28 .
This first rinsing of the seeds 12 b allows them to begin to absorb moisture but is not so pronounced as to cause cracking of the cotyledons such as might be caused by uneven expansion of the cotyledon material in the presence of excessive liquid. Rinsing also serves to further reduce surface contaminants. Other ways to prevent cracking include pre-incubation in a humid atmosphere or seed priming.
At least one hour later and preferably two hours later, the timer 52 operates to close valve 30 and open valve 48 for a predetermined time to fill the container 20 with the tissue culture media from the tissue culture solution reservoir 50 . The tissue culture media is held within the chamber for 8-13 hours after which the tissue culture media is drained by the timer 52 opening valve 30 . The container 20 is then refilled (via valve 44 operated by timer 52 ) with rinse solution from the rinse reservoir 46 for 15-30 minutes without draining (timer 52 holding valve 30 closed), the excess solution being used as a carrier for the excision step or drained (i.e., for use with an auger) as will now be described. When the seeds 12 are contained in a tissue culture medium without circulation, an ethylene inhibitor may be used.
Other methods of hydration are also contemplated in the present invention including an aerobic method in which the liquid is sprayed on the seeds without accumulating or where a gas is bubbled through the growth medium using an aerator or the like or media may be recirculated. It is also envisioned that other sizes and shapes of containers with different combinations of inlets and outlets, different methods of separating liquid from seeds, different solutions for different times, and the like may also serve the purpose of hydration.
Referring now to FIGS. 1 and 3 , after hydration, the seeds 12 b are poured together with the rinse liquid into a hopper 54 of an auger feed 56 such as provides a controlled feeding of the seeds 12 b and rinse liquid into a first hopper 58 of an automated excision machine 60 . Such auger feeds 56 are well known in the art. The speed of the feeding of the seeds 12 b is determined initially by inspection to reduce clumping of the seeds 12 b at the rollers and to minimize visual damage to the embryos. Ultimately this feed speed may be determined empirically by using varying speeds and observing embryo viability. The auger feed 56 may be an Accu-Rate Feeder, manufactured in Whitewater, Wis. Other feed systems may be used in place of the auger feed 56 including, for example, pumps (with the seeds held in a slurry), conveyor belts, or vibrating conveyor systems such as are well known in the art. In addition, the rinse liquid could be separated from the seeds prior to input into the feeder. This step may also be performed manually without the use of a feeder.
Referring now to FIGS. 3 and 13 a , the auger feed 56 provides a discharge tube 57 , ejecting seeds 12 along a horizontal axis perpendicular to the axis of rotation of rollers 62 , 66 and 70 as will be described below. The seeds 12 fall from the discharge tube 57 through hopper 58 into a gap between the rollers 62 , concentrated along a centerline 160 by the limited size and circular aperture of the discharge tube 57 .
This spatial concentration of seeds 12 , shown by a seed distribution curve 162 peaking near the centerline 160 , can cause a crushing of seeds 12 when multiple seeds 12 pass through the rollers 62 gapped to provide efficient separation of the seed coat embryos and cotyledons at the edges of the rollers 62 .
Accordingly, referring to FIG. 13 b , a diverter bar 164 may be placed between the discharge tube 57 and the rollers 62 extending fully across the hopper 58 along the axis of discharge tube 57 at the centerline 160 . This diverter bar 164 reduces the peak of the new seed distribution 162 ′ providing a smaller seed distribution variance 170 than the seed distribution variance 170 ′ obtained without the diverter bar as shown in FIG. 13 a.
Similar methods of mechanical redistribution to even the solid flows may be made prior to or between successive sets of rollers if more than one roller pair are utilized.
The rollers 62 , 66 and 70 are part of an automated excision machine 60 performing the excision step 18 of the present invention to separate the seeds 12 b into embryos 12 c , cotyledons 12 d , and seed coats 12 e . The excision operation may be conducted in a clean room to minimize contamination from bacteria and mold.
The first hopper 58 of the automated excision machine 60 directs the seeds 12 b into a pair of horizontally opposed rollers 62 , each rotating about mutually parallel horizontal axes. The seeds 12 pass through these rollers 62 to be received by a second hopper 64 and a second pair of horizontally opposed rollers 66 with mutually parallel horizontal axes. The seeds 12 pass between these rollers 66 and are received by a third hopper 68 and a following third pair of horizontally opposed rollers 70 with mutually parallel horizontal axes.
From the last set of rollers 70 , the seeds 12 fall into a collection vessel 72 as will be described further below. The use of three separate stages of rollers ensures that the components of most seeds 12 are fully separated by the time they arrive in the collection vessel 72 .
The left rollers as depicted in FIG. 3 , (i.e., rollers 62 a , 66 a and 70 a ) turn clockwise in unison as driven by overlapping timing belts 74 a which is driven by a first motor 76 attached to a first motor controller 78 . The clockwise direction causes a downward progression of the seeds 12 between the roller pairs.
Similarly, the right rollers as depicted in FIG. 3 , (i.e., rollers 62 b , 66 b and 70 b ) are interconnected by overlapping timing belts 74 b and turned by a second motor 80 having an independent second motor controller 82 . Here, a counterclockwise direction causes a downward progression of the seeds 12 between the roller pairs.
A sprocket 84 on motor 80 and engaging with the teeth of the timing belt 74 is larger than the corresponding sprocket 86 on motor 76 so as to provide a different (faster) rotational rate to the rollers 62 b , 66 b , and 70 b on the right than the rollers 62 a , 66 a , and 70 a on the left. For example, the rollers on the right may turn at about 30 rpm and the rollers on the left may turn at about 90 rpm. The motor controllers 82 and 78 may be adjusted to further refine the speed difference. Seeds 12 contacting both rollers of a pair thus experience a shear force acting on their outer surfaces.
It will be understood that other methods of driving the rollers at controlled speeds may be used including gear drives, direct drive servo motors, and the like. It is also understood that different speeds of turning the rollers may be used.
Referring still to FIG. 3 , a sterile liquid or disinfectant solution source may attach through liquid line 87 to a flow meter 88 to be metered via pressure regulator 90 into a manifold connected to a set of spray heads 92 a through 92 g . The liquid may further contain additional ingredients to surface sterilize or condition the embryos including but not limited to disinfectants, ethylene inhibitors, antioxidants, and surfactants. Spray head 92 a is directed down-ward through hopper 58 to provide a steady wash of sterile liquid or disinfectant solution to wash the seeds 12 through the excision machine 60 and to lubricate and orient the seeds 12 and to dilute any contamination that may be introduced from the seed coats 12 e . The rate of liquid flow and pressure may be controlled to empirically determined values.
Spray heads 92 e through 92 g spray the under surface of rollers 70 a , 66 a , and 62 a , respectively, directed against the tangential direction of rotation of the rollers to help dislodge seed material stuck on the rollers and further urge the seed through the machine. Likewise, spray nozzles 92 c through 92 f spray the under surface of rollers 62 b , 66 b , and 70 b , respectively, directed against the tangential direction of rotation of the rollers.
It is anticipated that other methods may be used to introduce liquids into this step. Examples include, but are not limited to, the use of a distribution manifold, overflow weir, pipe, etc.
A sterile air source from air filter 96 may be connected to the liquid manifold via a valve 98 to purge the water lines between use to prevent the accumulation of biofilm and bacterial contamination. The air further dries the lines and provides a positive pressure to the lines reducing the risk of contamination of the lines.
Referring now to FIG. 4 , each roller 62 , 66 , and 70 has a generally cylindrical central portion 100 presenting a serpentine longitudinal profile 108 . The cylindrical central portion 100 is mounted on a concentric longitudinal axle 102 . The axle 102 may be supported at either end by conventional ball bearings 104 , and includes at one end, a sprocket 106 such as receives toothed timing belts 74 a or 74 b as described with respect to FIG. 3 . The cylindrical central portion 100 may be coated with an elastomeric material, such as neoprene, Buna-N, chlorobutyl, EPDM, Viton, etc., that is resistant to wear and provides a cleanable and sanitizable surface that nevertheless is soft so as to conform slightly to the seed 12 b and to provide improved gripping of the seeds 12 . Referring momentarily to FIG. 3 , the softness of the elastomeric material may be increased for lower roller pairs with the roller pair 62 a and 62 b providing the hardest outer surface and the roller pair 70 a and 70 b providing the softest outer surface. For example, the elastomeric material of the upper rollers may be durometer 35 of the next pair of rollers, durometer 25 and 35 , and the bottom pair, both durometer 25 . It is understood that different seeds may require a particular gap angle, geometry, configuration, outer profile, diameter, or durometer.
Referring now to FIG. 5 , the serpentine profile 108 of each roller 62 a , 66 a , or 70 a may be aligned with a corresponding surface serpentine profile 108 ″ of the corresponding roller 66 b , 62 b , and 70 b to which it is opposed to create therebetween, a substantially constant width serpentine channel 110 whose cross-section encourages separation of the seeds 12 b as they pass through the rollers and provides for multiple engaging surfaces that are curved to conform with the curved outer periphery of the seeds 12 b . Setting of the separation between pairs of the rollers may be accomplished by lateral movement 111 of bearing 104 and may be facilitated by the insertion of a feeler gauge 113 at either edge of the central portion to ensure the rollers are substantially parallel.
Referring to FIG. 6 , the bearing 104 may be held on a pillow block 112 having ears, one of which is mounted pivotally to a frame (not shown) of the automated excision machine 60 and the other which is mounted to an elongated hole 114 in the frame so as to allow lateral motion 111 , as shown in FIG. 5 . The roller separation or diameter may be changed to accommodate different types of seeds 12 and may be increased for lower roller pairs with the roller pair 62 a and 62 b providing the narrowest serpentine channel 110 and the roller pair 70 a and 70 b providing the widest serpentine channel.
Other methods of excising the seeds 12 other than rollers are contemplated including disks, rollers with pins and the like which may stab at the cotyledons and press them together.
Referring now to FIG. 7 , in an initial stage of the separation process 117 (of FIG. 1 ), collection vessel 72 fills with clean liquid or disinfectant solution 116 produced from the nozzles 92 and also, in part, from the rinse liquid used during the hydration step 16 . An opening 118 near the upper edge of the collection vessel 72 provides a weir 120 over which liquid 116 may flow near the surface of the collection vessel 72 . Although the inventors do not wish to be bound by a particular theory, it is believed that the seed coats 12 e entrap air during the excision step 18 and thus float out over the weir 120 to be separated from the cotyledons 12 d and embryos 12 c , the latter which settle to the bottom of the collection vessel 72 . This early separation of the seed coats 12 e in a wash of sterile liquid or disinfectant is believed to significantly reduce bacterial or fungal contamination of the embryos 12 c and prevents the seed coats 12 e from trapping embryos 12 c or clogging separation screens in later separation steps.
Referring now to FIG. 8 , the embryos 12 c may be separated from the cotyledons 12 d by means of a hydroscreen 126 providing a sloped wire mesh 128 (Tyler number six screen) having square openings approximately one-quarter inch on a side. Other functionally similar materials may be used in place of the wire mesh including, for example, perforated sheets of metal or plastic, loosely woven and non woven fabrics, nets, grids, and the like.
The wire mesh 128 is sloped so that a mixture of cotyledons 12 d and embryos 12 c in a sterile liquid or disinfectant solution may be introduced at the upper edge of the sloped wire mesh 128 to wash generally down the slope, at which point embryos 12 c pass through the wire mesh 128 , whereas cotyledons 12 d follow the wire mesh 128 to its edge and are discharged through an ejection port 132 . A separate drain port 134 may be provided for the embryos 12 c.
In an alternative embodiment, the cotyledons 12 d and embryos 12 c , as shown in FIG. 9 , may be introduced into a tray submerged in sterile liquid or disinfectant solution and having a bottom wire mesh 128 . The tray may be reciprocated in a horizontal direction 140 so that the embryos 12 c pass through the wire mesh 128 into an outer container. The tray 129 may be removed from the outer container 131 and the embryos 12 c recovered.
Referring now to FIG. 14 , in an alternative embodiment, the tray 129 of FIG. 9 may be adapted to provide a cylindrical wall with an upper flange 174 allowing it to rest on top of the upper lip of a cylindrical tank 176 . As before, the bottom of the tray is fit with a wire mesh 128 . The wire mesh 128 is sized to block cotyledons and seed coats but to allow passage of the embryos.
The cylindrical tank 176 is filled with liquid to a liquid level 186 so that seeds placed within the tray 129 (when the tray 129 is in the tank 176 ) are submerged within the liquid at rest on the wire mesh 128 . A cap 188 may fit over the top of the tank 176 covering the tray 129 to pre-vent splashing.
Positioned beneath the tray 129 , when the tray is in position in the tank 176 , is an aerator assembly 190 having a central hub 192 from which horizontal and radially extending spokes 194 are attached. The hub 192 provides a connection to an air line 196 which receives a source of high-pressure air through valve 200 controlled by pulse timer 202 .
Referring to FIG. 16 , the hub 192 may be a generally cylindrical inverted cup attached and sealed to a vertical air pipe 212 by a lower bearing 214 fit about the vertical air pipe 212 . The bearing 214 allows the hub 192 to rotate freely about a vertical axis. The spokes 194 attached to the hub are hollow tubes communicating with the interior of the hub 192 (and hence with the vertical air pipe 212 ) at one end and plugged at their opposite ends. The spokes 194 have a series of upwardly facing holes 216 allowing the escape of air bubbles 210 and at least one laterally opening hole 218 . This laterally opening hole 218 reinforced by other similarly oriented holes in other spokes 194 provides for rotative motion under the reactive force of escaping air bubbles 210 moving the spokes 194 in a circular motion to ensure even distribution of the air impinging on the bottom of the wire mesh 128 .
The pulse timer 202 receives a waveform 204 providing for an agitation time period 206 and a rest time period 208 . This duration of each of these time periods 206 and 208 may be freely adjusted so as to provide alternating periods of intense agitation of the liquid in the tray 129 as moved by the liquid roiled by the discharge of air bubbles 210 from the aerator assembly 190 .
The discharge of air during the agitation time period 206 is such as to lift the cotyledons, seed coats, and embryos (not shown in FIG. 14 ) from the wire mesh 128 . During the rest time period 208 , the lifted material descends again through the liquid so that the embryos may pass through the wire mesh 128 unobstructed by seed coats and cotyledons which tend to fall through the liquid at a different rate.
The tank 176 has a funnel shaped bottom 180 terminating in an outlet for 182 having a control valve 184 . The embryos selectively passing through the wire mesh 128 are received by the funnel shaped bottom 180 and may be discharged through the outlet for 182 as controlled by valve 184 .
Referring to FIG. 15 , the air jet assembly 190 ′ may alternatively be a stationary ring or other figuration so as to introduce air bubbles 210 of sufficient volume to provide the necessary agitation. Instead of bubbles, the liquid itself may be pumped using impellers or other pumping systems in place of the air jet assembly 190 ′.
Sufficient air to produce a vigorous boiling of the liquids within the tray 129 can provide not only improved separation of the seed coats, cotyledons and embryos, but may provide for some excision as well.
Referring to FIG. 10 , in yet another alternative embodiment, a drum 135 may be partially immersed approximately one-third to one-half in liquid held in container 141 . The drum 135 has wire mesh 128 attached to its outer cylindrical periphery and may filled with cotyledons 12 d and embryos 12 c into solution and rotated as indicated by arrow 142 , causing the embryos 12 c to pass out of the drum 135 , which retains the cotyledons 12 d.
It is envisioned that other methods of embryo separation may also be used. For example, manual or automated sieving may be performed. Manual sieving may be performed using sieve trays immersed in liquid and gently shaking the trays.
Referring to FIG. 11 , in an alternative separation method, the cotyledons 12 d and embryos 12 c may be introduced into a sucrose solution 146 of predetermined density selected to cause flotation of the embryos 12 c and the sinking of the cotyledons 12 d and seed coats 12 e which may then be separated by a skimming or pouring off the embryos 12 c . The sucrose solution should be approximately 30-40% with thirty-seven percent preferred; however, concentrations of 10-70% will also provide some separation. After a few minutes, the embryos 12 c rise to the surface of the container. The sucrose may be substituted with other biologically neutral compounds such as propylene glycol or Ficol, for example.
For each of these processes, the removed embryos may not be perfect, however, experimentation has shown that embryos with obscured meristems are still transformable. This separation need not be perfect as transformable tissue includes the embryo 12 c with the primary leaves removed or with the primary leaves intact or with a partial cotyledon 12 d.
Referring now to FIGS. 1 and 12 , once the embryos 12 c are collected, they may be rinsed in sterile liquid or other solutions and then may be inoculated in a gene transfer step 155 with the desired genes using one of a variety of techniques, for example in soybean, sonication, as described in U.S. Pat. No. 6,384,301 issued May 7, 2002, assigned to the assignee of the present invention and hereby incorporated by reference, or particle delivery as described in U.S. Pat. No. 5,914,451 issued Sep. 22, 1992, assigned to the assignee of the present invention and also hereby incorporated by reference. Monocotyledonous plants could be transformed using the methods described in U.S. Pat. No. 5,591,616 issued Jan. 7, 1997, or PCT application WO95/06722 published Mar. 9, 1995, herein incorporated by reference. Cotton could be transformed using the methods described in U.S. Pat. No. 5,846,797 issued Dec. 8, 1998, or U.S. Pat. No. 5,004,863 issued Apr. 2, 1991 all hereby incorporated by reference.
Optionally, as indicated in process block 156 in FIG. 1 , after sonication or other gene transfer step 155 , the trans-planted embryos 150 may be placed in a liquid culture 152 for fifteen to thirty days to identify which embryos 12 c are still viable. This culturing also allows easier identification of the root and stem tips of the embryos 12 c for proper planting of the viable embryos in an agar block 154 or further culture in liquid medium for selection. Up to this viability test, the amount of hand labor may be negligible and therefore nonviable embryos may still be removed at relatively low cost. Viability may also be tested on solid or semi-solid medium as well as liquid medium.
The proven viable embryos 12 c are then grown on an agar block 154 such as may be treated with compounds or environmental conditions to help identify those embryos that have successfully received the implanted gene according to methods described in above-referenced U.S. Pat. No. 6,384,301.
The above-described techniques may be suitable for any plant whose transformable tissue can be derived from seeds and is especially useful for seeds of oilseed plants, such as soybean, canola, rapeseed, safflower, and sunflower, as well as other plants of commercial interest, such as legumes, cotton, corn, rice and wheat.
Generally each of the steps of FIG. 1 may be used independently of the others. It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.
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A process of mechanical separation of embryos from seeds for genetic transplantation employs counter-rotating cylinders together with one or more culling, hydration, separation, and viability testing steps to provide high-throughput of viable, transplantable tissue.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/876,344 filed Dec. 21, 2006 entitled “Ice Crushing Mechanism.”
BACKGROUND OF THE INVENTION
[0002] Ice crushing mechanisms are known, particularly those used in refrigeration appliances. U.S. Pat. Nos. 6,082,130 and 7,111,473 disclose an ice crushing mechanism in a refrigeration appliance. U.S. Pat. No. 4,123,918 discloses an ice dispensing machine with rotatable keeper elements for moving ice towards a discharge opening.
[0003] In an ice dispenser, and particularly those used in refrigeration appliances, freezer air is permitted to flow through the ice chute to the exterior of the appliance due to an open flow path through the ice dispenser, which may include an ice crushing mechanism. This causes condensation to occur on the ice chute door and in the dispenser housing. As the condensation occurs, water will begin to drip from the dispenser into the dispenser tray. This may cause the user of the appliance to believe that service is required to “fix the leak,” resulting in an unnecessary service call.
[0004] Also, the ice crushing blades are sometimes accessible from the opening of the ice dispenser chute which can lead to the entry of foreign objects into the area of the ice crushing blades, resulting in damage to the blades or the foreign object, or stalling of the motor driving the blades.
[0005] It would be an improvement in the art if there were provided an ice crushing mechanism which prevents the direct access of air from the freezer to the ice chute. Also, it would be an improvement if there were provided an ice crushing mechanism which prevents direct access to the ice crushing blades from the ice chute.
SUMMARY OF THE INVENTION
[0006] The present invention provides an ice crushing mechanism which, in some embodiments, may be mounted in a refrigeration appliance having a refrigerated compartment and an ice making mechanism.
[0007] The ice crushing mechanism includes a housing, a first chamber formed in the housing and defined by a first bottom wall with an opening therein, and a second chamber formed below the first chamber in the housing and defined on the top by the first bottom wall of the first chamber and also by a second wall with an opening therein angularly offset from the first bottom wall opening. A rotatable spindle is positioned in the housing extending essentially vertically through both the first and second chambers. At least one ice crushing blade is rotatably carried on the spindle and is positioned in the first chamber. A wiper is rotatably carried on the spindle and positioned in the second chamber. The second chamber, below the ice crushing chamber, with the offset opening from the second chamber prevents direct access from that opening to the ice crushing blades.
[0008] The second wall, which defines the second chamber may be a bottom wall of the second chamber, or it may be a surrounding wall of the second chamber.
[0009] In an embodiment, the first chamber may be further defined by a top wall with an opening therein angularly offset from the first bottom wall opening.
[0010] In an embodiment, the openings in the first bottom wall and the second wall each have an angular extent of less than 90 degrees.
[0011] In an embodiment, the first chamber and the second chamber are each defined by a circular outer wall.
[0012] In an embodiment, the wiper comprises at least one arm attached to be rotatably driven by the spindle with a free end terminating closely adjacent to the outer wall defining the second chamber.
[0013] In an embodiment, the wiper arm is made of a flexible and resilient material.
[0014] In an embodiment, the wiper arm comprises three arms attached to be rotatably driven by the spindle, each with a free end terminating closely adjacent to the outer wall defining the second chamber.
[0015] In an embodiment, the ice crushing mechanism may include a housing, a first chamber formed in the housing and defined by a top wall with a first opening therein, a first bottom with a second opening having an angular extent of no more than 110 degrees therein angularly offset from the top wall opening and a circular outer wall, a second chamber formed below the first chamber in the housing and defined on the top by the first bottom wall of the first chamber, on the bottom by a lower, second bottom wall with a third opening having an angular extent of no more than 110 degrees therein angularly offset from the first bottom wall opening by approximately 180 degrees and a circular outer wall. A rotatable spindle is positioned in the housing extending essentially vertically through a central portion of both the first and second chambers. At least one ice crushing blade is rotatably carried on the spindle and positioned in the first chamber. A wiper is rotatably carried on the spindle and positioned in the second chamber, the wiper comprising a plurality of arms, each attached to be rotatably driven by the spindle and each with a free end terminating closely adjacent to the outer wall. The arms of the wiper are angularly spaced apart from each other such that at least two arms block all paths between the second opening and the third opening. In this manner, direct access of air from the freezer to the ice chute is prevented.
[0016] In an embodiment, the openings in the top wall, the first bottom wall and the second bottom wall each have an angular extent of less than 90 degrees.
[0017] In an embodiment, the wiper arm is made of a flexible and resilient material.
BRIEF DESCRIPTION OF THE DRAWING
[0018] FIG. 1 is a front elevational view of a refrigeration appliance incorporating an ice crushing mechanism embodying the principles of the present invention.
[0019] FIG. 2 is a side sectional schematic view of the ice crushing mechanism.
[0020] FIG. 3 is a top sectional view of the ice crushing mechanism taken generally along the line III-III of FIG. 2 .
[0021] FIG. 4 is an isolated perspective view of the wiper used in the ice crushing mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] As illustrated in FIG. 1 , the present invention provides an ice crushing mechanism 20 which, in some embodiments, may be mounted in a refrigeration appliance 22 which includes an ice making mechanism 23 . In the embodiment shown in FIG. 1 , the refrigeration appliance 22 includes a refrigerated compartment 24 . In this compartment may be located various shelves 26 and drawers 27 for storing food items. The ice crushing mechanism 20 may be located on a door 30 of the cabinet 32 of the appliance 22 , as shown, or it may be located in the main refrigerated compartment 24 . The refrigeration appliance 22 may also include a second compartment 34 which could be maintained at a different temperature than the first compartment, and the ice crushing mechanism 20 could be located in either compartment, such as one kept above freezing or one kept below freezing.
[0023] As shown schematically in FIGS. 2 and 3 , the ice crushing mechanism 20 includes a housing 40 , a first chamber 42 formed in the housing and defined by a first bottom wall 44 with an opening 46 therein, and a second chamber 48 formed below the first chamber in the housing and defined on the top by the first bottom wall 44 of the first chamber and also by a second wall 50 with an opening 52 therein angularly offset from the first bottom wall opening 46 . A rotatable spindle 54 is positioned in the housing 40 extending essentially vertically through both the first 42 and second 48 chambers. At least one ice crushing blade 56 is rotatably carried on the spindle 54 and is positioned in the first chamber 42 . A wiper 58 is rotatably carried on the spindle 54 and positioned in the second chamber 48 .
[0024] The second wall 50 , which defines the second chamber 48 may be a bottom wall 60 of the second chamber, or it may be a surrounding wall 62 of the second chamber. The first chamber 42 may be further defined by a top wall 64 with an opening 66 therein angularly offset from the first bottom wall opening 46 .
[0025] In an embodiment, the openings 46 , 52 in the first bottom wall 44 and the second wall 50 each have an angular extent A of less than 90 degrees.
[0026] In an embodiment, the first chamber 42 and the second chamber 48 are each defined by a circular outer wall 68 , 62 . The two circular outer walls 68 , 62 may have the same diameter, or they may have different diameters.
[0027] In an embodiment, the wiper 58 comprises at least one arm 70 attached to be rotatably driven by the spindle 54 with a free end 72 terminating closely adjacent to the outer wall 62 defining the second chamber 48 . In an embodiment, the wiper arm 72 is made of a flexible and resilient material such that is a rigid obstacle is positioned between the wiper arm and an edge of either opening 46 , 52 , the arm will flex and the wiper 58 will continue rotating, without causing damage to the rigid obstacle.
[0028] In an embodiment as shown in FIGS. 3 and 4 , the wiper arm 72 comprises three arms 74 , 76 , 78 attached to be rotatably driven by the spindle 54 , each with a free end 80 , 82 , 84 terminating closely adjacent to the outer wall 62 defining the second chamber 48 .
[0029] In an embodiment, the opening 66 in the top wall 64 may have an angular extent of no more than 110 degrees and may be angularly offset from the opening 46 in the bottom wall 44 of the first chamber, such as by between 90 and 180 degrees.
[0030] In an embodiment, the wiper 58 is provided with a plurality of arms 70 , each attached to be rotatably driven by the spindle 54 and each with a free end 72 terminating closely adjacent to the outer wall 62 . The arms 70 of the wiper 58 are angularly spaced apart from each other such that at least two arms 70 block all paths between the opening 46 in the first bottom wall and the second opening 52 in the second chamber, regardless of the rotational position of the wiper. For example, as shown in FIG. 3 , the openings 46 and 52 may have an angular offset B of 180 degrees from each other, each with an angular extent A of no more than about 90 degrees. The wiper 58 may be provided with three arms 70 , each positioned at 120 degrees from each other. In such an arrangement, for any given rotational position of the wiper 58 in the second chamber 48 , at least one arm 70 will be positioned between the two openings 46 , 52 in each rotational direction. In this situation, and when the arms 70 of the wiper 58 have a vertical extent 92 as great as a height 94 of the second chamber 48 , that is, the distance between the first bottom wall 44 and the second bottom wall 60 , then the arms 70 will prevent a flow of air between the two openings 46 , 52 . In other arrangements, where blockage of air flow is not of concern, the vertical extent 92 of the arms 70 need not be as great as the height 94 of the second chamber 48 .
[0031] In an embodiment, the openings 66 , 46 , 52 in the top wall 64 , the first bottom wall 44 and the second bottom wall 60 each have an angular extent A of no more than about 90 degrees.
[0032] In operation, ice from the ice making mechanism 20 passes through the opening 66 in the top wall 64 of the first chamber 42 and onto the bottom wall 44 of the first chamber. The ice crushing blade 56 is rotated by the spindle 54 and pushes the ice against a fixed member 96 to crush the ice into small pieces. The small pieces are then carried along by the rotating ice crushing blade 56 until they fall through the opening 46 in the bottom wall 44 of the first chamber 42 . The crushed ice particles then fall to the bottom wall 60 of the second chamber 48 and they are pushed by the arm 70 of the rotating wiper 58 until they reach the side or bottom opening 52 in the second chamber where they will move through the opening 52 to be dispensed by another portion of the ice crushing mechanism 20 not described here. A possible dispensing arrangement is disclosed in U.S. Pat. No. 6,082,130, incorporated herein by reference.
[0033] Various features of the ice crushing mechanism 20 have been described which may be incorporated singly or in various combinations into a desired system.
[0034] As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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An ice making and storing system which may be mounted in a refrigeration appliance. The ice making and storing system includes an ice making mechanism, a removable ice storage receptacle positioned adjacent to the ice making mechanism, an insulated cover for the ice making mechanism with a portion engageable with the ice storage receptacle to provide a thermally tight seal between the cover and the ice storage receptacle.
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CROSS RELATED APPLICATION
This application claims the benefit of application Ser. No. 60/829,313 filed Oct. 13, 2006, which is incorporated in its entirety by reference.
BACKGROUND OF THE INVENTION
The field of the invention is rotary drum vacuum filters used in the pulp and papermaking industry to form a mat of wood pulp and separate the mat from its filtrate. In particular, the invention relates to gas vent on the drum suction control valve in the discharge elbow assembly of the filter.
FIG. 1 shows a rotary drum vacuum filter 10 that includes a rotary drum 12 in a vat 14 of pulp slurry. The drum is partially submerged in a pulp slurry vat vessel, such as up to the horizontal centerline of the drum. The drum turns in a clock-wise direction at a preferred rate of approximately 2 to 4 revolutions per minute (RPM) and most preferably at 3 RPM. As the outer drum surface rotates through the slurry (3:00 to 9:00 positions), a pulp mat 16 forms on the outer face 17 of the drum.
To promote mat formation, suction is applied to the drum porous outer surface 17 , e.g. a screened or wire surface. The porosity of the surface 17 is sufficiently fine to retain fibers on the surface and pass primarily filtrate into the channels 18 behind the porous surface. The channels 18 are arranged in a longitudinal array behind the screen and extending the length of the drum. The channels drain into radial channel 20 , or tubes, that lead to a central filtrate chamber 28 .
As the surface 17 of the drum travels up and out of the vat (corresponding to the 9:00 to 12:00 rotational positions of the drum), the pulp mat 16 on the surface is washed with a liquid spray 22 , e.g., wash water, that cleans the pulp mat of chemical liquor. The suction draws the water and liquor from the pulp mat into the channels 18 behind the drum surface 17 . The channels continue to drain into the channels 20 which drain into the filtrate chamber that is typically at one end of the drum and coaxial to the drum.
As the drum surface passes over the top rotational position (12:00 to 1:00), the wash water spray is stopped. As the drum rotates towards the 2:00 position, the suction stops, but water continues to drain through the pulp and into the channels and ribs. Air also starts to enter the channels and ribs because of the stoppage of wash water.
The concentrated pulp is generally referred to as a pulp cake. As the drum rotates through to the 2:00 to 3:00 position, a scraper 24 removes the pulp mat from the drum surface. The pulp cake is collected in a chamber 26 for further processing.
Vacuum washers typically receive a low consistency pulp slurry (1.5% pulp by weight) in the vat vessel. The pulp is thicken as the drum surface rises on the drum surface out of the vat to about a 10% consistency. The pulp is further thickened to a discharge consistency from the drum of 12% or greater.
After the cake is removed, the channels and ribs are typically filled with air. As the drum surface (now scraped clean of the pulp mat) rotates past the 3:00 position, the surface renters the vat 14 . Suction is reapplied to the channels and ribs after the surface is submerged into the vat. A pulp mat 16 begins to form again on the drum surface 17 . The formation of a pulp mat, water cleaning of the mat, and scraping of the map off the drum is a continuous process that occurs as the drum rotates.
The motive force for the suction on the drum surface is the vacuum created as the extracted filtrate drops approximately 30 feet (ft.) to 40 ft. (10 to 13 meters) from the rotary drum vacuum washer 10 to a filtrate tank (below the washer). The pipe through which the filtrate passes is known as a drop leg 32 ( FIG. 2 ).
FIG. 2 shows a conventional end of a rotary vacuum filter having a drum 12 and a drainage path for liquor and wash water (collectively filtrate) that flows from the longitudinal channels 18 ( FIG. 1 ) and radial channels to a filtrate chamber 28 typically at one end of the filter 10 and coaxial to the drum. Suction to the drum surface 17 is generally provided through the channels 18 that extend behind the screen on the drum face 17 . Liquor and water (collectively “filtrate”) enter the channels and are drawn by suction into rib conduits 20 that extend radially and partially axially from the channels near the drum face to an filtrate chamber 28 typically at one end of the drum.
The axial filtrate chamber 28 provides a drainage path for the flow of filtrate from the ribs and channel in the drum. The filtrate chamber 28 is traditionally coupled, (through a trunnion conduit 34 and an elbow joint 30 ), to a drop leg conduit 32 that drains the filtrate flow down below the vat 14 to a filtrate collection vessel (not shown).
The drainage of the filtrate into the drop leg 32 creates a suction that draws the filtrate through the filtrate chamber 28 , ribs 20 and channels 18 . To maintain high levels of suction, gas, e.g., air, should not flow into (or at least not become excessive) in the chamber 28 , elbow 30 or drop leg 32 . If too much air enters the drop leg, the suction level (sub-atmospheric pressure) lessens, the flow of liquid filtrate into the drop leg may be interrupted such that reduced suction will be applied to the filtrate chamber 28 , ribs and channels and air enters the filtrate flowing through the drop leg which may cause the filtrate to foam and require downstream processing to remove the air. Accordingly, there is along felt need to prevent gas from entering the elbow joint 30 and drop leg 32 .
FIG. 2 shows an exemplary prior art approach to preventing gas from entering the elbow joint 30 and drop leg 32 . The filtrate chamber 28 in the drum 12 is coupled to a trunnion conduit 34 that rotates with the drum. The trunnion conduit 34 is driven through a worm gear 36 and a matching drive worm gear collar 37 to rotate the drum. The elbow 30 and down leg 32 conduits are stationary. An inlet end of the elbow is coupled to the outlet of the rotating trunnion conduit. FIG. 2 is an exploded view of the trunnion conduit and elbow and down leg. In practice, the outlet of the trunnion conduit is rotatably coupled to the inlet to the elbow conduit 30 and the elbow and down leg 32 conduits are connected.
A center shaft 38 extends from the elbow into the trunnion conduit 34 . The center shaft is of a relatively small diameter as compared to the inner diameter of the filtrate passage in the elbow and down leg. The center shaft 38 is hollow to allow gases in the filtrate to vent into the shaft and avoid entering the filtrate passage in the elbow 30 and down leg 32 .
The center shaft supports a valve segment 40 that includes a generally arc shaped section that extends from about the 1:00 position to the 5:00 position relative to the rotation of the drum. The outer face of the valve segment is positioned in the filtrate chamber 28 and juxtaposed against the drainage outlets for the ribs 20 (as the ribs pass through the 1:00 position to the 5:00 position). The drainage outlets of the ribs open to the filtrate chamber 28 .
The valve segment blocks the outlets of the ribs 20 in the drum as the ribs rotate through the 1:00 to 5:00 positions. The arc width of a conventional valve segment is typically about 130 degrees which corresponds to rotating the drum through the 1:00 to 5:00 positions. The ribs are prevented by the valve segment from draining to the filtrate chamber 28 and into the trunnion conduit. As the ribs rotate from 1:00 to 5:00, filtrate and gases, e.g., air, in the ribs are intended to remain in the ribs. The valve segment 40 prevents most of the gases in the ribs from flowing into the filtrate chamber 28 and to the trunnion conduit 34 , elbow conduit 30 and down leg conduit 32 .
The valve segment 40 also prevents suction from being applied to the ribs as the ribs pass from the 1:00 to 5:00 positions. Suction is neither needed nor desired as the surface 17 of the drum passes from the 1:00 to 5:00 positions because gravity holds the pulp mat 16 on the surface until the scraper 24 ( FIG. 1 ) removes the pulp cake 16 at about the 2:00 to 3:00 position. Suction if applied from the 1:00 to 5:00 positions would draw air into the channels and ribs and impede removal of the pulp mat.
The valve segment 40 does not block the application of suction to the ribs or the drainage of filtrate from the ribs as the ribs rotate from the 5:00 position to the 1:00 position. As the ribs move through the vat, suction (applied through the ribs by the down leg) draws a pulp slurry onto the drum face screen and pulls filtrate through the screen and into the channels, ribs and to the filtrate chamber 28 . Similarly, as the ribs move up out of the vat to the top drum position (3:00 to 12:00), the suction draws filtrate, including the wash water, through the screen and into the channels, ribs and filtrate chamber. The flow of filtrate into the ribs moving from the 5:00 position to the 1:00 position is sufficient to create a substantial suction as the filtrate flows into the elbow conduit 30 and down leg conduit 32 . Substantial amounts of air are prevented from entering the elbow and down leg because the channels and ribs are substantially filled with liquid filtrate as the channels are submerged in the vat and pass under the water spray, which occurs as the drum moves from the 5:00 position to the 1:00 position. After the channels rotate past the water spray (at about the 12:00 to 1:00 position), the outlets to the ribs are block by the valve stem to prevent gas from entering the filtrate chamber and trunnion conduit.
The valve segment 40 does not prevent all gases from entering the elbow and down leg. Air enters the ribs as the liquid filtrate drains from the ribs rotating from the 1:00 position until the channels for the ribs enter the vat. The air remains in the rib as the rib rotates down into the drum. As the drum is submerged and filtrate fills the ribs, a filtrate air mixture, e.g., foam, occurs in the ribs and can flow into the filtrate chamber 28 . The residual air and foam in the ribs should not be drawn into the filtrate chamber, trunnion conduit, elbow conduit and down leg conduit as suction is applied to the ribs. However, when suction is reapplied as the outlet of the ribs rotate past the 5:00 position, the residual air and foam in the ribs flow into the filtrate chamber. This air and foam may be sufficient to reduce the suction created by the drop leg, and create air bubbles in the trunnion.
Air in a washer is detrimental because: (i) when the air is in the filtrate and the cake, it creates resistance to the flow of filtrate through the cake; (ii) air entrained in the filtrate and cake creates foam that is very stable and the foam must typically be eradicated with a costly defoaming agent, and (iii) air in the drop leg results in a lower vacuum created by the drop leg thereby reducing the motive force by which the washer operates.
Prior attempts to vent gases from the filtrate have included adding a gas vent slot in the valve segment that is in fluid communication with the inner conduit formed by the hollow center shaft 38 . See e.g., U.S. Pat. No. 5,264,138. The slot may be aligned with the 3:00 to 5:00 position on the drum such that as the channels and ribs rotate down into the vat, the filtrate entering the ribs forces air into the slot and out through the center shaft (rather than into the filtrate chamber and trunnion conduit). The center shaft has a gas vent and a filtrate drain that extends externally of the elbow. The center shaft removes gases in the ribs that would have otherwise entered the elbow. The filtrate drain on the center shaft removes liquid filtrate that enters the hollow shaft with the gases. The gas vent removes gases from the filtrate that are directed into the center shaft. A difficulty with this approach to venting gases is that the center shaft is elevated at or above the liquid level of the vat such some of the air and foam remain in the ribs. The vat fills the ribs with filtrate liquid only to a level in the ribs that is no higher than the vat level. The gap in the ribs between the vat liquid level and center shaft 38 remains filled with air. Another difficulty with the slot open to the center shaft is that the slot is relatively narrow, e.g., 16 degrees, and the center shaft is narrow. The narrow slot and center shaft may not be sufficient to allow gas and foam to vent from the ribs, especially if the drum rotates relatively fast, e.g., above 3 RPM. Another approaches to providing a gas vent for a rotary drum filter include the LaVally valve shown in, for example, U.S. Pat. No. 4,683,059, and the air inflow restrictors shown in U.S. Pat. Nos. 5,683,582 and 5,503,737. However, there remains a long felt need for improved devices and methods for venting gases before they enter the elbow and down leg conduits of a rotary drum filter.
BRIEF DESCRIPTION OF THE INVENTION
A gas vent has been developed for a valve segment of a rotary vacuum drum filter for condensing and washing pulp from a slurry to a pulp cake. The gas vent exhausts air in the filtrate piping, e.g., channels and ribs, of the drum before the air flows into a down leg where it could interrupt the suction needed for the drum. The gas vent is offset from the drum axis and has a large area inlet to vent all gases in the drum piping, even for fast rotating drums.
In a rotary drum for condensing pulp from a pulp slurry vat, the drum including drainage pipes delivering filtrate from a pulp mat on an outer surface of the drum to a filtrate conduit coaxial with a drum rotational axis, a valve segment has been developed for the filtrate conduit comprising: an outer surface juxtaposed against drainage outlets of the pipes as the pipes pass air received as the pulp mat is removed from the drum (e.g., angular positions of substantially 1:00 to 5:00, wherein the valve segment does not block the drainage outlets during a majority of the rotation of the drum while filtrate is discharged from the outlets; an inlet aperture on the outer surface of the valve segment aligned with the drainage outlets of the pipes, said inlet aperture extending at least a majority of a arc of the valve segment; a closed passage extending from the inlet aperture to a gas vent external to the filtrate conduit, wherein the closed passage is offset from and extends above and below the horizontal centerline of the filtrate conduit.
The valve segment may include a lower edge of the inlet aperture at an elevation no higher than a liquid level of the slurry vat and a lower portion of the closed passage at an elevation that is no higher than a liquid level of the slurry vat. The valve segment may comprise an outer plate supported on a support plate. The support plate may have an arc shape and conform substantially to an inner wall of the filtrate conduit and an inner support plate attached to the outer plate, wherein the closed passage is formed between the support plates.
A rotary drum filter has been developed for removing filtrate from paper pulp comprising: a housing including a chamber to receive a vat of a pulp slurry; a rotatable drum cylinder mounted in the housing wherein a portion of the drum cylinder extends down into the vat, the drum cylinder including a screen surface to receive a mat of pulp as the drum rotates through the vat; an array of filtrate conduits in the drum in fluid communication with the screen surface and having outlets at a filtrate chamber coaxial with a rotational axis of the drum; a stationary suction conduit coupled to the filtrate chamber receiving the filtrate flowing through the screen surface, filtrate conduit and filtrate chamber, wherein the suction conduit extends to an elevation below (e.g., 30 feet or 10 meters below) the vat to create a suction in the filtrate chamber, filtrate conduit and at the screen surface; a stationary valve segment in the filtrate conduit including an outer surface juxtaposed to block the outlets of the filtrate conduits only while the filtrate conduits are rotated from an elevated position down into the vat and while the conduits fill with air; said stationary valve segment includes an inlet aperture aligned with the outlets of the filtrate conduits and a passage extending from the inlet aperture to a gas vent external to the filtrate conduit, wherein the closed passage is offset from and below a centerline of the filtrate conduit.
The rotary drum filter may include a lower edge of the inlet aperture at an elevation no higher than a liquid level of the slurry vat and a lower portion of the closed passage at an elevation no higher than a liquid level of the slurry vat. The valve segment may be attached to a support outer plate having an arc shape and conforming substantially to an inner wall of the filtrate conduit. The outer support plate may be attached to an inner plate, wherein the closed passage is formed between the support plates. The valve segment may include an aperture plate including the inlet aperture and the aperture plate mounted on the outer surface.
A method has been developed for treating pulp including the formation of a pulp web on a porous surface of a rotating drum cylinder having a lower portion in a vat of a pulp slurry and a radial array of filtrate conduits for draining filtrate passing through the porous surface to an axial filtrate chamber, the method comprising: as the porous surface of the drum rotates through the vat, drawing filtrate from the slurry through the porous surface by the application of a suction to the filtrate conduits vacuum; draining the filtrate from the filtrate conduits into the filtrate chamber and to a filtrate suction conduit extending to an elevation below the vat; forming a pulp mat on the porous surface which passes filtrate and substantially blocks fibers; removing the pulp mat from the vat by rotating the porous surface of the drum rotates up and out of the vat; continuing the draining of filtrate from the filtrate suction conduit as the filtrate conduits are rotated through angular positions at which fluid applied to the surface of the pulp is sufficient to fill the conduits; after fluid is no longer applied to the pulp mat and before excessive gases passing through porous surface enter the filtrate conduits, switching the fluid flow from the filtrate conduits from a liquid fluid path directed to the filtrate suction conduit and to a gas vent passage, wherein the gas vent passage is offset and below from a drum rotational axis.
The method may further including switching the liquid fluid path directed to the filtrate suction conduit and to the gas vent passage at substantially a 1:00 rotational position of the drum. The method may further comprise switching the fluid flow from the gas vent passage to the filtrate suction conduit as the drum rotates through substantially past a 5:00 position. The method may further comprise switching the fluid flow from the gas vent passage to the filtrate suction conduit as the filtrate conduits become substantially filled with filtrate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a conventional rotary vacuum drum filter wherein the housing is shown in cross-section to expose the drum, vat and other interior components of the drum filter.
FIG. 2 is a side, perspective view of a conventional rotary drum filter with the trunnion conduit, elbow and drop leg conduits shown in exploded view.
FIG. 3 is a side view of a front side of a valve segment and support mounted on an elbow conduit.
FIG. 4 is a perspective view of a front side of a valve segment and support mounted on the elbow conduit shown in FIG. 3 .
FIG. 5 is a perspective view of a rear side of the valve segment and segment support mounted on the elbow conduit shown in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 is a perspective view of a front side of a valve segment 50 mounted on a cantilevered support 51 which extends from the inlet to an elbow conduit 52 . The elbow and conduit are stationary and coupled to a trunnion conduit 34 , such as is shown in FIG. 2 . The elbow has a mounting bracket 53 that couples to the stationary drive and bearing unit, in a conventional manner. The discharge of the elbow is connected to a down leg conduit 32 that extends to a filtrate collection vessel that is preferably at least 30 feet (10 meters) below the drum filter washer.
The valve segment 50 may be a plate having an arc shaped in cross section. The valve segment 50 forms an arc of preferably about 130 degrees and extends preferably from the 1:00 to 5:00 positions with respect to the rotation of the vacuum drum. The valve segment is juxtaposed with the drainage outlets of the ribs 20 and extends into the filtrate chamber 28 in the drum 12 . The valve segment is off-set from the centerline 54 of the trunnion conduit 34 . The plate that forms the valve segment 50 includes one or more gas inlet apertures 58 arranged to be in alignment with the discharge of the ribs 20 in the drum. In the arrangement shown in FIG. 3 , the gas aperture 58 is positioned at or near a distal end (opposite to the elbow) of the valve segment support 51 .
The cantilever support 51 for the valve segment has a closed passageway 56 that extends from the valve segment plate 50 through the trunnion conduit 34 and into the elbow conduit 52 . The passageway 56 allows gas and foam collected from the ribs 20 to be exhausted out of the filtrate drum and out of the elbow. The outlet of the passageway 56 includes an upper gas vent 68 and a liquid filtrate drain 70 .
The gas aperture(s) 58 of the valve segment preferably extend collective a majority of the arc of the valve segment 50 , as is shown in FIG. 3 . In the embodiment shown here, the gas aperture(s) 58 collectively form an opening that extends up to about 100 degrees of the 130 degree arc formed by the valve segment. It is preferred that the aperture(s) 58 extend collectively at least 65 degrees.
Further, the gas aperture(s) 58 may extend from a near top drum position of the valve segment 50 to a lower position 60 on the valve segment that corresponds to where the ribs have been fully vented of gas and foam, and are entirely filled with liquid filtrate. The elevation of the liquid level in the vat typically corresponds to the centerline 54 of the drum 12 . As the drum surface moves further into vat, liquid filtrate fills the ribs 20 and forces air and foam out of the ribs and into the aperture 58 of the valve segment. Preferably, the lower edge 60 of the aperture(2) 58 is at or below the angular drum position at which the ribs have been purged of air and foam. As shown in FIG. 3 , the lower edge of the aperture 60 is at about the 4:00 position, plus or minus 5 degrees. The lower edge 60 may be determined for each drum based on the rotational drum position at which the ribs are filled with filtrate and no longer exhausting gas and foam.
The large cross-sectional area of the gas aperture(s) 58 in the valve segment 50 ensures that substantially all gases vented from the ribs enter the gas passage 56 in the valve segment even for relatively fast rotating drums. The aperture(s) 58 are relatively long (AW) in the direction of drum rotation. This length facilitates the venting of gases from the ribs 20 into the passage 56 as the ribs move across the length (AW) of the aperture 50 . The low position, e.g., 4:00 to 5:00 position, of the lower edge 60 of the aperture 58 ensures that all air and foam are discharged from the ribs and into the passage 56 .
The plate of the valve segment 50 may be mounted on an outer plate 64 of the valve segment support 51 . The outer plate may have an arc cross-sectional shape that faces and conforms to the inside wall surface of the trunnion conduit. The valve segment 50 may be a plate that has an arc cross-sectional shape that conforms to the outer plate 64 . The valve segment 50 is mounted, e.g., bolted, to the outer plate 64 and fits over an opening (not shown) in the outer plate 64 .
The position of the valve segment 50 on the outer plate 64 may be adjustable, such as thorough the use of oval or race-track slots 66 in the plate that receive the bolts that attach the plate 62 to the outer plate 64 of the valve segment support 51 . Alternatively, the valve segment 50 may be welded to the outer plate 64 once the valve segment has been properly positioned with respect to the outlets to the ribs 20 in the drum.
By adjusting the position of the valve segment 50 on the outer plate 64 , the apertures 58 can be optimally positioned with respect to the angular movement of the drum and the outlet of the ribs 20 . The ribs pass filtrate from the drum surface to a filtrate chamber 28 . The ribs serve as drainage pipes for the drum. For example, the valve segment 50 may be moved slightly up or down on the support plate 64 to align the lower edge 60 of the aperture 58 to be sufficiently below the elevation at which the ribs 20 have fully discharged air and foam, and are discharging liquid filtrate. The valve segment 50 may also be positioned laterally, e.g., parallel to the axis 54 of the drum axis, to be aligned with the discharge of the ribs 20 .
The valve segment 50 may include a plurality of openings that define the gas aperture 58 . Between the openings may be a support bar 66 integral with the plate of the valve segment and bisecting the plate. The support bar 66 provides structural stiffness for the valve segment and the apertures 58 . The solid portions 65 of the valve segment (including the support bar) are relatively narrow (in the direction of AW) and have a relatively small cross-sectional area. Reducing the solid areas 65 , 66 of the valve segments avoids unduly reducing the area of the aperture 58 or adversely disrupt the flow of gases into the gas vent passage 56 .
The internal passage 56 in the valve segment support 51 vents gases that pass through the aperture(s) 58 of the valve segment and are from the ribs and filtrate chambers. The passage 56 is offset from and extends above and below the centerline 54 of the trunnion conduit and drum axis. The lower portion of the passage is preferably at or just below the bottom edge 60 of the apertures 58 . Similarly, the lower portion of the passage 56 should be at or just below the angular position of the drum in which the ribs are filled with filtrate and gases and foam have been exhausted from the ribs.
The internal passage 56 may extend from the inlet aperture(s) 58 of the valve segment 50 and to the elbow 52 . The passage 56 may have a gas vent 68 at an upper end of the passage and elbow, e.g., above the centerline 54 . The passage 56 also has a filtrate drain 70 extending out of the passage and through the elbow. The filtrate drain is at a lower portion of the passage 56 and below the centerline 54 of the trunnion conduit and drum axis and preferably below the elevation of the lower edge 60 of the aperture(s) 58 . A substantial amount of filtrate may pass through the passage 56 as air and foam are discharged from the ribs into the passage. Further, liquid filtrate in the ribs may serve a purging action to push out air and foam from the ribs and the pushing liquid filtrate may flow into the passage 56 .
Alternatively, the valve segment 50 may be integrated into the valve segment support such that the distal end of the outer plate constitutes the valve segment and openings in the outer plate constitute the gas apertures leading to the gas passage 56 . Further, the outer plate 64 and valve segment support 51 may be formed by a sturdy tube having a relatively large cross-sectional area and offset from and lower than the axis 54 of the drum. The tube may have an oval or kidney shaped cross-section to reduce the blockage to fluid flow in the trunnion conduit and conform to the inside wall surface of the trunnion conduit.
FIG. 4 is a perspective view of a valve segment 50 supported by a valve segment support 51 . The valve segment is mounted on an outer plate 64 of the support. The support 51 is attached to the elbow conduit 52 and extends as a cantilever to the segment. A mounting bracket 53 provides a coupling for the elbow to the stationary drive and bearing unit.
FIG. 5 is a perspective view of a rear plate 72 of the valve segment support 51 . The valve segment support may be formed by welding together the pair of plates 64 , 72 along their respective upper and lower edges. The outer plate 64 forms the front surface of the valve segment support and may have an arc shape that generally conforms to the inner wall of the trunnion conduit. The rear plate 72 may be an arc, flat or bent inward along a crease line (as shown in FIG. 5 ).
The rear plate 72 and outer plate 64 of the valve segment support 51 form a sturdy support and the gas vent passage 56 . The valve segment support may extend as a cantilever from the inlet of the elbow 52 into the trunnion conduit. A cylindrical post 78 on the distal end of the valve segment support may fit into a bushing 79 ( FIG. 3 ) in the drum axle and inward of the axial filtrate chamber. Further, a triangular brace 80 may be welded to an inside surface of the rear plate 72 to provide additional support for the valve segment support.
The internal gap between the front and rear plates of the valve segment support defines the gas passage 56 . End caps 82 welded to opposite longitudinal ends of the plates seal the ends of the passage. The passage 56 may alternatively be a tube extending along a back surface of the outer front plate and thereby render the rear plate optional.
The valve segment 50 provides a means for removing the air from filter drum before the air enters the drop leg. The valve segment allows the ribs to vent gases into the passage 56 for substantially the entire rotational period during which the suction is not applied to the ribs. Further, the valve segment allows gas and foam from the ribs to vent entirely into the passage 56 (along with a substantial amount of liquid filtrate) to minimize air entering the elbow and down leg conduits. These features are contrary to the conventional approach of blocking liquid fluid flow through the ribs during most of the portion of the rotational in which suction is not applied to the ribs.
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 to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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In a rotary drum for condensing pulp from a pulp slurry vat, the drum including radial conduits delivering filtrate from a pulp mat on an outer surface of the drum to at least one filtrate conduit coaxial with a drum rotational axis, a valve segment in the filtrate conduit including: an outer surface juxtaposed against drainage outlets of the radial conduits as the conduits pass through an angular range extending from an upper drum position to an immersed in a vat position, wherein the valve segment does not block the drainage outlets during a majority of the rotation of the drum; at least one inlet aperture on the outer surface aligned with the drainage outlets, said inlet aperture extending at least a majority of a width of the valve segment, and a closed passage extending from the inlet aperture to a gas vent external to the filtrate conduit, wherein the closed passage is offset from and below a centerline of the filtrate conduit.
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CLAIM OF PRIORITY
This patent application, and any patent(s) issuing therefrom, claims priority to U.S. provisional patent application No. 60/628,652, filed on Nov. 18, 2004, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to an improved switching regulator and/or amplifier, and more specifically, to a novel, cost effective design for a switching regulator and/or amplifier that provides for both high efficiency and high slew rate.
BACKGROUND OF INVENTION
It has been known in the prior art to utilize switching regulators/amplifiers in applications such as, but not limited to: (1) voltage regulators utilized for supplying a relatively fixed DC voltage to a load whose current demands change very quickly such as CMOS logic processors whose activity can go from negligible (such as in standby) to very high or vise-versa in a few nanoseconds, for example, at the change of state of a control signal; and (2) “digital” amplifiers or programmable regulators where the load is relatively fixed but its voltage is changed very rapidly in response to an external command, such as DSL line drivers and supplies or modulators for communication transmitters where the power level or information signal level is changed often and abruptly over a wide dynamic range.
It is also noted that the foregoing applications are characterized by a step down operation where the supply voltage is relatively fixed or slowly varying (such as, for example, a battery), and the widely varying load current is sourced at a voltage that is either fixed or varying, but at a lower value than the supply voltage.
Prior art designs for switching regulators/amplifier to be utilized in the foregoing applications have generally included buck topology switching regulators having low value inductors, high switching frequencies and hysteretic control algorithms without loop filters to achieve high load current slew rates. As is known:
( ⅆ I ⅆ t ∝ Vin - Vout L ) .
However, the use of such low value inductors results in large values of ripple current and conduction losses, while high switching frequencies result in larger switching losses, both of which undesirably lower efficiency.
In an effort to satisfy performance requirements, it has been known in the prior art to add a cascaded linear amplifier/low drop out regulator immediately before the load, even though the losses due to the load current at the required voltage overhead of the linear stage can be large. Such prior art systems are described, for example, in U.S. Pat. Nos. 4,378,530 and 5,905,407. FIG. 1 illustrates an exemplary block diagram of such a device.
Referring to FIG. 1 , the device includes a programmable switching regulator 12 cascaded with a linear amplifier stage 14 . In addition, the device includes overhead voltage reference supply 16 , and resistors R 1 and R 2 , which are coupled in series to one another and to the output node, V O . The overhead voltage reference supply 16 causes V R =V O +V B1 , which is necessary for the linear amplifier to operate, as V R must be larger than V O by an “overhead voltage”. Resistors R 1 and R 2 form a voltage divider circuit, and provide a feedback signal to the linear amplifier stage 14 . The output of the linear amplifier stage 14 operating in conjunction with the output of the programmable switching regulator 12 generate the output voltage, V O , of the device, which is coupled to the load (e.g., a power amplifier in a cell phone application). V SUPPLY corresponds to the voltage source for the device (e.g., a battery in a cell phone application), and V REF sets the output voltage needed to supply the power level required by the load. It is noted that in some applications, V REF will represent the instantaneous power requirement of the load and will include content data (e.g., voice or data information to be transmitted) which is superimposed on the V REF signal utilizing any suitable modulation technique. In operation, the linear amplifier stage 14 essentially functions as the power supply regulator operative to generate a substantially clean signal, V O , which is representative of the instantaneous power required for the task currently at hand.
However, if the output voltage of the switching regulator cannot change rapidly enough to follow voltage changes in V REF , then V R must be set to the instantaneous peak value of V O plus enough additional voltage margin B so that the linear amplifier does not “clip” on signal peaks. If the supply voltage, V SUPPLY , is significantly greater than V R , use of the switching regulator saves most of the power equal to I LOAD *(V SUPPLY −V R ), which would otherwise be dissipated in the linear amplifier.
While these known prior art devices provide for an improvement in efficiency, for example, by allowing for a reduction in the switching frequency of the switching regulator, due to the requirements of today's applications and the continued demand for reducing power requirements so as to extend battery life, a further increase in the overall operating efficiency of switching regulators/amplifiers is necessary. It is an object of the present invention to satisfy these needs.
SUMMARY OF THE INVENTION
In view of the foregoing, it is a primary objective of the present invention to provide a novel switching regulator/amplifier which exhibits improved efficiency and slew rate performance relative to known prior art devices. It is also an objective of the present invention to provide a cost effective design for the novel switching regulator/amplifier so that the device represents a practical solution to the aforementioned problems.
Specifically, the present invention relates to a regulating apparatus having an output node and being operative for regulating the voltage level at the output node in response to a reference signal provided as an input to the regulating apparatus. The regulating apparatus includes a linear amplifier stage operative for receiving the reference signal and being capable of sourcing current to the output node when the reference signal indicates that the present voltage level at the output node is less than a desired voltage level at the output node. The regulating apparatus further includes a switching regulator, which is controlled by the linear amplifier stage, and which is operative for sourcing current to the output node when the amount of current being sourced to the output node by the linear amplifier stage exceeds a predetermined threshold.
The switching regulator/amplifier of the present invention provides numerous advantages over the prior art. One advantage of the present invention is that it provides a highly efficient switching regulator/amplifier that minimizes the power requirements for operation. This is accomplished in-part by reducing the power dissipated by the linear amplifier contained in the device, by providing a separate current path that is capable of providing the steady state current requirements to the load (i.e., the linear amplifier is activated only during fast changing transient voltage swings in the load). As a result, as one example, the present invention advantageously allows for an extension of battery operation time of a cell phone between charges.
In addition, the switching regulator/amplifier provides for an increased slew rate capability. As the result of the design of the present invention, which incorporates the use of a “free-wheeling” switch, it is possible to rapidly reduce the load current to substantially zero (i.e., on the order of a few nanoseconds). Moreover, when the load current is reduced in the foregoing manner, the design of the present invention does not immediately dissipate the current (i.e., as explained below the current is temporarily stored), and therefore if the load must be increased shortly after the reduction, the stored current is again coupled/provided to the load. The foregoing operation allows the switching regulator/amplifier of the present invention to exhibit both a high slew rate capability and increased operating efficiency.
Yet another advantage of the present invention is that the design provides a “feed-forward” control system in which the switching regulator/amplifier reacts to changes in the desired voltage set point when adjusting the current delivered to the load. The control of the switching regulator/amplifier does not utilize the output voltage signal. As a result, the design of the present invention further improves both slew rate performance (as the load current is adjusted more rapidly in comparison to a device that modifies the current delivered to the load based on changes in the output voltage of the regulator) and efficiency performance (as there is no sense resistor coupled to the output of device, which would result in an increase in power dissipation).
Additional objects, advantages, and novel features of the invention will become apparent to those skilled in the art upon examination of the following description, or may be learned by practice of the invention. While the novel features of the invention are set forth below, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated into and form a part of the specification, illustrate several aspects and embodiments of the present invention and, together with the general description given above and detailed description given below, serve to explain the principles of the invention. Such description makes reference to the annexed drawings. The drawings are only for the purpose of illustrating preferred embodiments of the invention and are not to be treated as limiting the invention.
In the drawings:
FIG. 1 illustrates a block diagram of a prior art implementation of a switching regulator/amplifier that utilizes a linear amplifier in the design.
FIG. 2 illustrates an exemplary block diagram of a switching regulator/amplifier in accordance with the present invention.
FIG. 3 illustrates a schematic diagram of an exemplary implementation of the switching regulator/amplifier of the present invention.
FIG. 4 illustrates a first alternative embodiment of the output stage of the linear amplifier stage.
FIG. 5 illustrates a second alternative embodiment of the output stage of the linear amplifier stage.
Throughout the above-mentioned drawings, identical reference numerals are used to designate the same or similar component parts.
DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein: rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art, like numbers refer to like elements throughout.
Referring to FIG. 2 , similar to the prior art design illustrated in FIG. 1 , the switch regulator/amplifier of the present invention comprises a programmable switching regulator 12 cascaded with a linear amplifier stage 14 , as well an overhead voltage supply 16 and resistors R 1 and R 2 . The linear amplifier stage 14 receives V REF as an input signal. The foregoing components are coupled together in the same manner as illustrated in FIG. 1 . However, the design also includes a second switching regulator 18 coupled between the supply voltage V SUPPLY and the output, V O , as shown in FIG. 2 . V R is the minimum supply voltage for the linear amplifier that allows it to follow the signal peaks of V REF without clipping. The linear amplifier stage 14 provides control signals 17 to the second switching regulator 18 , which govern the operation of the second switch regulator 18 .
As explained in more detail below, the inclusion of the second switching regulator 18 disposed between the power supply, V SUPPLY , and the load, V O , provides for a second current path so as to allow for the steady state current (or slowly changing current) required by the load to be delivered to the load via the second switching regulator 18 without accessing/utilizing the linear amplifier stage 14 . In the present invention, the linear amplifier stage 14 is primarily utilized to deliver fast changing (i.e., transient) current requirements to the load. As a result of this design, the utilization of the linear amplifier stage 14 , which exhibits low efficiency and high power dissipation, is minimized thereby increasing the overall efficiency of the device.
FIG. 3 illustrates a schematic diagram of an exemplary implementation of the switching regulator/amplifier illustrated in FIG. 2 . It is noted that the present invention is not limited to the specific embodiment disclosed in FIG. 3 , as variations to the particular design are clearly possible.
Referring to FIG. 3 , the programmable switching regulator 12 receives V SUPPLY as an input voltage and generates an output voltage signal V R . In addition, overhead voltage reference supply 16 is coupled to the programmable switching regulator 12 . It is noted that the programmable switching regulator 12 furnishes an output voltage, V R , which is equal to the average value of the linear amplifier output voltage, V O , plus an additional voltage V B1 , where V B1 equals the peak to average value of V O and a small additional voltage necessary to assure that linear amplifier 14 does not clip (i.e., voltage saturate) on peaks of the V REF signal. As such, the programmable switching regulator 12 need only have a response time fast enough to follow the average value of V O and not its instantaneous value or envelope.
More specifically, the output voltage, V R , of the programmable switching regulator follows the value of its input reference voltage, (V O +V B ), within the capability of its control bandwidth or response time as set forth by its internal clock or switching frequency. Thus, the voltage V R follows the average value of V O plus the additional voltage of V B1 , where the averaging period is set by the control bandwidth of the programmable switching regulator or may be adjusted to a specific value by adding an additional low pass filter in its control input line. The choice of averaging period and value of V R are selected to match the characteristics of the V REF signal and linear amplifier response such that the value of V B1 is equal to the maximum value of V O average to positive peak value during any sliding time averaging period as a window. The objective is to minimize the value of V B1 to the smallest value of the average to peak during the response time of the switching regulator so that most of the voltage difference between V SUPPLY and V O can be absorbed by the switching regulator at typically 90% efficiency rather than be wasted as voltage drop across the linear amplifier. Thus, by choosing an appropriate V B1 to match the AC signal characteristics of V O (and therefore V REF when not distorting) and the response time of the switching regulator, essentially any programmable switching regulator response time and signal characteristic of V O can be accommodated. However, it is noted that if the switching regulator response is too slow relative to the rate of change of the V REF signal, efficiency improvements from use of the programmable switching regulator may be small and overall system efficiency inadequate.
Continuing, in the given embodiment the linear amplifier stage 14 includes an error amplifier 22 , a linear amplifier 24 comprising an NPN transistor, resistor R 11 coupled between the base and emitter terminals of the linear amplifier 24 , resistor R 12 coupled to the collector of the linear amplifier 24 , and capacitor Cc and resistor Rc connected in series and coupled to the output of the error amplifier 22 . The emitter of the linear amplifier 24 is coupled to the load, V O . As shown in FIG. 3 , the output signal, V R , of the programmable switching regulator 12 is coupled to both resistor R 12 and the error amplifier 22 and functions as the amplifier supply voltage. In operation, the error amplifier 22 and the linear amplifier 24 form a linear amplifier/regulator that has sufficient bandwidth to allow the output, V O , to follow the reference V REF in the presence of rapid time variations in V REF and/or the load current. As shown, a portion of the output signal, V O , is fed-back to the input of the error amplifier 22 so as to allow the error amplifier to generate an output signal indicative of the difference between the desired output voltage level and the actual output voltage level, and cause V O to follow (V REF *(R 1 +R 2 )/R 2 ).
Referring again to FIG. 3 , in the given embodiment, the second switching regulator 18 comprises a first comparator 26 having a first input and a second input which are coupled across resistor R 12 , and a second comparator 28 having a first input and a second input which are coupled across resistor R 11 . The second switching regulator 18 further includes a first switch 27 , which is a pMOS device, a second switch 29 , which is an nMOS device, an inductor 31 and an active diode 32 . As shown, the output of the first comparator 26 is coupled to the first switch 27 , which has a source terminal coupled to the supply voltage, V SUPPLY . The output of the second comparator 28 is coupled to the gate of the second switch 29 . It is noted that the inductor 31 is coupled between the source and drain terminals of the second switch 29 , and the body of the second switch 29 is not connected to either its source or drain, but rather to ground as shown in FIG. 3 . The inductor 31 is also coupled between the drain terminal of the first switch 27 and the load, V O . It is further noted that the drain terminal of the first switch 27 and the source terminal of second switch 29 are coupled together and are also coupled to diode 32 . In the preferred embodiment, the diode 32 is an “active” type diode comprising a comparator and NMOS transistor as described in pending application Ser. No. 11/094,369 filed Mar. 31, 2005, which is hereby incorporated by reference in its entirety.
Turning to the operation of the device as a system, it is noted that without the second switching regulator 18 in the device, the entire load current would have to pass through the linear amplifier stage 14 , and as a result the power dissipation due to the load current times the overhead voltage B 1 required for proper operation would greatly reduce the efficiency of the device. However, by including the second switching regulator 18 , which has minimal switching and conduction losses, most of the load current passes through the second switching regulator 18 and therefore bypasses the linear amplifier stage 14 , thereby greatly improving overall efficiency. It is noted, however, that the linear path is always present and can supply the entire incremental load current during transients.
At initial turn of the power supply, V SUPPLY , with V REF already having a desired value and V B1 set appropriately as described earlier, V O is zero and the input to the programmable switching regulator is V B1 . The programmable switching regulator output voltage V R rises toward (V O +V B1 ) at a rate set by its inherent response time, and the linear regulator now has a non-zero supply voltage, and so long as V O <(V REF *(R 1 +R 2 )/R 2 ), it continues to increase V O toward V R , and therefore the output voltage V O thus ramps up at a rate set by the slew rate of the programmable switching regulator. When V O =(V REF *(R 1 +R 2 )/R 2 ), V O has reached steady state and its stays at that voltage until the programmable switching regulator output, V R , has reached [(V REF *(R 1 +R 2 )/R 2 )+V B1 ], at which point it remains static unless or until V REF changes. Thus, power on requires no special function within the device design, and the operation of the second switching regulator will be the same as described in the following for all modes of operation including start up.
Continuing, during operation, if the second switching regulator 18 off, the load current flows through the linear amplifier stage 14 including the linear amplifier 24 . This results in an increase in the voltage drop across R 12 , which if greater than the upper threshold of the first comparator 26 , results in the turn on of first switch 27 and therefore the supply of current to the load, V O , through the inductor 31 . As the inductor current increases, the current in the linear amplifier 24 decreases because their sum is the present load current. This reduces the voltage drop across R 12 until such time that the reduction in voltage across R 12 causes it to become less than the lower threshold of the first comparator 26 and turns off the first switch 27 , thereby preventing further current from being supplied to the load from V SUPPLY . Thus, at steady state, the comparator 26 switches on and off at some duty cycle, and most of the load current flows through the inductor 31 , and consists of a DC component and an AC triangular component. The sum of the DC component and AC component of the inductor current and the linear amplifier current equals the load current. Thus, the linear amplifier AC current is 180 degrees out of phase with the AC component of the inductor current and there is no AC voltage ripple present at the load, V O .
The switching frequency of the second switching regulator 18 is set by the relationship between V SUPPLY −V O , the value of the inductor 31 , the value of hysteresis set by the first comparator 26 and the voltage drop from the current through resistor R 12 . It is noted that when the first switch 27 is off, inductor current flows through the diode 32 , which as noted above is preferably of the “active” type, and therefore has a forward voltage drop that is negligible with respect to V O . The actual values utilized for the various components are typically based on the specific application for which the device will be utilized n conjunction with well known design relationships.
From the foregoing discussion, it is clear that the circuit of the present invention is capable of handling steady state and increasing load current exceedingly well. However, the circuit is also capable of handling rapidly decreasing load currents, and does so in a manner which provides for both high slew rates and improved efficiency. In operation, during transients when the inductor current is larger than the load current, the linear amplifier stage 14 starts to turn off when the voltage across R 11 becomes less than V BE of linear amplifier 24 , thereby turning off linear amplifier 24 . The value of R 11 is part of the amplifier design and the threshold of comparator 28 should be about 0.8*V BE with a few millivolts of hysteresis to avoid noise effects. At this time, the second comparator 28 turns on the second switch 29 , which allows the inductor current to recirculate and slowly decay in value without being passed into the load, V O . Specifically, the inductor current recirculates in an autonomous loop formed by the inductor 31 and the second switch 29 (which is referred to herein as a free-wheeling switch). Thus, the foregoing configuration allows the load current to be rapidly reduced to substantially zero on the order of a few nanoseconds. In other words, the device allows the total current sourced by the overall regulator/amplifier to go to nearly zero during transients even though the linear amplifier stage 14 can only source current, and prevents voltage overshoots in most any dissipative load without degrading efficiency. Further, as V O is not used to control the second switching regulator 18 , it has no ripple voltage and can precisely track V REF .
It is further noted that by utilizing the “free-wheeling” switch 29 in the device of the present invention, when the load current is reduced in the foregoing manner, the device of the present invention does not immediately dissipate the current (i.e., the current is temporarily stored in the inductor and autonomous loop). As such, if the load current must be increased shortly after the reduction, the stored current is again coupled to the load. This would occur upon deactivation of the second switch 29 , which occurs when the linear amplifier stage 14 becomes active again (i.e., V REF indicates a desired increase in load voltage) and the voltage across R 11 is greater than the trip point of the second comparator 28 . This operation of not dissipating the inductor current and allowing for the reuse of the stored inductor current allows the switching regulator/amplifier of the present invention to exhibit high slew rates and increased efficiency.
It is also noted that by sensing the collector current of linear amplifier 24 instead of the output current of the linear amplifier stage 14 , the output impedance of the linear amplifier stage 14 is advantageously not increased by a sensing resistor. Furthermore, the value of R 11 can be relatively large so that a small current threshold of the second comparator 28 can be achieved with minimal error due to the voltage offset of the second comparator 28 .
While an exemplary embodiment of the present invention is set forth above in FIG. 3 is it noted that the present invention is not intended to be limited to the disclosed embodiments as various implementations of the device are clearly possible. For example, FIGS. 4 and 5 illustrate alternative embodiments of the output stage of the linear amplifier 24 .
More specifically, in a first variation, the linear amplifier 24 can comprise two matched parallel transistors 24 A and 24 B, as shown in FIG. 4 , where the emitter area of 24 A , is K* (area of 24 B ) and R 2 is K*R 2 . Thus, with K large, R 2 can be sized more conveniently but still maintain the threshold of the first comparator 26 the same with respect to the total collector current of linear amplifier 24 of FIG. 3 , and the total current gain of the linear amplifier 24 will not change appreciably even if transistor 24 B voltage saturates. In a second variation, an additional linear amplifier stage consisting of transistor 25 and mirror 26 also could be added to linear amplifier 24 , as shown in FIG. 5 , to further lower the output impedance of the linear amplifier and make its frequency compensation easier without changing the operating voltages from those of the configuration shown in FIG. 3 or 4 . It is noted that if utilizing the alternative embodiments for the linear amplifier 24 , in addition to the linear amplifier, the resistor R 12 would be replaced by the circuit shown in FIGS. 4 and 5 , and the inputs of the first comparator would be coupled across R 12 ′. In FIG. 5 , the inputs of the second comparator would be coupled across resistor R 11 ′.
As noted above, the switching regulator/amplifier of the present invention provides numerous advantages over the prior art. One advantage of the present invention is that it provides a highly efficient switching regulator/amplifier that minimizes the power requirements for operation. This is accomplished in-part by reducing the power dissipated by the linear amplifier contained in the device, by providing a separate current path that is capable of providing the steady state current requirements to the load (i.e., the linear amplifier is activated only during fast changing transient voltage swings in the load). As a result, as one example, the present invention advantageously allows for an extension of battery operation time of a cell phone between charges.
Another advantage is that the switching regulator/amplifier of the present invention provides for an increased slew rate capability. As the result of the present invention, which incorporates the use of a “free-wheeling” switch, it is possible to rapidly reduce the load current to substantially zero (i.e., on the order of a few nanoseconds). Moreover, when the load current is reduced in the foregoing manner, the design of the present invention does not immediately dissipate the current (i.e., as explained above the current is temporarily stored), and therefore if the load must be increased shortly after the reduction, the stored current is again coupled to the load. The foregoing operation allows the switching regulator/amplifier of the present invention to exhibit high slew rate capabilities and improved efficiency.
Yet another advantage of the present invention is that the design provides a “feed-forward” control system in which the switching regulator/amplifier reacts to changes in the desired voltage set point when adjusting the current delivered to the load. The control of the switching regulator/amplifier does not utilize the output voltage signal. As a result, the design of the present invention further improves both slew rate performance (as the load current is adjusted more rapidly in comparison to a device that modifies the current delivered to the load based on changes in the output voltage of the regulator) and efficiency performance (as there is no sense resistor coupled to the output of device, which would result in an increase in power dissipation).
While specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize.
For example, it is noted that the programmable switching regulator 12 operates to maintain V R −V O greater than the linear stage drop out voltage even if the short term voltage slew of V O exceeds V R , by choosing voltage offset B 1 appropriately. This is necessary to maintain efficiency if the V SUPPLY −V O voltage differential is much larger than the dropout voltage of the linear regulator. In the event that the V SUPPLY −V O voltage differential is not larger than the dropout voltage of the linear regulator, it is possible to omit the programmable switching regulator from the design.
The aforementioned variations are merely examples. Further, the terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification and the claims. Rather, the scope of the invention is to be determined entirely by the following claims, which are to be construed in accordance with established doctrines of claim interpretation.
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A regulating apparatus having an output node and being operative for regulating the voltage level at the output node in response to a reference signal provided as an input to the regulating apparatus. The regulating apparatus includes a linear amplifier stage operative for receiving the reference signal and being capable of sourcing current to the output node when the reference signal indicates that a present voltage level at the output node is less than a desired voltage level at the output node. The regulating apparatus also includes a switching regulator, which is controlled by the linear amplifier stage, and which is operative for sourcing current to the output node when the amount of current being sourced to the output node by the linear amplifier stage exceeds a predetermined threshold.
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BACKGROUND OF THE INVENTION
The present invention relates to milking chairs and especially to a power operated movable milking chair for milking a plurality of cows without the operator moving from the milking chair.
In the past, the most common milking stools have been small lightweight stools which are of the general height required for a person to sit upon to place him in the general area required for milking a cow. There is also a platform available for an operator to stand upon if the need arises. Each cow is milked individually by hand or the stool may be used while connecting the cow to an automatic milking machine. After each hookup the stool can be picked up and moved to the next location for the next cow. Alternatively, the operator may simply walk to each cow, bend over and stay in a bent or kneeling position while connecting up each milking machine. This has been somewhat improved by some of the milking parlors which load cows onto carousels or other cow-moving devices so that the operator may stand in one general position while hooking up each cow to an automatic milking machine. One such system may be seen in my co-pending patent application, Ser. No. 347,162 for Milking System. This prior system operates handily in conjunction with the present milking chair and allows an operator to be moved rapidly from one cow to the next and to adjust the position of the operator for connecting and disconnecting the milking machine from each cow and allows the operator to connect up one row of cows and then automatically move his operating chair to a different position for connecting up a second row of cows to the milking machines and returning to the first row for disengaging the milking machines in a predetermined sequence so that the operator is continuously kept occupied but does not injure his back by the continuous bending, walking, stooping and standing normally required to hook up a large number of milking machines. It should be observed that the present milking stool is particularly useful with my previously mentioned milking system but may also be adapted for use with other systems such as the commonly used carousel milking parlor, or in herringbone, sawtooth, side opening or walkthrough milking parlors.
SUMMARY OF THE INVENTION that
The present invention relates to a mobile milking stool or chair for use in milking parlors for placing the operator in a correct and comfortable position for connecting and disconnecting a milking machine to a cow and for moving one cow to the next to more fully automate milking parlors. The milking stool includes a wheeled frame or platform which is power driven in a forward and backward direction at the control of the operator. An operator's seat is provided which is connected to the platform in a manner that it can swing from one side to the other of the platform and may also be adjusted in an up and down position suitable to the particular operator and for putting him in better position for connecting up individual cows. The seat includes a control system connected thereto so that the operator controls the back and forth movement of the platform and the swinging of the chair as well as other adjustments to the operator's position without the operator leaving his seat. The mobile chair can be hydraulically or electrically operated as desired. Hydraulics or pneumatics are preferred since they eleminate electrical shock hazards in the milking parlor. The movable platform may ride on a track, if desired, and may be used in a variety of milking parlors.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of this invention will be apparent from a study of the written description and the drawings in which:
FIG. 1 is a perspective view of a mobile milking chair in accordance with the present invention illustrated next to a milking parlor;
FIG. 2 is a perspective view of the milking chair with portions cut away from the platform;
FIG. 3 is a perspective view of the milking chair in yet another position with portions cut away;
FIG. 4 is a side sectional view of the milking chair in accordance with FIGS. 1 through 3;
FIG. 5 is a top sectional view with portions cut away of the milking chair in accordance with FIGS. 1 through 4; and
FIG. 6 is a perspective view of a milking chair in accordance with the present invention connected next to a carousel type milking parlor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 through 6 of the drawings, an automatic milking chair 10 is illustrated generally riding upon a platform or frame 11 and has a chair, stool or seat 12 riding upon the platform 11. The platform 11 rides upon wheels 13 and may have one wheel riding upon a track 14 running down the floor 15 of a milking parlor 16. The milking parlor may include walls 17 along with movable platforms 18 which ride upon wheels 20 attached of a track 21 which platform 18 has a pair of sections 22 and 23 connected together and may be moved into position as illustrated, and then moved away for loading and unloading the cows onto the platform 18 at a position different from the milking location. A second tract 24 has wheels 25 for laying a second platform 18 located in position on the opposite side whereby the chair 12 may be swung around to the opposite platform for milking the cows on a platform on track 24 riding upon wheels 25. Each platform 18 also has a plurality of railings 26 for holding the cows in individual stalls, which stalls are blocked on one end with gates 27 having feeding buckets 28. A plurality of railings 30 are connected to the walls 17 of the milking parlor 16. A bar or grid system 31 allows waste products to be disposed of from the platforms 18 while nozzles 32 allow the cows to be sprayed and damp dried while loaded on the platform 18. This type of milking parlor has been described in my previous patent application Ser. No. 347,162, hereinbefore described, and is mentioned briefly to show the milking stool 10 in contact with the milking parlor for a more clear understanding of the invention.
The milking stool 10, platform 11 has a framework 40 attached thereto along with a central shaft 41 connected to the framework 40 for mounting the chair 12 upon the platform 11. An additional frame 42 connects to the shaft 41 in a rotatable fashion with wheel 43 mounted to the end thereof which in turn is mounted to a frame 44 having cylinder member 45. Frame 44 is in turn attached to the chair 12 and holds the chair 12 in position. Thus the chair 12 can be rotated on the wheel 43 which rotates on the platform 11 and the frame 42 will turn on the shaft 41 so that the operator can be turned in circular fashion substantially around the platform 11, or with modifications the chair could rotate a full circle 25 to position the operator closer or further away from the milking platform 18, as well as to swing the operator from the platform track 21 to platform track 24. For clarity, the frames have been slightly exaggerated so that the operation can be more clearly seen in these views. A flexible electrical cable 46 is connected to a swivel connection 45 at one end to a rotatable mounted rigid pipe 49 at the opposite end which pipe 49 is rotatably or movably connected to an electrical swivel connection and support 47 which in turn is attached to the wall 17 of the milking parlor 16 and is connected to an electrical source through conductor 48.
At this point it can be seen that the milking stool 10 can move back and forth on the track 14 and can also be swung around on the platform 11 and thus has great flexibility in the positioning of the operator and also in the movement from one milking platform to the next.
The electric current that is fed through line 46 through swivel connection 45 can be fed through a cable to an electric motor 51. Electric motor 51 drives the hydraulic system and sits upon a hydraulic reservoir 52, and drives a hydraulic pump 53. Hydraulic fluid is pumped from the reservoir 52 through pipe 54 and produces hydraulic fluid under pressure in the flexible fluid line 55. The reservoir 52 has a flexible return fluid line 56 for returning fluid to the reservoir 52. The line 55 directs the hydraulic fluid under pressure directly to the control box 57, which is controlled from the box 57 through several individual lines by a plurality of hand switches 60 and which may also be controlled by a pair of foot switches 61 which are connected through pipe 62 to the control box 57. Foot control switches 61 are desirable for most workers but all hand control switches 60 are especially useful for some handicapped workers. Hydraulic lines from the hydraulic control box 57 are fed to a hydraulic motor 63 through cylinder 41, hydraulic swivel connection 51 and hydraulic line 69. Hydraulic motor 63 drives a pulley 64 which in turn is connected to a frame 65 which drives a pulley 66 attached to a shaft riding in a bearing 67 and which is connected to a bearing bracket 68 riding upon the platform 11. The shaft and pulley 66 are also connected to a wheel 70 and operation of the hydraulic pressure fluid from the hydraulic box 57, the motor 63 can be driven in a forward or reverse direction to drive the belt 89 in a forward or reverse direction along with the wheel 70 to move the platform 11 along the track 14. The return line 79 from the motor 63 passes through hydraulic swivel connection 99 into cylinder 41 and back through control box 57. Reversing the direction of fluid to hydraulic motor 63 reverses the direction of the direction of travel of the platform 11 on track 14. Platform 11 rides on the wheels 13 which in turn ride on shaft 71 which are connected to the platform 11 by shaft support members 72.
The hydraulic control box 57 is utilized to control by means of hydraulic lines 73 the hydraulic motor 74 which is fixedly attached to a hydraulic motor support bracket 75 and has a pulley 76 for driving a belt 77 which drives a pulley connected to its shaft connected to the wheel 78. The shaft rides in the yoke 80 which supports the wheel 78 and which is attached to the support cylinder 45 and to the frame support 44. Thus by operating the controls 57 the motor 74 can be driven in a forward or reverse direction in the same manner as hydraulic motor 63 to drive the wheel 78 in a forward or reverse direction moving the frame 42 attached to the shaft 41 and also moving the frame 44 to move the chair 12 as the wheel 78 rotates on the platform 11.
The control box 57 may also provide for controlling the hydraulic cylinder 81 which drives a hydraulic cylinder rod 82 attached with a pin 83 to a bracket 84 and to a frame member 85 to swing the frame 44 on the support cylinder 45 to swing the chair 12 back and forth for better positioning of the operator. This is necsssary in order to prevent the chair 12 from running into the platform if the chair has to be moved a substantial distance around the platform 11.
Hydraulic cylinder 86 drives hydraulic cylinder rod 87 conected to a bracket 88 by pin 90 which hydraulic cylinder is also connected by a pin 91 to the bracket 84. Bracket 88 is attached to a support member 92 riding on a cylindrical hollow shart 93 which rides on a shaft 94 and site upon a fixed cylindrical support 95 which fixedly holds the shaft 94. Thus driving the cylinder 86 with the control box 57 in a forward or reverse direction will drive the seat 12 in a partial rotation around the shaft 94 to position the chair at an angle convenient to the operator. Finally, the control box 57 through hydraulic lines 96 may control a hydraulic cylinder 97 attached to a support bed 98 to drive a hydraulic rod 100 to move the support bracket 101 which is movably attached to a support 102 attached to the back of the chair 12 and has a dovetailed track 103 riding thereon so that the chair can be moved up and down at the operator's control. The chair 12 provides a seat portion 104, arm supports 105, back support 106 and a foot support or standing platform 107 connected to a back portion 108. The chair also has a container 110 for holding supplies for the operator along with the foot controls 61 previously discussed. The chair 104 can be further adjusted for a particular operator by the attachment to brackets 111 by means of pins 112. It should be noted that the hydraulic system controls work in a conventional manner with commerically available control components and utilize commerically available hydraulic motors as well as commerically available electric motors.
FIG. 6 illustrates an alternate embodiment having all of the features in the chair as previously described but riding in a circular track 120 to follow a carousel or rotational type milking parlor 121 and having an electrical cable 122 fed from a spring loaded retractable spool 123 attached by brackets 124 to a roof 125 of a milking parlor. Carousel 121 rides on wheels 126 as illustrated but could be moved in any manner desired without departing from the spirit and scope of the invention.
It should be clear at this point that a milking chair which is operated and movable in a great variety of positions as well as on a track has been provided, but it should also be clear that other variations are contemplated such as having two chairs riding on a single platform without departing from the spirit and scope of the invention. Accordingly, this invention is not to be construed as limited to the particular forms disclosed herein, since these are to be regarded as illustrative rather than restrictive.
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A mobile milking chair apparatus which is controlled by the operator to place the operator in a position to milk a series of cows in a milking parlor. The chair conveys the operator along a line of cows and can position the operator properly for connecting and disconnecting a milking machine for each cow and then provides for swinging the operator to the opposite side for another series of cows.
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BACKGROUND OF THE INVENTION
[0001] To prevent sink water from flowing into a dishwasher, a portion of a dishwasher's discharge hose needs to be higher than the highest level of water in a sink basin that shares a drain with the dishwasher. Some discharge hoses are connected to anti-siphon devices that mount above countertop level, but these devices make a mess when they fail. Commonly, dishwasher discharge hoses are provided with a high rise loop by attaching a bracket near the top of a kitchen's sink base cabinet before a sink is installed. It is often nearly impossible to remove such a bracket without removing the sink, so changing the hose or trying to loosen the hose to be able to pull out a dishwasher becomes challenging. There is a need for an easy method to position and remove a high rise loop for a dishwasher's discharge hose.
SUMMARY OF THE INVENTION
[0002] The preferred embodiment of the present invention uses a stainless steel bracket characterized by a handle portion having a hose support portion on one end and a cabinet mount portion on the other end. When this high-loop bracket is installed, a high rise loop is formed in a discharge hose supported by the hose support portion, preferably as high as possible between a sink basin and a wall of a sink base cabinet. The discharge hose is passed through the hose support portion, and then the handle portion is used to manipulate the discharge hose to create and position a high rise loop in a desired position. Once positioned, the mount portion is secured to the sink base cabinet using one or more fasteners, preferably screws. Unlike common hose brackets, the relatively long handle portion causes the mounting means to be adequately spaced below the high rise loop such that the mounting means is visible and easily accessible below the sink basin. With easy access to the mount portion, a common screwdriver is employed to screw the mount portion to the sink base cabinet. Alternative hose support portions and mounting means will be discussed, but all high-loop brackets will include a handle portion that makes it easy to create and position a high rise loop.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a side view of a preferred high-loop bracket of the present invention.
[0004] FIG. 2 is perspective view of the high-loop bracket of FIG. 1 .
[0005] FIG. 3 is a front view of the high-loop bracket of FIG. 1 .
[0006] FIG. 4 is a perspective view of the high-loop bracket of FIG. 1 being positioned under a counter top.
[0007] FIG. 5 is a perspective view of the high-loop bracket of FIG. 1 mounted to a sink base cabinet.
[0008] FIG. 6 is a side view of a first alternative embodiment characterized by an alternate hose support portion.
[0009] FIG. 7 is a perspective view of the high-loop bracket of FIG. 6 .
[0010] FIG. 8 is a front view of the high-loop bracket of FIG. 6 .
[0011] FIG. 9 is a plan view of stamped sheet metal used to form another alternative high-loop bracket.
[0012] FIG. 10 is a perspective view of the high-loop bracket formed by folding the sheet metal shown in FIG. 9 .
[0013] The following is the list of numerical callouts used in FIGS. 1-10 :
[0014] 10 High-loop bracket
[0015] 12 Hose Aperture
[0016] 14 Hose support portion
[0017] 16 Guard
[0018] 18 Split
[0019] 20 Bend
[0020] 22 Handle portion
[0021] 24 Mount portion
[0022] 26 Folded edge
[0023] 28 Curled end
[0024] 30 Discharge hose
[0025] 32 High rise loop
[0026] 40 Sink base cabinet
[0027] 42 Countertop
[0028] 44 Sink basin
[0029] 46 Garbage disposal
[0030] 48 Spot welds
[0031] 50 Hand
[0032] 52 Slot
[0033] 54 Hook
DETAILED DESCRIPTION OF THE INVENTION
[0034] This detailed description will describe a high-loop bracket 10 from the top down, followed by its installation. Generally, as shown in the various figures, the high-loop bracket has a hose support portion 14 above a handle portion 22 and a mount portion 24 . In the most preferred embodiment, such as is shown in FIGS. 1-5 , the high-loop bracket is made from a single piece of stainless steel that is cut, folded and bent to shape so that it is strong and reliable for at least the life of a dishwasher. Other rigid materials, such as plastic or aluminum, could be used to mold or form a high-loop bracket. When metal is used, folded edges 26 in the handle portion should reduce the risk of sharp edges cutting people or surroundings while adding strength to the high-loop bracket. Alternate embodiments of the present invention will follow the description of the preferred embodiment and its installation. Where reference numbers in one figure are the same as another figure, those reference numbers carry substantially the same meaning. Preferred sizes, materials and methods of attachment will be discussed, but these preferences are not intended to exclude other suitable or functionally equivalent sizes, materials or methods of attachment.
[0035] As shown in FIGS. 1-3 , the top of the preferred high-loop bracket 10 has a hose support portion 14 characterized by a hose aperture 12 . An outer diameter of the hose support portion will be determined by the type and thickness of the material used to make the high-loop bracket. The preferred hose support portion is made from approximately 1 mm thick stainless steel (such as 22 gauge) that is die cut to have about a 60 mm outer diameter. An inner diameter of the hose support portion, which effectively defines the hose aperture, is large enough, such as about 40 mm, for an electric dishwashing machine's waste water discharge hose 30 to pass through the hose aperture far enough so that approximately a mid-section of the hose can be supported. When a high-loop bracket is constructed from metal, a guard 16 is preferably installed around an inner diameter of the hose support portion such that there are no sharp edges around the hose aperture that could wear or cut a discharge hose. One such guard is a length of u-shaped plastic or rubber that is pressed around an inside edge of the hose support portion, with the ends of the guard meeting at a split 18 . Alternatively, the guard could be tape, foam or other non-abrasive material.
[0036] As shown in FIGS. 1-3 , the hose support portion 14 is connected to the handle portion 22 of the high-loop bracket 10 by a bend 20 . Preferably, the entire high-loop bracket is made from a single sheet of stainless steel, so the bend is made for the purpose of providing a flat mounting surface that causes a discharge hose to run along a cabinet wall. The preferred bend will make about a 90 degree turn so that a plane defined by the handle portion is substantially perpendicular to a plane defined by the hose aperture. When twisting the sheet metal to form the bend, it is preferred that a tangent of an outer diameter of the hose support portion lies approximately in the plane defined by the handle portion so that a discharge hose can be positioned close to a wall of a base cabinet without interfering with the ability to mount the high-loop bracket.
[0037] The handle portion 22 of the high-loop bracket 10 shown in FIGS. 1-3 is at least partially continuous with the bend 20 . To allow for enough material to make the folded edge 26 , the initial width of the sheet metal that is part of the handle portion is much wider than the sheet metal at the bend. The preferred width of sheet metal is about 20 mm, with the each folded edge on either side of the width consuming about 3 mm of the sheet metal. The folded edges should be flattened against the handle portion to reduce exposure of any sharp edges. If desired, a plastic coating or cover can be placed over the handle portion. The overall length of the handle portion in FIGS. 1-3 is about 13 cm, but it could be much longer to accommodate deeper sink basins, such as 30 cm or longer. The free end of the handle portion can be finished so that it is smooth and rounded.
[0038] Near an end of the handle portion 22 , opposite the hose support portion 14 , is a mount portion 24 . The mount portion shown in the preferred embodiment is preferably characterized by holes in the handle portion that are sized for common wood screws. The holes shown have about a 4 mm diameter. One or more of the holes can be selected for use at the time the high-loop bracket is installed. A separate holder could be secured to a base cabinet to accept the mount portion, such as by snapping or sliding into place, which might be preferred if the high-loop bracket is constructed of plastic.
[0039] To install the preferred high-loop bracket 10 , a discharge hose 30 is passed through the hose support portion 14 , as shown in FIG. 4 . If desired, a hot water supply hose for a dishwasher can be passed through the hose support portion at this time. An installer then grasps the handle portion 22 of the high-loop bracket with their hand 50 and manipulates the high-loop bracket until a desired high rise loop 32 is formed in the discharge hose in a desired position. The high-loop bracket is preferably pushed upward until the hose support portion is near or abuts a countertop 42 . Grasping just the handle portion 22 of the high-loop bracket will allow an installer to blindly manipulate the discharge hose between a sink base cabinet 40 and a sink basin 44 until a high rise loop 32 is formed in the discharge hose. As shown in FIG. 5 , the mount portion is secured against a wall of the sink base cabinet. A piece of double sided foam tape (not shown) can be used to temporarily position the handle portion against the cabinet. A screw is used to secure the mount portion to the cabinet; and additional screws can be used as deemed necessary. The discharge hose is connected to a garbage disposal 46 in the normal way.
[0040] FIGS. 6-8 show an alternate embodiment of the high-loop bracket 10 of the present invention. Rather than bending the handle portion 22 by about ninety degrees where it meets the hose support portion 14 , the sheet metal is simply curled back on itself to form the hose support portion. Rivets or spot welds 48 can be used to fix the curled end of the hose support portion. The curled end 28 effectively meets the handle portion without any twisting so that forming the high-loop bracket is a relatively simple process. The installation of the high-loop bracket shown in FIGS. 6-8 is the same as for the preferred embodiment. If desired, the folded edges 26 can be extended into the hose support portion so that they are continuous all the way to the curled end.
[0041] FIGS. 9 and 10 show another alternate embodiment of the high-loop bracket 10 of the present invention. Sheet metal is stamped to form the piece shown in FIG. 9 , including a slot 52 and hook 54 . The sheet metal is folded and then rolled until the curled end is close enough to the slot such that the hook can be pushed into the slot to form the hose support portion 14 . The hook may be bent to keep it from slipping out of the slot. The hook could be unhooked, if desired, to allow the discharge hose to be inserted into the hose support portion, and then the hook may be reinserted into the slot.
[0042] The various embodiments of the present invention can be molded or formed from plastic rather than from sheet metal. One skilled in the art will adjust the thickness of the plastic to achieve a desired strength. Similarly, any folded edges and bends desired in a metal construction can be eliminated to allow for known equivalent structures and processes when making a part out of plastic. As already mentioned, it may be beneficial to make a plastic high-loop bracket as multiple piece parts that are assembled during installation, such as by snapping or sliding parts of the high-loop bracket together.
[0043] While a preferred form of the invention has been shown and described, it will be realized that alterations and modifications may be made thereto without departing from the scope of the following claims.
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A high-loop bracket has a handle portion that allows a user to manipulate a hose support portion that supports an electric dishwasher's discharge hose into a position that easily forms a high rise loop. The high rise loop is fixed against a sink base cabinet by securing an easy to reach mount portion of the high-loop bracket. Preferably, the high-loop bracket is formed from a single sheet of stainless steel that is bent to create the various portions of the bracket.
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TECHNICAL FIELD
[0001] The present invention relates generally to vehicle-mounted auger drivers, including post hole diggers. More particularly, the invention pertains to a vehicle-mounted post hole digger which may be readily removed and re-fitted to a motorized vehicle or other piece of equipment.
BACKGROUND
[0002] The use of vehicle-mounted post hole diggers is known in the prior art. More particularly, vehicle-mounted post hole diggers previously devised and utilized are known to consist basically of many seemingly-basic structural configurations, including a plurality of designs presenting the prior art which have been developed for the fulfillment of various objects and requirements dictated by the circumstances faced by the inventors. For example, U.S. Pat. No. 4,124,081 teaches a mobile hydraulic driving machine which comprises: a) a wheeled vehicle having a frame; b) a pedestal mounted on and supported by the frame, having an upright mast; c) a sleeve rotatable on the mast; d) a lower derrick boom pivoted on the upper end of the sleeve; e) an upper derrick boom telescoped in the lower boom; f) a driving tool removably mounted on the end of the upper boom beyond the end of the lower boom; g) a means for rotating the sleeve to position the derrick boom circumferentially of the vehicle; and h) a means for extending and retracting the upper boom to space the driving tool relative to the vehicle. The driving tool has: i) an adjacent upright post with a foot adapted to rest on the ground; ii) a means for controlling the attitude of the post relative to the upper derrick boom; iii) a carriage slidable on the post; iv) a hammer guide mounted on the carriage; v) a spring-loaded anvil depending from the hammer guide; vi) a hammer slidable in the hammer guide adapted to impact against the anvil; vii) a hydraulic lift mechanism for the hammer; viii) tension springs stretched by the lift mechanism for propelling the hammer against the anvil; ix) a dump valve for the mechanism having open and closed cycles; x) a means controlling the rate of the cycles to control the stroke and impact rate of the hammer; and xi) and means for down-crowding the carriage to hold the anvil continuously against the work piece to be driven by the hammer. U.S. Pat. No. 4,869,002 provides an attachment adapted to be mounted to a vehicle for accommodating one of a plurality of tools including a digging bucket, a log splitter, a lifting arm, a post driver or an earth boring auger. The attachment comprises: a) a plurality of horizontal vehicle mounts attached by means of fasteners to the underneath of the front of the vehicle and extending forwardly from the vehicle to form a cradle for receiving a horizontal frame member; b) a horizontal frame member resting in the cradle and held in place by fasteners; c) three sets of swivel devises mounted to the horizontal frame member for receiving a boom swivel or a swing cylinder; d) a boom swivel selectively mounted in any one of the three sets of swivel devises with a swing cylinder mounted in one of the remaining sets; and e) a boom arm having one end pivoted to the boom swivel and adapted to selectively mount one of the plurality of tools. U.S. Pat. No. 4,961,471 sets forth a post hole digger comprising: a) a support base adapted to be mounted on a vehicle for a pivotal movement about a vertical axis; b) a post hole digging auger and motor assembly; c) an elongated support structure pivotally connected at one end to the support base about a horizontal axis. The auger and motor assembly are pivotally connected to the other end of the elongated support structure about a horizontal axis, and the elongated support structure is extendible or retractable to enable positioning of the auger and motor assembly at a desired location and to adjust as the auger and motor assembly lowers and penetrates the ground. The auger and motor assembly are suspended from the elongated support structure so that in a free state the auger and motor assembly is suspended substantially vertically. There is a control handle means present which is adapted to be manually gripped to guide the auger and motor assembly and resist lateral forces occurring during operation of the auger and motor assembly. U.S. Pat. No. 5,746,277 describes an auguring means comprising: a) an extendable mast means having a first mast member and a second mast member, the first mast member having an axis; b) a downcrowding means for extending the second mast member away from the first mast member and for pulling the second mast member towards the first mast member; c) a kelly assembly means having a plurality of telescoping kelly sections which include at least an outer kelly section and an inner kelly section, the outer kelly section having an axis parallel to and spaced apart from the axis of the first mast member; d) a kelly bearing means for rotatably supporting the outer kelly section and for preventing axial displacement of the outer kelly section relative to the kelly bearing means; e) a first support means for supporting the kelly bearing means, and for causing displacement of the outer kelly section along the axis thereof in response to displacement of the second mast member along the axis of, and relative to, the first mast member; f) a kelly rotating means for slidably rotating the outer kelly section about the axis thereof; and g) a second support means for supporting the first mast member and for supporting the kelly rotating means. U.S. Pat. No. 6,155,359 discloses a hole digger system, comprising: a) a spaced apart pair of adjustably extendible support braces, wherein the support braces each have a forwards end; b) an elongate base having a pair of opposite ends, wherein the base is pivotally coupled to the forwards ends of the support braces; c) a telescopic boom arm having a pair of opposite ends and a longitudinal axis extending between the ends of the boom arm, wherein a first of the ends of the boom arm are pivotally coupled to the first of the ends of the base; d) a motor, pivotally coupled to a second of the ends of the boom arm, wherein the motor has a rotating shaft outwardly extending therefrom; e) an elongate auger having opposite mounting and digging ends, wherein the mounting end of the auger are attached to the rotating shaft of the motors. The boom arm has a lowered position wherein the boom arm and the base are extended substantially parallel to one another. The base has a boom rest forwardly extending therefrom, and the boom arm is rested on the boom rest when the boom arm is positioned in the lowered position.
[0003] While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose a post hole digger that may be fitted to existing vehicles, such as pickup trucks in such a way as to be readily removable from the vehicle for storage, servicing, or placement on another vehicle. In addition, none of the prior art provides a post hole digging apparatus which enables a person owning a pickup truck to add the capability of post hole digging to their vehicle in a matter of seconds. According to the present invention, there is provided such a device, which now means that all which a person needs in order to dig a post hole at any desired location is a pickup truck, a device according to the invention, and a couple minutes of time.
[0004] In these respects, the vehicle mounted post hole digger according to the present invention substantially departs from the concepts and designs of the prior art, and provides an apparatus useful for digging post holes in the ground which can be rapidly affixed to any vehicle with a trailer hitch and driven to any desired location to deliver a hole in the ground at a selected location. In addition, a device according to the invention is readily operated by a single person, unlike prior art devices. Thus, two men with two trucks can drastically reduce the amount of time necessary to complete a job task, such as installation of a fence. Finally, the motive energy which a device according to the invention is located on-board of the device, i.e., it has its own source of motive power, as opposed to prior art devices which rely upon PTO's or other motive means.
SUMMARY OF THE INVENTION
[0005] The present invention provides a device useful for drilling holes in the earth, and it comprises a horizontal frame member having a first end portion and a second end portion. There is a vertically inclined tubing casing having a first end portion, an open second end portion, a length dimension, and a hollow interior portion, wherein the first end portion of the vertically inclined tubing casing is attached to the second end portion of the horizontal frame member. The vertically inclined tubing casing further comprises a hole disposed through it along its length, the hole having an axis, wherein the axis of the hole is substantially perpendicular to the length dimension of the vertically inclined tubing casing. There is also a vertically inclined brace portion having a first end portion, a second end portion and a length dimension, and the first end portion of the vertically inclined brace is attached to the horizontal frame member at a location between the first end portion of the horizontal frame member and the second end portion of the horizontal frame member, such that the length dimension of the vertically inclined brace portion and the length dimension of the vertically-inclined tubing casing are substantially parallel to one another. There is also an adjustable height support having a first end portion, a second end portion, a length dimension, and a length dimension axis, and the first end portion of the height support and at least a portion of the length of the height support is slidably disposed within the vertically inclined tubing casing. The height support further comprises a plurality of holes disposed through it along its length, and these holes each have an axis, and their axes are substantially perpendicular to the length dimension of the height support. There is a two-axis hinge which is hingedly connected to the second end portion of the height support, and the two-axis hinge has a degree of freedom which enables its rotational movement about the length dimension axis of the height support. There is also a substantially linear vertical guide outer member having a first end portion, an open second end portion, and a length dimension, and the first end portion of the vertical guide outer member is pivotally connected to the height support by means of the two-axis hinge such that the vertical guide outer member is given a sufficient degree of freedom to rotate rendering its second end portion capable of striking out an arc which intersects the adjustable height support at a point along the length of the height support. There is a hydraulic ram having a hydraulic oil inlet, a hydraulic oil outlet, a length dimension, a first end portion disposed at the end of its stationary portion, and a second end portion disposed at the end of its moveable portion, and the hydraulic ram is attached to the vertical guide outer member such that the length dimension of the hydraulic ram and the length dimension of the vertical guide outer member are substantially parallel to one another. There is a substantially linear vertical guide inner member having a first end portion, a second end portion and a length dimension, and at least a portion of the first end portion of the vertical guide inner member is slidably disposed within the vertical guide outer member. The invention further includes a drilling head attached to the second end portion of the hydraulic ram and the second end portion of the vertical guide inner member, and an engine having an output shaft, wherein the engine is mounted to at least one of the horizontal frame member, the vertically inclined tube casing, or the vertically inclined brace portion. There is a hydraulic pump having an input shaft, and the input shaft of the hydraulic pump is in effective mechanical communication with the output shaft of the engine. The invention further includes a hydraulic oil reservoir, and a means for providing hydraulic fluid under pressure from the hydraulic pump to the hydraulic ram.
[0006] According to one embodiment, the drilling head comprises: i) a top plate portion; ii) a bottom plate portion having a first hole and a second hole disposed through it; iii) a hydraulic motor having a drive shaft, wherein the hydraulic motor is mounted to the bottom plate portion such that the drive shaft passes through the first hole in the bottom plate portion; iv) a first sprocket disposed on the drive shaft; v) a drilling shaft having a first end portion and a second end portion, the first end portion of the drilling shaft having a second sprocket disposed thereon, the drilling shaft being mounted through the second hole in the bottom plate portion by means of a bearing; vi) a motion communicator, selected from the group consisting of: chains and belts, in contact with each of the first sprocket and the second sprocket; vii) an auger bit having a length dimension, attached to the second end portion of the drilling drive shaft such that the length dimension of the auger bit is substantially parallel to the length dimension of the vertical guide inner member; and viii) means for providing hydraulic fluid under pressure from the hydraulic pump to the hydraulic motor. Preferably, the means for providing hydraulic fluid under pressure from the hydraulic pump to the hydraulic motor comprises a hydraulic conduit disposed between the outlet of said hydraulic pump and the inlet of said hydraulic motor. Preferably, this hydraulic conduit includes a valve means disposed along its length for selectively controlling the flow of hydraulic fluid. In addition, it is preferred that there is a hydraulic conduit for transferring hydraulic oil under low pressure from the outlet of the hydraulic motor to the reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the annexed drawings:
[0008] FIG. 1 shows a side perspective view of a device according to a preferred form of the invention in its extended, ready-for-use position;
[0009] FIG. 2 shows a perspective view of the drilling head portion of a device according to a preferred form of the invention;
[0010] FIG. 3 shows a side perspective view of a device according to a preferred form of the invention when in its collapsed configuration, ready for transportation or storage; and
[0011] FIG. 1 shows a side perspective view of a device according to a preferred form of the invention, in its extended, ready-for-use position, including hydraulic lines and attached to a pickup truck.
DETAILED DESCRIPTION
[0012] Referring to the drawings and initially to FIG. 1 there is shown a side perspective view of a quick detach vehicle-mounted auger driver 10 according to a preferred form of the invention. The auger driver 10 includes a horizontal frame member 5 , which is preferably comprised of a square tubing construction that is adapted to be inserted into the square hole trailer hitch which is common on motorized vehicles and is adapted to receive square trailer hitches, as is well known in the art. There is a vertically inclined tubing casing 3 which is attached to one of the end portions of the vertically inclined tubing casing such that the vertically inclined tubing casing intersects the horizontal frame member 5 at an angle, which is preferably any angle between about 90 degrees and 45 degrees, with an angle of about 75 degrees being most preferred. The vertically inclined tubing casing includes a hole 15 disposed through its side walls, and preferably comprises a hollow interior portion, which is adapted to receive an adjustable height support 11 in a slidingly telescoping fashion. Thus, the adjustable height support 11 is able to be moved in an out of the vertically inclined tubing casing. The adjustable height support includes a plurality of holes 13 along its sides which are disposed completely through the adjustable height support 11 . These holes 13 pass by the hole 15 in the vertically inclined tubing casing as the adjustable height support 11 is moved in or out of the vertically inclined tubing casing 3 , thus providing a means by which the adjustable height support 11 may be secured in a fixed position desired by the user of the device with respect to the vertically inclined tubing casing 3 by securing a pin through the hole 15 when the hole of the vertically inclined tubing casing is aligned with one of the holes in the adjustable height support.
[0013] There is a vertically inclined brace 31 which has two end portions, wherein one of its end portions is attached to the horizontal frame member 5 at a location between the two end portions of the horizontal frame member. The other end portion of the vertically inclined brace 31 is attached to a brace plate 33 which itself is also attached to the vertically inclined tubing casing 3 , to provide strength of the construction as a whole.
[0014] An oil reservoir 9 is attached to any of the basic frame members of a device according to the invention, the vertically inclined brace portion 31 , the brace plate 33 , or the vertically inclined tubing casing 3 , such as by welding. In fact, it is preferred that all of the structural members and other components of a device according to the invention are comprised of steel or any other metal known in the art, and all attachments are made by welding. However, the use of conventional fasteners is also useful, as one of ordinary skill will recognize after reading this specification and the appended claims. To aid the person in the art constructing a device according to the invention, brackets may be used, when deemed desirable or convenient for attaching the various components of the invention to one another, as the use of brackets are well-known in the art. The oil reservoir 9 is preferably attached to the vertically inclined tubing casing 3 , by welding. The purpose of the oil reservoir 9 is to contain the hydraulic fluid which is used to convey the forces required for the instant invention to be operated.
[0015] There is also an engine 7 which is responsible for providing all of the energy which drives the device 10 according to the invention, rendering it capable of being deemed as a self-powered device, unlike the devices of the prior art which rely in general on power supplied by the vehicle to which they are attached. The engine 7 may be a gasoline engine (either 2 cycle or 4-cycle), a diesel engine, or an electric engine, but is most preferably a gasoline engine having a horsepower rating of about 5 horsepower. The engine 7 is preferably attached to the device by welding either to the horizontal frame member 5 or the vertically inclined tubing casing 3 . In an alternate embodiment, the engine is attached to two angle iron brackets which are welded perpendicular to the frame member 5 , and the engine is bolted to these angle brackets. There is a hydraulic pump 35 , which is in effective mechanical contact with the output shaft of the engine 7 so as to provide hydraulic oil under pressure, which is used to operate the hydraulic ram and hydraulic motor, as elsewhere described herein, through the use of hydraulic valves 17 , which are used to selectively operate a fluid powered component device of the invention.
[0016] As described above, the adjustable height support 11 has two end portions, with one of its end portions being disposed in the interior of the vertically inclined tubing casing 3 . The other end portion of the adjustable height support is equipped with a two-axis hinge 19 . The two-axis hinge 19 is attached to the outer surface of the adjustable height support 11 in such fashion as to enable rotation of the entire two-axis hinge as a whole about the adjustable height support 11 in the direction indicated by the arrow surrounding the z-axis in FIG. 1 . The two-axis hinge 19 also includes a yoke sub element 20 , which is pivotally connected to one of the end portions of a vertical guide outer member 23 by means of a pin P which pin P is disposed through both forks of the yoke 20 and through the vertical guide outer member 23 , so as to enable the vertical guide outer member 23 to move in a swinging motion whose general direction is indicated by the arrow in FIG. 1 which is disposed about the pin P. The vertical guide outer member 23 is of hollow tubular construction, and its end portion which is not connected to the two-axis hinge 19 is an open end, which is adapted to receive a first end portion of vertical guide inner member 25 in a sliding arrangement. The other (second) end of the vertical guide inner member 25 is attached to the drilling head, which is described in greater detail below.
[0017] Also attached to the two-axis hinge 19 by means of a bracket 21 is the end portion of the stationary section 27 of a hydraulic ram, which hydraulic ram hangs vertically and in substantial parallel orientation with respect to the vertical guide outer member 23 and vertical guide inner member 25 when the device 10 of the invention is in use. The hydraulic ram has a moveable portion 85 whose free end is attached to the drilling head, which is also described in greater detail below.
[0018] The drilling head includes a hydraulic motor 43 , which is powered by hydraulic fluid caused to be under pressure from the operation of the engine 7 . The hydraulic motor 43 includes a first sprocket disposed on its output shaft, which is coupled to a second sprocket 49 that is disposed on the end of a boring drive shaft 83 by means of a motive communicator, which is preferably a drive chain 45 . The boring drive shaft is mounted by means of a bearing 59 . The drilling head also preferably comprises a tang 39 , which is adapted to be received by a loop of metal 37 disposed on the vertically inclined tubing casing 3 during storage and transportation of a device according to the invention, so as to preclude rotation of the vertical guide outer member 23 and hydraulic ram about the z-axis during transportation and/or storage.
[0019] While the components of the invention which are cooperatively connected in a sliding arrangement (the vertically inclined tubing casing 3 , the adjustable height support 11 , the vertical guide outer member 23 and the vertical guide inner member 25 ) are preferably comprised of tubing which is square-shaped in cross section, any cross sectional geometry which accomplishes this same result is functionally equivalent for purposes of the present invention, including without limitation, round tubings, oval tubings, triangular tubings, etc. The main requisite of the materials of construction chosen from which to fabricate these elements is structural strength, as the device as a whole is subjected to significant stresses during the boring of a hole in the earth, and for this reason it is preferred that these elements be comprised of steel tubing. In addition, steel tubing lends itself well to attachment by welding.
[0020] FIG. 2 shows the drilling head used in accordance with a preferred form of the invention. In this figure, it can be seen that the drilling head includes a top plate portion 61 , to which the ends of the vertical guide outer member 25 and moveable portion 85 of the hydraulic ram are attached. There is also a bottom plate portion 63 , which is attached to the top plate 61 by means of brackets 91 and 93 , which are either welded or bolted to one another. The bottom plate portion 63 includes hydraulic motor 43 attached to the bottom plate and having its drive shaft pass through a hole in the bottom plate by means of a bearing 57 . Fluid under pressure is supplied to the hydraulic motor by means of hydraulic lines 53 . The drive shaft 55 of the hydraulic motor 43 has a first sprocket disposed on its end portion. There is also a boring drive shaft 83 mounted through another hole in the bottom plate portion 63 by means of a bearing 59 , and at one end of the boring drive shaft is disposed a second sprocket 49 . The first sprocket are caused to be in effective mechanical contact with one another by means of a motion communicator 67 , which is preferably a drive chain ( 45 in FIG. 1 ). The other end of the boring drive shaft 83 is connected to an auger, which is rotated with sufficient motive energy to drill a hole in the ground by virtue of energy conveyed to the drive shaft from the hydraulic motor 43 by the motion communicator 67 . The drilling head preferably includes a tang portion 39 , which is rectangular in its frontal view in one preferred form of the invention, and is thus well adapted to be received by the tang slot 37 on the vertically inclined tubing casing 3 when the device 10 is being stored or transported as is more clearly shown in FIG. 3 .
[0021] FIG. 3 shows a device 10 according to the invention in its collapsed form, such as while being transported or stored. In this configuration, the vertical guide inner member 25 is seen to be recessed in the vertical guide outer member 23 , and the hydraulic ram moveable portion 85 is recessed within the hydraulic ram stationary portion 27 , which compacts the device 10 considerably as opposed to when the device is in hole-drilling mode. The tang portion 39 is disposed within the tang slot 37 , which prevents the vertical guide outer member 23 and hydraulic ram from rotating about the z-axis ( FIG. 1 ) and swinging from side to side during movement of the truck 100 ( FIG. 4 ) to which such a device 10 is attached, such as between job locations. In this FIG. 3 are shown the various elements of a device according to the invention in their respective positions, including the horizontal frame member 5 , vertically inclined tubing casing 3 , hydraulic pump 35 , engine 7 , vertically inclined brace 31 , brace plate 33 , hydraulic oil tank 9 , hydraulic valves 17 , adjustable height support 11 , two-axis hinge 19 , vertical guide outer member 23 , brace 21 , hydraulic ram stationary portion 27 , hydraulic lines 53 , and hydraulic motor 43 .
[0022] FIG. 4 shows a side view of a device according to the invention in its normal configuration when being used to drill a hole in the ground, including the hydraulic lines which were omitted from FIG. 1 for purposes of clarity. In this FIG. 4 are shown the various elements of a device according to the invention in their respective positions, including the horizontal frame member 5 , vertically inclined tubing casing 3 , hydraulic pump 35 , engine 7 , vertically inclined brace 31 , brace plate 33 , hydraulic oil tank 9 , hydraulic valves 17 , adjustable height support 11 , holes 13 , hole 15 , two-axis hinge 19 , vertical guide outer member 23 , vertical guide inner member 25 , brace 21 , hydraulic ram stationary portion 27 , hydraulic ram moveable portion 85 , hydraulic lines 53 , hydraulic motor 43 , auger 41 , and motorized vehicle 100 , which is a pickup truck.
[0023] As previously described, a device according to the invention includes two devices which are powered by hydraulic fluid under pressure, which are the hydraulic motor 43 and the hydraulic ram, having a stationary portion 27 and a moveable portion 85 as its sub-components, as is well known in the art. Each of these devices which are powered by hydraulicfluid have a fluid inlet portion and a fluid outlet portion. Each of the fluid inlet portions of these fluid operated devices are in effective fluid contact with the high pressure side of the hydraulic pump 35 through means of the various hydraulic lines 53 , which high pressure lines have a control valve disposed between the hydraulic pump high pressure side and the fluid inlet on the fluid-driven devices, to enable selective control of these devices by the operator. The fluid outlets of each of the fluid-driven devices are routed back to the oil reservoir 9 , whose bottom portion is fitted with an outlet ( 16 in FIG. 1 ) from which the hydraulic pump 35 is fed.
[0024] To use a device according to the present invention which is attached to a pickup truck and in its collapsed position as shown in FIG. 3 , the operator starts the engine 7 , and pulls the pin out from the hole 15 , thus freeing the adjustable height support 11 to move within the vertically inclined tubing casing. Fluid under pressure is caused to enter the hydraulic ram, thus pushing the stationary portion 27 of the hydraulic ram, the vertical guide outer member 23 , and the adjustable height support 11 upwards, since the tang 39 is engaged in the tang slot 37 . Thus it is seen that the tang 39 and tang slot 37 serve a dual purpose of keeping the assembly as a whole stable during storage and transportation, and also as an anchor for the drilling head to be held stationary whilst the above-mentioned components are caused to move upwards at the onset of the procedure for using a device 10 according to the invention. Once the stationary portion 27 of the hydraulic ram, the vertical guide outer member 23 , and the adjustable height support 11 have been moved upwards sufficiently to place them in their desired position for operation of the device, the pin is placed back in the hole 15 to render the adjustable height support 11 to once again be in rigid contact with the vertically inclined tubing casing 3 . Next, the flow of hydraulic fluid to the hydraulic ram is reversed, which causes the tang 39 of the drilling head to be lifted out of the tang slot 37 , thus freeing the drilling head from its former stored position abutting the vertically inclined tubing casing 3 . Under the influence of gravity, the drilling head then swings out into the position shown in FIG. 1 and FIG. 4 . Next, the drill auger 41 is installed on the boring drive shaft 83 and pressure is applied to the hydraulic ram to cause the auger 41 to contact the earth, and the hydraulic motor 43 is activated, thus causing a hole to be drilled in the ground by virtue of a constant downward force applied by the hydraulic ram and the spiraling motion of the auger 41 . Once the desired depth of hole has been achieved, the auger 41 is retracted by actuation of the hydraulic ram, and the pickup truck to which the device is attached is driven to the site of the next desired hole.
[0025] On shutdown, the drilling auger 41 is removed, and the drilling head is swung until the tang 39 is disposed above the tang slot 37 , at which time the ram is actuated sufficiently to enable the tang to completely enter the slot. Then the pin is removed from the hole 15 and the adjustable height support 11 is returned to its stowed position as shown in FIG. 3 , and the pin replaced into hole 15 .
[0026] Consideration must be given to the fact that although this invention has been described and disclosed in relation to certain preferred embodiments, obvious equivalent modifications and alterations thereof will become apparent to one of ordinary skill in this art upon reading and understanding this specification and the claims appended hereto. Accordingly, the presently disclosed invention is intended to cover all such modifications and alterations, and is limited only by the scope of the claims that follow.
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The present invention provides a device useful for boring holes into the earth, and is especially useful for drilling holes in which fence posts are to be placed. A device according to the invention is completely self-powered, having its own on-board engine which supplies all of the power necessary for the boring operation and other movements of the device associated therewith. A device according to the invention is readily removable from and attachable to a motorized vehicle equipped with a trailer hitch, and is adapted to configure itself in a retracted position for ease in storage and transportation.
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FIELD OF THE INVENTION
This invention relates to the field of fenestration including the mounting of doors, windows, skylights, and the like in building walls, ceilings and the like, and more particularly to a jamb mounting assembly that reduces the amount of labor, time and materials needed for installation of a jamb.
BACKGROUND OF THE INVENTION
Conventional methods for installing a door jamb, window jamb or the like in a building wall or roof have generally involved positioning the jamb in a rough opening and filling the gaps between framing members of the opening and the jamb with wood shims. Properly trimming and installing the shims between the jamb and the frame defining the opening requires a considerable amount of time, skill and effort to properly fit the jamb in the opening so that the jamb is plumb. After the shims have been properly positioned, nails are driven through the jamb and the shims into the supporting framing members defining the opening. Thereafter, protruding pieces of the shims, if any, are cut flush with the edge of the jamb.
It is of course desirable to eliminate the use of shims and to simplify jamb installation. To this end, numerous efforts have been directed toward simplified, shimless jamb mounting systems. While many of these systems have very substantially reduced the amount of time and effort needed to install a jamb in a building panel structure, such as a wall or roof, further improvements are desirable. In particular, it would be desirable to reduce the number of fasteners needed for jamb installation and to provide simpler, easier to manufacture and less expensive jamb mounting brackets, and to provide a jamb mounting assembly that may be at least partially pre-installed on the jamb prior to shipment from the factory.
SUMMARY OF THE INVENTION
In one aspect of the invention, a building fenestration is provided which includes a jamb positioned in an opening defined by a building panel structure, at least one bracket receiving slot on an outwardly facing planar surface of the jamb, and a bracket having first and second legs at a right angle to each other, the first leg of the bracket received in the bracket receiving slot and the second leg of the bracket fastened to the building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate defined on or attached to the jamb. In accordance with this aspect of the invention, the jamb may be mounted in a building panel opening by positioning the jamb in the opening with one or more bracket receiving slots pre-defined or installed on outwardly facing planar surfaces of the jamb, the jamb being positioned so that it is plumb with the opening, inserting the first leg of the bracket into the bracket receiving slot and fastening the second leg of the bracket to the building panel structure.
In accordance with another aspect of the invention, there is provided a jamb mounting assembly comprising a jamb having planar outwardly facing peripheral surfaces; a bracket receiving slot on at least one of the planar outwardly facing peripheral surfaces of the jamb; and a bracket having first and second legs at a right angle to each other, the first leg of the bracket configured to be received in the bracket receiving slot and the second leg of the bracket configured for attachment to a building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate. In accordance with this aspect of the invention, installation is further simplified by providing a jamb having premounted or pre-defined bracket receiving slots, whereby installation of the jamb may be achieved by steps generally involving positioning of the jamb in an opening defined in a building panel structure, the jamb being positioned plumb with the opening, inserting the first leg of a panel bracket into each of the bracket receiving slots and fastening the second leg of each bracket to the building panel structure.
In accordance with another aspect of the invention, there is provided a jamb mounting assembly comprising a substantially flat plate adapted to be fastened to a planar outwardly facing peripheral surface of a jamb to define a bracket receiving slot, and a bracket having first and second legs at a right angle to each other, the first leg of the bracket configured to be received in the bracket receiving slot, and the second leg of the bracket configured for attachment to a building panel structure. The jamb mounting assembly in accordance with this aspect of the invention may be used on generally any jamb having planar outwardly facing peripheral surfaces.
In another aspect of the invention, there is provided a bracket for mounting a jamb to a wall with or without a bracket receiving slot. The bracket includes first and second legs at a right angle to each other and tangs projecting at a right angle from one of the legs to facilitate fastening of the bracket to the jamb.
In a further aspect of the invention, there is provided another bracket for mounting a jamb to a wall with or without a bracket receiving slot. This bracket includes first and second legs at a right angle to each other and tabs projecting at a right angle from one of the legs to facilitate fastening of the bracket to the jamb.
These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a rough opening in a building wall that is about to receive a door jamb.
FIG. 2 is an enlarged fragmentary perspective view of the door jamb shown in FIG. 1 to illustrate certain details.
FIG. 3 is a fragmentary, side view of the door jamb shown in FIG. 2 .
FIG. 4 is a perspective view of a bracket for securing a jamb in a rough opening.
FIG. 5 is a fragmentary, front elevational view of a jamb installed in a rough opening employing the bracket shown in FIG. 4 .
FIG. 6 is a fragmentary side view of an alternative embodiment of a jamb having an integrally formed bracket receiving slot.
FIG. 7 is a perspective view of an alternative bracket for securing a jamb in a rough opening.
FIG. 8 is a fragmentary perspective view of the bracket shown in FIG. 7 being used to secure a jamb in a rough opening.
FIG. 9 is a fragmentary perspective view of another alternative bracket being used to secure a jamb in a rough opening.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Shown in FIG. 1 is a rough opening 10 in a wall structure 12 formed by studs 14 , and header 16 supported by liner members 18 . Wall structure 12 may be covered with drywall panels 20 or the like to provide a finished wall, either before or after installation of jamb 22 in accordance with the invention.
The jamb mounting assemblies of this invention may be used for generally any type of building fenestration, including doors, windows, skylights and the like. In general, such fenestrations may be provided in accordance with this invention in various building panel structures, including exterior and interior wall structures, and roof structures.
As shown in greater detail in FIG. 2 , outwardly facing peripheral surfaces 23 of jamb 22 are provided with panel bracket receiving slots 26 . As shown in FIGS. 2 and 3 , panel bracket receiving slot 26 may be defined between one of the outwardly facing planar surfaces 23 of jamb 22 and a substantially flat plate 28 . The expression “substantially flat” as used to describe plate 28 is meant to encompass the fact that plate 28 is formed or bent slightly to allow flush mounting of opposite ends 30 and 31 of plate 28 to surface 23 of jamb 22 while allowing a sufficient gap between the ends of plate 28 to define a slot 26 into which a leg of a bracket may be received. Alternatively, as shown in FIG. 6 , plate 28 A can be formed as an integral section of the material used to fabricate jamb 22 . This may be achieved such as by cutting and stamping operations. Thus, bracket receiving slot 26 may be defined by pre-installed plates 28 fastened to surface 23 of jamb 22 with fasteners 32 , 34 (screws, rivets or the like) by the jamb manufacturer; attached by the jamb installer; or integrally pre-formed on jamb 22 .
After installation, pre-installation or integral forming of bracket receiving slots 26 on jamb 22 , jamb 22 is positioned in plumb in opening 10 . Thereafter, a bracket 34 is used to secure jamb 22 in plumb in rough opening 10 . Bracket 34 includes a first leg 36 and a second leg 38 which is at a right angle to leg 36 . A forward edge 40 of first leg 36 is inserted into bracket receiving slot 26 until second leg 38 is flush against finish panels 20 (e.g., drywall or the like) or flush against liner 18 or stud 14 . Thereafter, each bracket 34 may be secured to the building panel structure (e.g., wall structure or ceiling structure) with a single fastener (such as a screw or nail). However, bracket 34 may be configured for attachment with multiple fasteners if desired. In the illustrated embodiment, a single fastener aperture 42 is provided through second leg 38 of bracket 34 .
In those cases in which bracket 34 is attached directly to studs 14 or liner member 18 , drywall or other finish wall material 20 may be subsequently installed over bracket 34 . In the case where bracket 34 is installed over drywall or other finish wall material 20 , exposed surfaces of leg 38 of bracket 34 may be primed, covered with spackle or the like to facilitate application of paint, wallpaper or the like. Thus, the invention facilitates installation of a door or window jamb in a wall or installation of a skylight in a roof generally any time after framing of the walls or roof have been completed. After jamb 22 and finish wall material 20 have been installed, various trim options may be employed to cover the gap between jamb 22 and the wall and to conceal brackets 34 . If desired, insulation (such as foam or glass fiber) may be inserted into the gap between jamb 22 and the wall prior to adding the finish trim.
As can be seen by reference to FIG. 2 , flat plate 28 can be located entirely between corners 41 and 42 of the outwardly facing planar surface 23 of jamb 22 . This arrangement allows exceptional flexibility with respect to the use of exposed trim for concealing the gap between rough opening 10 and surfaces 23 of jamb 22 . Further, because plate 28 is substantially flat and/or is located entirely between the edges of the outwardly facing planar surfaces 23 of jamb 22 , pre-installed plates 28 have a very low profile that should not interfere with or require modification to packaging materials or shipping procedures for pre-hung doors, pre-hung windows and the like.
In the illustrated embodiment, the details of which are shown in FIG. 2 , flat plate 28 includes a tab 48 which projects from a lateral edge of flat plate 28 and which extends through an aperture 50 defined in leg 38 of bracket 34 ( FIG. 4 ) when leg 36 of bracket 34 is inserted into slot 26 . As shown in FIG. 5 , tab 48 may optionally be bent at a right angle flush with the exposed surface of leg 38 or bracket 34 .
As shown in FIG. 4 , leg 38 of bracket 34 may be provided with one or more scribe lines 49 that may be aligned with a plumb line 51 ( FIG. 5 ) drawn on the wall, liner 18 , stud 14 or the like.
Leading edge 40 of leg 36 of bracket 34 may have a tapered shape that becomes progressively narrower away from second leg 38 , and may be curved to facilitate easier insertion of leg 36 of bracket 34 into slot 26 .
FIG. 7 shows an alternative bracket 53 having a first leg 36 and a second leg 38 , in which tangs 52 are provided. Tangs 52 project at a right angle from second leg 38 along a plane parallel to first leg 36 in the direction of leg 36 , and have sharp or pointed ends 54 that allow bracket 53 to penetrate an edge 56 of jamb 22 as shown in FIG. 8 to firmly secure bracket 53 to jamb 22 . Bracket 53 is otherwise generally similar to and used in a similar way to bracket 34 . However, bracket 53 may be used either with or without plate 28 or 28 A.
FIG. 9 shows another alternative bracket 60 having a first leg 36 and a second leg 38 , in which fastener tabs 62 are provided. Tabs 62 projects at a right angle from second leg 38 along a plane parallel to first leg 36 in a direction opposite leg 36 . Tabs 62 may be provided for firmly securing bracket 60 to outwardly facing planar surface 23 of jamb 22 . Bracket 60 is otherwise generally similar to and used in a similar way to bracket 34 . However, bracket 60 may be used either with or without plate 28 or 28 A, and is normally used before wall covering 20 is installed.
The various aspects of this invention provide a simple, fast, effective way to secure jambs to building panel structures such as wall structures and roof structures. In accordance with certain aspects of the invention, installation is further simplified by integrally forming or factory installing structure to define a bracket receiving slot, whereby after the jamb has been properly positioned in a rough opening, installation is completed by simply sliding a bracket into each of the bracket receiving slots provided and fastening each bracket to the building panel structure. The invention may be used with either new construction or during remodeling or renovation, and with or without finish material (e.g., drywall) applied to the building panel structure. Because the structure defining the bracket receiving slot is separate from the brackets until installation is nearly complete, bracket 34 is self-adjusting to various wall thicknesses with or without finish material applied to the building panel structure. For a typical installation, only one screw per bracket is needed. Thus, for a typical pre-hung door jamb installation, after proper positioning of the door and door jamb in a rough opening, installation is completed by merely inserting a bracket into each of the seven bracket receiving slots, and securing each of the brackets to the wall structure, such as with a single fastener (e.g., a screw).
Another advantage with the substantially flat configuration of plate 28 or 28 A is that it is very inexpensive, and therefore can be pre-installed or pre-formed on every jamb shipped from a manufacturer without interfering with an installer's ability to either employ brackets 34 as disclosed herein or to employ conventional installation methods if desired. In accordance with this aspect of the invention, incorporating pre-formed or pre-installed plates 28 or 28 A, manufacturers are provided with control over where and how often attachment of a jamb takes place, allowing positioning and placement of the jamb bracket to be controlled by the manufacturer. Because of the very simple, low profile and compact design of the structure ( 28 or 28 A) defining the bracket receiving slots 26 , structure 28 or 28 A does not interfere with or require any modification of typical shipping and delivery methods that are currently employed. The invention allows full insulation of the cavity defined between a jamb and a building panel structure because attachment of the jamb may be achieved by securement of brackets 34 to the interior side of an exterior wall. This allows the cavity to be filled, usually from the inside, with fiberglass or foam insulation to increase energy efficiency of the installation as whole, making the total unit more energy efficient in the completed fenestration. Because the installation is very simple and self-adjusting, poor workmanship issues are eliminated or very substantially reduced, decreasing warranty issues.
The above description is considered that of the preferred embodiment(s) only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment(s) shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.
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A building fenestration that reduces the amount of time, effort and expense associated with installing a jamb in a rough opening of a building panel structure includes a jamb positioned plumb in the opening, the jamb having outwardly facing planar surfaces, at least one bracket receiving slot on at least one of the outwardly facing planar surfaces of the jamb, and a bracket having first and second legs at right angles to each other, the first leg of the bracket received in the bracket receiving slot and the second leg of the bracket fastened to the building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate.
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BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] The present invention relates generally to clips and hanger devices for attachment to suspended ceilings. More particularly, the present invention relates to resilient, plastic clips designed to be snap-fitted to suspended ceiling rails for supporting miscellaneous objects, and it relates to a method and apparatus for installing such clips. Pertinent prior art clips germane to the invention can be found in United States Patent Class 248, Subclasses 228.1, 228.3, 228.4, 228.7, 317, 318, 339 and 340.
[0003] II. Description of the Prior Art
[0004] Suspended ceilings are in widespread use, particularly in commercial environments including retail stores, business offices and the like. Typical suspended ceilings comprise an elevated array of grid-like, metal support rails that are suspended from adjacent ceiling structure. Typical ceiling support rails have an inverted, “T-shaped” vertical cross section. They comprise a planar, perpendicular portion disposed vertically with respect to ground, and an integral, horizontal flange portion forming the bottom. Typical suspended ceilings comprise multiple panels or ceiling tiles that are captivated between and supported upon the adjacent, spaced apart rails forming the superstructure. Some of the tiles or ceiling panels may mount various air-conditioning vents or louvers. Usually a plurality of light fixtures also supported by the rails are interspersed between various tiles. The tiles and light fixtures rest upon the horizontal “flanges” on the supporting rails, and they are horizontally restrained by abutment with the integral vertical portions. The mutually orthogonal edges of the spaced apart support rails form a regular, grid-like pattern, visually dividing the suspended ceiling into a plurality of rectangles or squares.
[0005] In many retail sales establishments, such as discount stores, grocery stores and the like, it is advantageous to prominently display various signs, flags, banners, advertisements, markers, placards, or the like. Frequently, diverse ornamental or utilitarian items such as toys, novelty displays, mobiles, stuffed animals, or Christmas decorations are also mounted to the ceiling structure for maximum visibility. In addition, flower pots or baskets are commonly suspended for aesthetic purposes. Items that are mounted as high as possible are more likely to be readily observed by customers. Obviously, mounting from the ceiling maximizes potential visibility. Another advantage with ceiling mounting is that the suspended item is positioned out-of-the way, and inadvertent or unwanted physical human contact is avoided.
[0006] A variety of hanging devices have been previously proposed for suspending various items from ceiling structures. Items are typically suspended from ceilings with easily releasable fasteners using magnets or quick-installing clips. Typical prior art clips usually comprise some form of jaw structure or engaging the horizontal flange portion of the metal rails.
[0007] For example, U.S. Pat. No. 3,743,228, comprises a hanger clip for suspended ceilings that has a pair of spring biased jaws. The jaws are normally biased together by a coiled spring. Each jaw has a horizontal portion that grasps the ceiling rail, and when manually deflected apart they can be forced into a captivating position to attach themselves to a rail. Various items may thus be hung from a ceiling with the clip. However, manual installation and removal are required, usually with the use of ladder. This can be time-consuming and dangerous for the workman. In addition, this clip comprises several working parts that complicate the design and increase its cost.
[0008] U.S. Pat. No. 6,027,091 comprises an integral, extruded clip that similarly comprises a pair of oppositely disposed, jaw-like channels. Installation is preceded by manually compressing the clip, to leverage the channels apart. Upon release, they retract to grab and thus captivate the ceiling rail flange.
[0009] U.S. Pat. No. 4,223,488 discloses a metal hanger with an integral, U-shaped end portion that initially grabs a portion of the ceiling rail. A separate retaining clip is required for completing installation. The clip fastens to the opposite side of the hanger, in engagement with the exposed edge of the ceiling rail.
[0010] U.S. Pat. No. 4,221,355 discloses a metal clip with a central body forming a center. A pair of integral flanges are radially spaced-apart relative to the center. The flanges are adapted to be rotated into a grasping position, whereby edge portions of a suspended ceiling rail are captivated by the clip flanges. The design necessitates a number of separate fasteners.
[0011] U.S. Pat. No. 4,323,215 provides a clip that is functionally similar to that described in U.S. Pat. No. 4,221,355 discussed above. A pair of radially spaced-apart flanges on opposite edges of the clip body are rotated into a captivating, gripping position upon installation.
[0012] U.S. Pat. No. 4,315,611 comprises a ceiling hanger with a central metal plate equipped with integral, cooperating flanges. The spaced-apart flanges snap into engagement across the ceiling rail.
[0013] U.S. Pat. No. 4,065,090 shows a resilient plastic clip that may be snap-fitted to a rail. The resilient walls of the generally V-shaped structure are deformable. They are integral with an apertured body from which a variety of items may be suspended.
[0014] U.S. Pat. No. 3,952,985 comprises a metallic hanger clip having a single edge portion that is frictionally forced into contact with the horizontal flange of a ceiling rail. An integral bent portion of the clip stabilizes the arrangement by frictional contact with the exposed underside of the ceiling rail.
[0015] Other diverse clips of possible relevance are seen in U.S. Utility Pat. Nos. 3,463,432, 3,561,718, 3,936,913, 4,073,458, 4,041,668, 5,490,651, and 5,806,823. Design patents D289,251 and D364,799 also disclose analogous ceiling attachment clips.
[0016] Prior art ceiling clips are deficient for several reasons. Prior art metal versions comprising compound parts are simply too expensive. Many clips fail to adequately grasp the ceiling rail. Some ceiling clips can twist or drop off if item being supported by the clip is bumped or twisted. Many clips are difficult to install, and some require special tools. In addition, it is often difficult and time-consuming to install or remove known suspended ceiling clips. Installation difficulties are further compounded when installing clips in congested areas.
[0017] Installation often requires the use of ladders, scaffolding, or power lifts that can elevate at least one workman into an accessible position. Successful, timely installation projects often requires several workmen. Often stepladders or ladders have to be used while one person holds the sign and the other person attaches wires or hangers to an overhead support. Also, to avoid customers inconvenience, signs or displays are often installed or removed when the store is closed for business, thereby increasing labor costs. Not surprisingly, hand tools with elongated handles that facilitate installation from the ground or floor have previously been developed.
[0018] For example, U.S. Pat. No. 5,247,725 discloses an elongated, pliers-like tool that can compress and elevate a ceiling clip for installation. The handles may be compressed manually, or a draw string may be deployed in hard-to-reach situations.
[0019] U.S. Pat. No. 5,632,519 discloses a retractable pole for attaching items to previously-installed ceiling clips. It can be telescoped between elongated deployed positions and retracted, storage orientations.
[0020] Similar elongated tools for mounting ceiling clips or items to be suspend from such clips are seen in U.S. Pat. Nos. 4,135,692, 5,052,733, 5,188,332, 5,267,764, 5,938,255, 6,048,010,
[0021] Known installation tools have several disadvantages. Conventional tools are cumbersome and complex. They require substantial manual dexterity and hand-eye coordination. For example, the tool disclosed in U.S. Pat. No. 5,188,332 has pivoting jaws which require substantial force. This makes it difficult to grab or release an object at the same time the jaws are being operated. Further, prior art tools are often incomplete, in that the installer-user must have a set of hand tools in addition to the clip-installation tool for successful use and installation.
[0022] Thus a rapidly deployable clip that can be easily and safely installed from the ground by a single person would be highly desirable. Such a clip must be inexpensive and lightweight, and at the same time, strong and dependable. Further, would be advantageous to avoid complex metallic tools with compound parts. A resilient plastic clip that accomplishes these goals, and a apparatus and a method for installing such a clip are proposed. SUMMARY OF THE INVENTION
[0023] Our invention comprises a unique system for hanging diverse objects from conventional suspended ceilings. Resilient, injection-molded plastic clips described herein are adapted to be snap-fitted to the conventional, exposed rails in a typical suspended ceiling. Installation is conveniently done from the ground, without ladders or lifting equipment. A new barrel-like installation tool releasably captivates our clips, and holds them in a convenient installation position. The barrel tool threadably couples to conventional wooden poles and handles with ACME threads, so the assembly can be easily elevated into position adjacent a ceiling rail. Once the hook to be installed is appropriately positioned, it may be snap-fitted to the rail by pushing the pole. When the hook engages the ceiling rail, the pole and the barrel tool may be conveniently withdrawn, and the clip slides out of the tool.
[0024] We have proposed a pair of clips, one of which is J-shaped, and the other of which is U-shaped. Each of our new clips comprises a resilient plastic body comprising an upper clasp, an integral, lower hook portion for hanging an item from the ceiling, and an integral, midportion connecting the clasp and the hook. Each hook comprises a pair of halves that are resiliently coupled together.
[0025] The hook clasps comprise a opposed jaws that may be yieldably deflected apart during installation. Each generally C-shaped jaw comprises opposed, upper flanges that forcibly grip the ceiling rails. When pushed towards the ceiling rails the jaws snap apart and surmount the horizontal rail portion. When released, the jaws retract, with their flanges firmly gripping the rail.
[0026] The clip midportions are specially configured to engage the barrel-like installation tool. The preferred installation tool comprises a generally cylindrical body resembling a barrel. A pair of special receptacles formed on the body. The body comprises an internal, threaded bore having ACME threads adapted to be mated to the installation pole. Each clip midportion comprises a flat, gradually narrowing, trapezoidal section that is adapted to be inserted within a special gap in the tool's special receptacles, that function as docking stations for removably receiving clips to be mounted. Each tool receptacle comprises a pair of generally planar retaining arms that face one another over a transverse captivation slot. The midportions of the clips slidably fit within the captivation slots to enable the barrel tool to remotely manipulate the clips when elevated by the installation pole.
[0027] A method of installing ceiling clips comprises the steps of providing resilient clips and barrel installation tools constructed as aforesaid. A suitable threaded pole is threadably coupled to the installation tool to provide access to the required height. The midportions of the clips are slidably mated to the installation tool's docking stations, being temporarily confined within the captivation slots. After clips to be installed are thereby temporarily secured to the mounting tool, the user may press the clips upwardly into engagement with the ceiling rails. When appropriately elevated and aligned, the assembly may be thrust towards the rails, and the clips snap-fit over the horizontal rail bottom. Afterwards the desired item or items to be hung are merely suspended from the clips.
[0028] Thus, our invention provides a unique solution for quickly hanging miscellaneous objects upon exposed ceiling support rails.
[0029] A basic object is to provide clips and an installation method and apparatus for quickly suspending miscellaneous objects from ceilings with said clips.
[0030] A related object is to provide resilient plastic clips that can be quickly attached to exposed suspended ceiling rails for hanging or mounting a variety of utilitarian and aesthetic items.
[0031] A similar object is to provide a simple, multi-piece clip assembly that is easily installed with minimal tools.
[0032] A related object is to provide resilient suspension ceiling clip that can be safely installed from the ground.
[0033] Another object of our invention is to provide a tool that enables a single person to install suspended ceiling clips of the character described.
[0034] Another object is to provide a safe method of attaching clips to ceilings or to suspended ceiling frame rails from the ground, without ladders, stools, lifting equipment, scaffolding or similar elevating structure.
[0035] Another simple object of the present invention is to provide a clip for installation upon a suspended ceiling rail, and a convenient, easily operated system for installing the clips.
[0036] A further object of our invention is to provide a manipulating tool of the character described that can be employed with common household or office poles bearing standard threads.
[0037] It is yet a further object of our invention to provide a ceiling clip installation tool system that may be readily operated by a single individual from a relatively safe position on the ground or floor.
[0038] Another important object is to avoid the requirement of complex special tools or equipment utilizing compound parts or heavy metal components.
[0039] Conversely, an important object is to provide a simple plastic tool for aiding in the installation of ceiling-mounted suspension clips.
[0040] A related object is to provide a clip for suspension ceiling mounting that is inexpensive.
[0041] A still further object of our invention is to provide a clip of the character described that is strong, lightweight, and dependable.
[0042] These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
[0044] [0044]FIG. 1 is a fragmentary isometric view showing portions of a conventional suspended ceiling, showing a plurality of preferred clips installed upon the ceiling rails, and showing an installation tool and method for installation;
[0045] [0045]FIG. 2 is a fragmentary, isometric view of the underside of the suspended ceiling of FIG. 1;
[0046] [0046]FIG. 3 is an enlarged isometric view of a preferred suspension clip constructed in accordance with the best mode of the invention;
[0047] [0047]FIG. 4 is a side elevational view of the preferred clip;
[0048] [0048]FIG. 5 is a left end view of the preferred clip, taken from a position generally to the left of FIG. 4;
[0049] [0049]FIG. 6 is a right end view of the preferred clip, taken from a position generally to the right of FIG. 4;
[0050] [0050]FIG. 7 is a bottom plan view of the preferred clip, taken from a position generally beneath FIG. 4 and looking upwardly;
[0051] [0051]FIG. 8 is a top view of the preferred clip, taken from a position generally above FIG. 4 and looking downwardly;
[0052] [0052]FIG. 9 is an enlarged sectional view taken generally along line 9 - 9 of FIG. 4;
[0053] [0053]FIG. 10 is an enlarged, bottom isometric view of the ceiling clip installer;
[0054] [0054]FIG. 11 is an enlarged frontal isometric view of the ceiling clip installer,
[0055] [0055]FIG. 12 is a fragmentary sectional view of the preferred installation tool taken generally along line 12 - 12 of FIG. 11;
[0056] [0056]FIG. 13 is a side elevational view of the preferred installation tool;
[0057] [0057]FIG. 14 is a left end view of the preferred tool, taken from a position generally to the left of FIG. 13;
[0058] [0058]FIG. 15 is a bottom plan view of the preferred tool, taken from a position generally beneath FIG. 13 and looking upwardly;
[0059] [0059]FIG. 16 is a top plan view of the preferred tool taken generally from a position generally above FIG. 13 and looking downwardly;
[0060] [0060]FIG. 17 is a right end view of the preferred tool, taken from a position generally to the right of FIG. 13;
[0061] [0061]FIG. 18 is a side elevational view of the preferred clip coupled to the preferred tool for subsequent installation;
[0062] [0062]FIG. 19 is a left side elevational view taken from a position generally to the left of FIG. 18;
[0063] [0063]FIG. 20 is a bottom plan view, taken from a position generally beneath FIG. 18 and looking upwardly;
[0064] [0064]FIG. 21 is a top plan view taken from a position generally above FIG. 18 and looking downwardly;
[0065] [0065]FIG. 22 is a right end view, taken from a position generally to the right of FIG. 18;
[0066] [0066]FIG. 23 is an enlarged isometric view of the preferred clip coupled to the preferred tool for subsequent installation;
[0067] [0067]FIG. 24 is an enlarged, bottom isometric view of the preferred clip coupled to the preferred tool that is similar to FIG. 23;
[0068] [0068]FIG. 25 is an enlarged, rear isometric view of the preferred clip coupled to the preferred tool that is similar to FIGS. 23 and 24;
[0069] [0069]FIG. 26 is an enlarged, frontal isometric view of the preferred clip coupled to the preferred tool that is similar to FIGS. 23 - 25 ;
[0070] [0070]FIG. 27 is an enlarged isometric view of an alternative clip coupled to the preferred tool for subsequent installation;
[0071] [0071]FIG. 28 is an enlarged, side elevational view of an alternative clip;
[0072] [0072]FIG. 29 is a left side elevational view of the alternative clip, taken from a position generally to the left of FIG. 28 and looking towards the right;
[0073] [0073]FIG. 30 is an enlarged isometric view of an alternative clip coupled to the preferred tool for subsequent installation;
[0074] [0074]FIG. 31 enlarged, left side elevational view of the alternative clip, taken generally from a position to the left of FIG. 27;
[0075] [0075]FIG. 32 is an enlarged bottom plan view of an alternative installation tool, showing an optional recess and a through-passage for an optional hex-bolt used to temporality hang items from the barrel; and,
[0076] [0076]FIG. 33 is a fragmentary sectional view taken generally along line 33 - 33 in FIG. 32.
DETAILED DESCRIPTION
[0077] Turning initially to FIGS. 1 and 2 of to the appended drawings, a suspended ceiling 50 is illustrated. The ceiling comprises a plurality of regularly spaced apart rails 52 that are arranged in orderly grids. As will be readily appreciated by those skilled in the art, the ceiling comprises an array or mutually orthogonal rails, including rails (not shown) that intersect rails 52 and divide the ceiling area into an orderly arrangement of regularly arranged rectangles. Typical rails 52 have a cross section generally in the form of an “inverted T,” comprising a narrow and flat, horizontal bottom 56 and an integral, upwardly projecting vertical portion 58 (FIG. 2). Normally a plurality of ceiling tiles, not shown, will extend between and be supported by the rails 52 , resting upon horizontal rail bottoms 56 .
[0078] Several of our preferred clips, generally designated by the reference numeral 60 , are shown in spaced apart relation mounted upon the rails 52 . However, clip 61 (FIGS. 1, 2) is illustrated in an intermediate position being installed upon a ceiling rail. Clips are installed with the aid of a barrel-like installation tool 66 , which is hand-manipulated by a user (not shown) with a conventional elongated, wooden pole 65 . (An alternative installation tool is discussed later in conjunction with FIGS. 32 - 33 ). The barrel tool 66 is releasably, threadably engaged by pole 65 , which can be manipulated from the floor or ground and functions as a temporary installation handle. Typical poles useable for this job may comprise handles for rakes or other garden or lawn implements, commode plunger poles, mop handles, paint-roller poles, or conventional threaded handles for brooms, mops or the like. Preferably, the barrel tool 66 has a standard ACME thread to match that used on many common poles. Once a clip 60 to be installed is fitted to the barrel tool 66 , as hereinafter described in detail, the user may elevate the assembly into appropriate position proximate the suspended ceiling and then press-fit the clip onto the desired rail. By first aiming appropriately, and then gently pushing pole 65 to snap-fit the clip over the target rail, installation is readily insured.
[0079] With emphasis now directed concurrently to FIGS. 3 - 9 , the preferred ceiling clip 60 is generally “J”-shaped. As detailed hereinafter, an alternative ceiling clip to be described hereinafter is generally “U”-shaped (i.e., FIGS. 28 - 30 ). Clip 60 is preferably injection molded from resilient plastic. Each clip comprises an upper clasp 64 adapted to be coupled to the ceiling rails, a lower portion in the form of a hook 68 that can support the item to be suspended, and an integral, intermediate midportion 67 connecting clasp 64 and hook 68 . It will be appreciated that the clip comprises two very similar halves that are resiliently coupled together.
[0080] Clasp 64 comprises a pair of opposed jaws 70 , 72 that face each other across a void 74 . Each jaw 70 , 72 is generally C-shaped in cross section, and with hook 68 they aesthetically contribute to the overall, generally J-shaped appearance of the clip 60 . Jaws 70 , 72 respectively comprise opposed, upper flanges 76 , 76 A that face each other across void 74 . The gripping flanges 76 , 76 A on the top of each jaw are integral with lower, horizontal projections 77 , 77 A and the arcuate midsections 78 , 78 A. The jaws are adapted to grasp the rails of the suspended ceiling to mount the clips. They are displaced apart somewhat (as described in detail later) and then pushed into place surmounting the horizontal rail bottom 56 (FIG. 1). When released, the jaw flange portions 76 , 76 A contract and firmly grasp the rail.
[0081] The jaws are integral with the midportion 67 , forming a ninety degree intersection therewith. Midportion 67 comprises a flat, intermediate panel 80 on the left side and a companion, spaced apart intermediate panel 80 A that is curved slightly as indicated. Intermediate panels 80 , 80 A are of substantially uniform width and thickness, and they are respectively integrally joined with lower intermediate panels 82 , 82 A that are on non-uniform width (FIGS. 5, 6). Panels 82 , 82 A are thus shaped somewhat like trapezoids, with their width gradually and smoothly decreasing towards the lower hook 68 . Preferably, an interior reinforcing web 84 (FIGS. 3, 4) integrally, transversely extends between panels 80 , 82 A at the juncture with hook 68 . Panels 80 and 82 are converged as aforesaid so that they functionally fit to the barrel tool 66 during installation, as hereinafter described.
[0082] Hook 68 comprises a pair of arcuate, spaced apart walls 90 , 92 that are integral with panels 82 , 82 A respectively. These complimentary curved walls 90 , 92 (FIG. 3) meet at a foot 94 forming a retaining end of the arcuate hook 68 . At each side of the hook 68 there is a hollow void 97 (i.e., FIGS. 3, 23) between walls 90 , 92 . Preferably, an interior reinforcement web 96 (FIG. 9) transversely runs between walls 90 , 92 to reinforce the clip and especially hook 68 . Web 96 extends between foot 94 and the previously discussed transverse web 84 (FIG. 3). The web 84 forms a flexure point for the opposed jaws 70 , 72 to be yieldably and temporarily displaced apart.
[0083] Turning now to FIGS. 10 - 15 , a preferred installation tool 66 is shown in detail. Each tool 66 is preferably injection molded from resilient plastic. The tool comprises a generally cylindrical, barrel-like body 89 whose periphery comprises a pair of opposed, faceted sides 91 , 91 A and a pair of receptacles 93 , 93 A (FIGS. 10, 11, 14 , 17 ). The body 89 of tool 66 is preferably provided with a threaded, internal bore 87 (i.e., FIG. 24) that defines a tubular interior. Preferably, ACME threads 95 (FIG. 12) are used, so that bore 87 threadably mates with common household poles 65 (FIG. 1) that are readily available to the user. The top 94 of the barrel tool 66 is closed. Over-tightening of the pole is prevented by an internal, circular ridge lock 98 (FIG. 12) that is spaced apart upwardly within the bore 87 above the threads 95 .
[0084] Importantly, receptacles 93 and 93 A (FIGS. 10, 11) function as docking stations for removably and temporarily receiving and controlling the clips 60 , 61 to be mounted. These twin, integral receptacles are very similar, but they are dimensioned somewhat differently to fit clips of different sizes and configurations. The receptacle 93 A (FIGS. 11, 16, 17 ) preferably comprises a pair of opposed, generally planar retaining arms 100 , 102 that face one another across a central gap 104 (FIG. 17). Each retaining arm 100 , 102 is offset from an inner, generally rectangular barrel edge surface 106 . An elongated, transverse captivation slot 110 (FIGS. 11, 15, 16 ) is defined between the arms 100 , 102 and the inner edge surface 106 of the barrel tool (FIGS. 11, 15). The captivation slot 110 is generally in the form of a rectangular parallelepiped. Similarly, receptacle 93 (FIG. 10) comprises a pair of opposed, planar arms 114 , 116 (FIG. 10) separated by a gap 117 . Arms 114 , 116 are offset from generally rectangular barrel edge 119 . A captivation slot 122 is defined between edge 119 (FIG. 10) and offset arms 114 , 116 .
[0085] With additional reference now directed to FIGS. 18 - 23 , the receptacles 93 and 93 A enable the clips 60 , 61 to be removably coupled to the barrel tool 66 . The clip midportions previously described slidably fir within these captivation slots. The clips are temporarily secured by the arms 100 , 102 that engage the midportion sections. Referring again to FIGS. 3 and 5, the intermediate clip panels 80 and 82 are specially dimensioned as aforesaid. The clip 60 may be fitted to the barrel tool 66 by grasping the clip firmly, and placing intermediate panel 82 between gap 104 and into captivation slot 110 . By sliding the clip downwardly, the midportion's panel 82 will be positioned within slot 110 , with panel 80 positioned just above it (FIG. 18). Thus, the temporarily captivated clip 60 will be firmly grasped by and between the retaining arms 100 , 102 , which will project into void 74 (FIG. 4) and contact the inner surface 81 (FIG. 4) of panel 80 .
[0086] To install the clip, an adequate pole 65 (FIG. 1) is coupled to the barrel tool 66 . As the pole is threaded (i.e., with ACME threads) it is threadably mated t the threaded barrel tool 66 . After a clip 60 to be installed is temporarily, slidably coupled to a receptacle 93 or 93 A on the barrel tool 66 , the user may elevate the assembly by thrusting the pole 65 upwardly into the immediate proximity of the ceiling rail. The previously described clip jaws will then snap-fit over the horizontal rail bottom section. Afterwards, various diverse items may be easily hung from the hook 68 of the J-shaped clip 60 or 61 (FIG. 1). For example, by way of illustration only, FIG. 1 illustrates a miscellaneous item 57 hung from the ceiling rail. Item 57 is connected via loop or wire 59 to the hook portion of the clip.
[0087] Turning now to FIGS. 27 - 31 , an alternative suspended ceiling clip 160 is generally “U”-shaped. The injection molded clip 160 comprises an upper clasp 164 , a lower, loop-like hook 169 that can support the item to be suspended, and an integral, intermediate midportion 167 extending between clasp 164 and hook 169 . Clip 160 is symmetrical, with each half comprising a mirror image of the opposite half. Unlike the “open” hook 68 of clip 60 , hook 169 of clip 160 is “closed” (i.e., FIG. 28).
[0088] Upper clasp section 164 comprises opposed jaws 170 , 172 that are separated by a gap 174 . As before, each jaw 170 , 172 is generally C-shaped in cross section. The opposed, upper flanges 176 , 176 A face each other across gap 174 (FIG. 28). The gripping flanges 176 , 176 A on the top of each jaw are integral with lower, horizontal projections 177 , 177 A (FIG. 28). The jaws can be deflected apart and then released to grasp the horizontal rail bottoms 56 (FIG. 1) of the suspended ceiling to mount clips 160 . The clip's jaw flanges 176 , 176 A firmly grasp the rail horizontal bottom 56 (FIG. 1).
[0089] The jaws are integral with midportion 167 , that is in the form of a trapezoid. An intermediate panel 180 (FIG. 29) is somewhat rectangular, but the lower, adjacent portion 182 decreases in width until it smoothly meets the hook portion 169 at a boundary junction 171 . Portion 182 is the same in width as the width 183 (FIG. 29) of the hook 169 .
[0090] The preferred installation tool 166 (FIG. 27) is identical to that previously described. As before, receptacles 193 identical with those previously discussed are integrally formed on its body. The tool 166 is threaded as before to receive a threaded mounting pole 65 (FIG. 1). Receptacle 193 (FIG. 27) comprises a pair of opposed, generally planar retaining arms 200 , 202 spaced across gap 204 (FIG. 27). The retaining arms 200 , 202 are offset from barrel tool edge 206 . An elongated, transverse captivation slot 210 is defined between the arms 200 , 202 and edge 206 .
[0091] The U-shaped clip 160 slidably fits to barrel tool 166 . Capture occurs as the clip's trapezoidal midportion is fitted within and to the captivation slots 210 . When inserted edgewise, integral hook 169 fits neatly within and between barrel tool gap 204 . By thereafter sliding the clip downwardly, its trapezoidal midportion 167 mates within captivation slot 210 , and the clip is temporarily secured by arms 200 , 202 (FIG. 27). Installation proceeds as previously discussed.
[0092] Finally, with reference to FIGS. 32 and 33, a modified installation tool 220 has been shown in detail. Tool 220 comprises a generally cylindrical, barrel-like body 222 having peripheral, faceted sides 224 , 226 , and a pair of radially spaced apart receptacles 228 , 229 similar to those described earlier. Clip midportions are mated to the receptacles as before. The body has an internally-threaded bore 230 , preferably equipped with ACME threads 232 . Bore 230 threadably receives the installation pole in the manner described earlier. Unlike the closed top 94 previously described, top 238 (FIG. 33) is not completely closed.
[0093] Instead, as depicted in FIG. 33, the top 238 has a central orifice 240 defined in it, which is coaxial with the body 222 . The orifice 240 is also coaxial with respect to an inner, hexagonal recess 247 (FIG. 32) defined in the underside 238 A (FIG. 32) of the installation tool's top 238 . An optional hex nut or bolt can be conveniently seated within this hexagonal recess 247 . When a hex bolt, for example, is positioned with its head flushly seated within recess 247 , it's elongated shank will project out of top 238 through orifice 240 , where it will be exposed for rapid interconnection with miscellaneous desired items. For example, once a clip or multiple clips is/are installed, the tool can be lowered for subsequently, temporarily grasping an item to be thereafter suspended from the previously-installed clip. Numerous items to be suspended from the clips as aforesaid can be temporarily supported by suitable conventional hex bolts penetrating orifice 240 .
[0094] From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
[0095] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
[0096] As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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A system for hanging objects from conventional suspended ceilings comprises resilient clips snap-fitted to ceiling rails, an installation tool for controlling the clips, and an elongated pole that threadably couples to the tool, enabling clip manipulation. Each clip comprises an upper clasp, an integral, lower hook, and a midportion. Clasp jaws that yieldably deflect apart comprise opposed flanges that forcibly grip the ceiling rails. The installation tool comprises receptacles for temporarily receiving the clips, and an internal, threaded bore mated to the installation pole. Each receptacle comprises a pair of generally planar retaining arms that partially block a captivation slot. The midportions of the clips slidably fit within the installation tool captivation slots. When pushed towards the ceiling rails the jaws snap apart and surmount the horizontal rail portion. When released, the jaws retract, with their flanges firmly gripping the rail.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a set-up/down weir made of a flexible sheet, and particularly relates to a set-up/down plural-span weir assembly made of flexible sheets and improved in set-down means based on the level of water upstream of the weir assembly.
2. Description of the Prior Art
A weir made of a flexible sheet such as a rubberized cloth and capable of being set up and down is provided with a bag made of the flexible sheet and mounted on at least the bed of a river or the like across the stream thereof, as disclosed in the Japanese Patent Publication Nos. 11702/65 and 2371/69. A pressure medium such as air, water, both of them or the like is introduced into the bag to inflate it to set up the weir. The pressure medium in the bag is discharged therefrom to deflate it to set down the weir.
A plurality of such single-span weirs can be installed in a river of large width across the stream thereof to facilitate the regulation of the level or flow rat of water, the removal of deposited earth and sand, the shut-off of the river or the like. In that case, the single-span weirs are coupled to each other through pillars so that a set-up/down plural-span weir assembly is constituted. The number of the single-span weirs to be thus coupled is not single, but may be two, three or more.
The single-span weirs of a conventional set-up/down plural-span weir assembly of such kind are provided with set-down means which do not act in conjunction with each other but act separately from each other, as shown in FIGS. 6 and 7, so that the single-span weirs are set down by the set-down means when the upstream water of the weir assembly has reached prescribed levels, respectively.
The set-down means of such a conventional set-up/down plural-span weir assembly shown in FIG. 6 are of a bucket type. When the upstream water W of the weir assembly has reached an automatic set-down level L 1 , the upstream water W flows into buckets 11a and 11c to move down the buckets to open butterfly valves 8a and 8c thereby to deflate the bags 1a and 1c of the single-span weirs of the assembly. As a result, the single-span weirs are set down. When the up-stream water W has reached another automatic set-down level L 2 , the upstream water W flows into another bucket 11b to move down the bucket to open another butterfly valve 8b therby to deflate the bag 1b of the other single-span weir of the assembly. As a result, the other single-span weir is set down.
The set-down means of such a conventional set-up/down plural-span weir assembly shown in FIG. 7 are of a float type. When the upstream water W of the weir assembly has reached an automatic set-down level L 1 , the upstream water flows into float containers 21a, 21b and 21c to lift floats 24a, 24b and 24c to the same level to open butterfly valves 8a and 8c by rods 22a and 22c coupled to the floats 22a and 24c, therby to deflate the bags 1a and 1c of the single-span weirs of the assembly. As a result, the single-span weirs are set down. When the upstream water W has reached another automatic set-down level L 2 , the float 4b is lifted further to open a butterfly valve 8a by a rod 22b coupled to the float, to deflate the bag 1b of the other single-span weir of the assembly. As a result, the other single-span weir is set down.
As understood from the above description, the single-span weirs of each of the conventional plural-span weir assemblies cannot be set down in prescribed order without presetting a plurality of different set-down levels for the upstream water. However, it is desired for the following reasons (1) and (2) that the single-span weirs can be set down in prescribed order (for example, each of the single-span weirs or every plurality of them can be sequentially set down) without presetting a plurality of different set-down levels for the upstream water.
(1) As for the discharge of stored water at the time of low level of the upstream water or at the slow gradient of the river or the like, it takes much time to store enough water upstream of the weir assembly set up again after being set down completely. In that case, it is not easy to obtain enough water shortly. For that reason, each of the single-span weirs of the assembly or every plurality of the single-span weirs, for example, should be sequentially set down according to the rate of increase of the upstream water so that the discharged quantity of stored water upstream of the weir assembly is reduced as much as possible.
(2) It is preferable that water can be always obtained from the weir assembly for electricity generation, tape water supply or the like. For that reason, the upstream water of the weir assembly should be maintained on a prescribed level or above it. If the upstream water is to be discharged downstream, the single-span weirs of the assembly should not be all set down simultaneously but each of the single-span weirs or every plurality of them, for example, should be sequentially set down according to the rate of increase of the upstream water to keep the level of the upstream water as high as possible.
SUMMARY OF THE INVENTION
The present invention was made in consideration of the above-mentioned circumstances.
Accordingly, it is an object of the present invention to provide a set-up/down plural-span weir assembly which is made of flexible sheets and comprises a plurality of single-span weirs and bucket-type set-down means by which the single-span weirs can be set down in prescribed order on the same level of the upstream water of the weir assembly. Bags made of the flexible sheets and constituting the bodies of the single-span weirs are mounted on the bed of a river. A pressure medium such as air and water is introduced into the bags to inflate them to set up the single-span weirs. The pressure medium in the bags is discharged therefrom to deflate them to set down the single-span weirs. The single-span weirs are coupled to each other through pillars across the stream of the river so that the set-up/down plural-span weir assembly is constituted. The single-span weirs are provided with the bucket-type set-down means in which the upstream water is introduced into the buckets of the single-span weirs through an upstream water level detection pipe to move down the buckets to open air or water discharge valves in air or water discharge pipes communicating with the bags of the single-span weirs, to deflate the bags as the up-stream is on the prescribed level. The set-up/down plural-span weir assembly is characterized in that the upstream water is directly introduced from the upstream water level detection pipe into the bucket of at least one of the single-span weirs; and the upstream water is indirectly introduced from the upstream water level detection pipe into the bucket of at least another one of the single-span weirs through the bucket of the former one of the single-span weirs or through the bucket of still another one of the single-span weirs.
It is another object of the present invention to provide a set-up/down plural-span weir assembly which is made of flexible sheets and comprises a plurality of single-span weirs and float-type set-down means in which the single-span weirs can be set down in prescribed order on the same level of the upstream water to the weir assembly. Bags made of the flexible sheets and constituting the bodies of the single-span weirs are mounted on the bed of a river. A pressure medium such as air and water is introduced into the bags to inflate them to set up the single-span weirs. The pressure medium in the bags is discharged therefrom to deflate them to set down the single-span weirs. The single-span weirs are coupled to each another through pillars across the stream of the river so that the set-up/down plural-span weir assembly is constituted. The single-span weirs are provided with the float-type set-down means in which the upstream water is introduced into the float containers of the single-span weirs through an upstream water level detection pipe to move up the floats of the weirs to open air or water discharge valves in air or water discharge pipes communicating with the bags of the single-span weirs, to deflate the bags as the up-stream water is on the prescribed level. The set-up/down plural-span weir assembly is characterized in that the upstream water is directly introduced from the upstream water level detection pipe into the float container of at least one of the single-span weirs; and the upstream water is indirectly introduced from the upstream water level detection pipe into the float container of at least another one of the single-span weirs through the float container of the former one of the single-span weirs or through the float container of still another one of the single-span weirs.
The buckets or float containers of each of the set-up/down plural-span weir assemblies provided in accordance with the present invention are connected to each other through the medium of the up-stream water so that the order of the setting-down of the single-span weirs on the same level of the upstream water (without employing the different levels thereof) can be predetermined.
The level of the upstream water, on which the single-span weirs provided with the bucket-type set-down means are set down in the predetermined order, can be changed by altering the height of a connection pipe for the buckets of the single-span weirs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of a set-up/down plural-span weir assembly which is an embodiment of the present invention and comprises single-span weirs of flexible sheets and set-down means of the bucket type;
FIG. 2 shows a schematic view of a set-up/down plural-span weir assembly which is another embodiment of the present invention and comprises single-span weirs of flexible sheets and set-down means of the bucket type;
FIG. 3 shows a schematic view of a set-up/down plural-span weir assembly which is still another embodiment of the present invention and comprises single-span weirs of flexible sheets and set-down means of the float type;
FIG. 4 shows a schematic view of a set-up/down plural-span weir assembly which is still another embodiment of the present invention and comprises single-span weirs of flexible sheets and set-down means of the float type;
FIG. 5 shows a schematic view of a set-up/down plural-span weir assembly which is still another embodiment of the present invention and comprises single-span weirs of flexible sheets and set-down means of the float type.
FIG. 6 shows a schematic view of a conventional set-up/down plural-span weir assembly comprising single-span weirs of flexible sheets and set-down means of the bucket type; and
FIG. 7 shows a schematic view of a conventional set-up/down plural-span weir assembly comprising single-span weirs of flexible sheets and set-down means of the flat type.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention are hereafter described in detail with reference to the drawings attached hereto. The same reference symbols in FIGS. 1, 2, 3, 4, 5, 6 and 7 denote mutually corresponding portions.
A schematic view of a set-up/down plural-span weir assembly, which is one of the embodiments and has set-down means of the bucket type, is shown in FIG. 1 as seen in the upstream direction of a river in which the weir assembly is installed. The weir assembly has single-span weirs 1a, 1b, 1c, . . . each made of a flexible sheet and capable of being set up and down. The single-span weirs 1a, 1b, 1c, . . . are coupled to each other through pillars 2a, 2b, . . . so that the set-up/down plural-span weir assembly is constituted. A blower 3 is provided to supply air into the single-span weirs 1a, 1b, 1c, . . . through air feed pipes 4a, 4b, 4c, . . . and air feed/discharge pipes 5a, 5b, 5c, . . . to set up the single-span weirs. The air in the single-span weirs 1a, 1b, 1c, . . . is discharged therefrom through the air feed/discharge pipes 5a, 5b, 5c, and air discharge pipes 6a, 6b, 6c, . . . to set down the single-span weirs. Air feed valves 7a, 7b, 7c, . . . , air discharge valves 8a, 8b, 8c, . . . , a main air feed valve 9, pulleys 13a, 13b, 13c, . . . , valves 14a, 14b, 14c, . . . , bellows pipes 15a, 15b, 15c, . . . and a water discharge valve 16 are provided further. The water discharge valve 16 is fitted in an upstream water level detection pipe 10.
The operation of the set-up/down plural-span weir assembly will be described. The upstream water W of the weir assembly flows through the upstream water level detection pipe 10 laid from the slope of the bank of the river, so that the upstream water is introduced first into the bucket 11a of the first single-span weir 1a, then into the bucket 11b of the second single-span weir 1b, then into the bucket 11c of the third single-span weir 11c, . . . in series. As a result, the buckets 11a, 11b, 11c, . . . are sequentially moved down so that the air discharge valves 8a, 8b, 8c, . . . , which are lever-type butterfly valves, are sequentially opened by wires 12a, 12b, 12c, . . . coupled to the buckets. The air in the single-span weirs 1a, 1b, 1c, . . . is thus sequentially discharged therefrom to sequentially deflate the bags of the weirs to set down the weirs in prescribed order (the weir 1a is set down first, the weir 1b is set down second, the weir 1c is set down third, . . . , as long as the upstream water W exists on an enough level.
A schematic view of a set-up/down plural-span weir assembly, which is another one of the embodiments and has set-down means of the bucket type, is shown in FIG. 2 as seen in the upstream direction of a river in which the weir assembly is installed. The difference of the weir assembly from that shown in FIG. 1 is that the upstream water W of the weir assembly is directly introduced from an upstream water level detection pipe 10 into a bucket 11c. For that reason, the bags of the single-span weirs 1a, 1b, 1c, . . . of the weir assembly shown in FIG. 2 are deflated in prescribed order so that the single-span weirs are set down in that order (the weirs 1a and 1c are set down before the weir 1b is set down) as long as the upstream water W exists on an enough level.
A schematic view of a set-up/down plural-span weir assembly, which is still another one of the embodiments and has set-down means of the float type, is shown in FIG. 3 as seen in the up-stream direction of a river in which the weir assembly is installed. The weir assembly has single-span weirs 1a, 1b, 1c, . . . each made of a flexible sheet and capable of being set up and down. The single-span weirs 1a, 1b, 1c, . . . are coupled to each other through pillars 2a, 2b, . . . across the stream of the river so that the set-up/down plural-span weir assembly is constituted. A blower 3 is provided to supply air to the single-span weirs 1a, 1b, 1c, . . . through air feed pipes 4a, 4b, 4c, . . . and air feed/discharge pipes 5a, 5b, 5c, . . . to set up the single-span weirs. The air in the single-span weirs 1a, 1b, 1c, . . . is discharged therefrom through the air feed/discharge pipes 5a, 5b, 5c, . . . and air discharge pipes 6a, 6b, 6c, . . . to set down the single-span weirs. Air feed valves 7a, 7b, 7c, . . . , air discharge valves 8a, 8b, 8c, . . . , a main air feed valve 9 and a water discharge valve 16 are provided further. The water discharge valve 16 is fitted in an upstream water level detection pipe 10.
The operation of the set-up/down plural-span weir assembly shown in FIG. 3 will be described. The upstream water W of the weir assembly flows through the upstream water level detection pipe 10 laid from the slope of the bank of the river, so that the upstream water is introduced first into the float container 21a of the first single-span weir 1a, then into the float container 21b of the second single-span weir 1b, then into the float container 21c of the third single-span weir 1c, . . . in series. As a result, the floats 24a, 24b, 24c, . . . in the float containers 21a, 21b, 21c, . . . are buoyed up to lift rods 22a, 22b, 22c, . . . to sequentially push up counterweights 23a, 23b, 23c, . . . attached to the air discharge valves 8a, 8b, 8c, . . . The air discharge valves 8a, 8b, 8 c, . . . are thus sequentially opened to sequentially discharge the air out of the single-span weirs 1a, 1b, 1c, . . . to set down the single-span weirs in prescribed order (the weir 1a is set down first, the weir 1b is set down second, the weir 1c is set down third, . . . ) as long as the upstream water W exists on an enough level.
Although the single-span weirs of the set-up/down plural-span weir assembly shown in FIG. 3 are inflated by the air, the present invention is not confined thereto but may be otherwise embodied so that the single-span weirs of a set-up/down plural-span weir assembly having set-down means of the float type are inflated by water as shown in FIG. 4. In that other embodiment, water discharge pipes are provided in lower positions instead of air discharge pipes in upper positions, and wires are attached to floats instead of rods and laid on pulleys to open water discharge valves in the water discharge pipes.
A schematic view of a set-up/down plural-span weir assembly, which is still another one of the embodiments and has set-down means of the float type, is shown in FIG. 5 as seen in the upstream direction of a river in which the weir assembly is installed. The difference of the weir assembly from that shown in FIG. 3 is that the upstream water W of the weir assembly is directly introduced from an upstream water level detection pipe 10 into a float container 21c. A a result, the bags of the single-span weirs 1a, 1b, 1c, . . . of the set-up/down plural-span weir assembly shown in FIG. 5 are deflated in prescribed order so that the single-span weirs are set down in that order (the weirs 1a and 1c are set down before the weir 1b is set down) as long as the upstream water W exists on an enough level.
The present invention is not confined to the above-described embodiments but may be embodied in other various ways. The set-down means of each set-up/down plural-span weir assembly provided in accordance with the present invention may operate so that each of the single-span weirs of the weir assembly or every plurality of them is set down in prescribed order depending on the speed of the increase in the flow rate of the river in which the weir assembly is installed. Besides, the set-down means may be of either the air inflation type or the water inflation type.
According to the present invention, a set-up/down plural-span weir assembly is composed of a plurality of single-span weirs each made of a flexible sheet and capable of being set up and down. The single-span weirs can be easily set down in prescribed order on the same level of the upstream water of the weir assembly.
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A set-up/down plural-span weir assembly is made of flexible sheets and comprises a plurality of single-span weirs coupled to each other through pillars across the stream of a river. A pressure medium is introduced into the bags of the single-span weirs to inflate them to set up the single-span weirs and also discharged therefrom to deflate them to set down the single-span weirs. The upstream water of the weir assembly is directly introduced from an upstream water level detection pipe into a bucket or float container of at least one of the single-span weirs, and is indirectly introduced from the upstream water level detection pipe into the bucket or float container of at least another one of the single-span weirs through the bucket or float container of the former one of the single-span weirs or through that of still another one of the single-span weirs.
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BACKGROUND OF THE INVENTION
The present invention relates to an emerizing apparatus including an emery-covered roller having multiple beater blades arranged about the periphery of the roller in parallel relation to its axis of rotation.
Emerizing machinery of the above-referenced type is known for working the surface of a textile web to provide a smooth napping of the web face. Typically, the textile web is guided to travel under tension, e.g. under a tractive force, with the web face to be napped in peripheral contact with the emery-covered roller, usually by means of guide rollers or rods contacting the web in advance of and following the emery-covered roller to tension the traveling web along the extent of its travel in contact with the emery-covered roller. The tractive force operating on the web is independent of the emery roller which may be rotated in a direction independent of the direction of travel of the textile web. The beater blades of the roller strike the surface of the web in a wiping-like manner, the abrasive nature of the emery covering of the roller raising the fibers of the web to produce a napped surface.
West German Gebrauchsmuster DE-GM 19 67 718 discloses an apparatus by which the surface fibers of a textile fabric web are loosened and raised to increase the web thickness. For this purpose, the apparatus is provided with one or more rollers each equipped with multiple beater blades for performing a beating and agitating operation on the web surface. In a preferred embodiment, multiple rollers are arranged in an arc and the fabric web is guided to travel in an essentially tangential path in succession over each of the rollers. In this manner, the surface yarns of the fabric web are loosened and raised by the striking action of the beater blades to provide a plush surface effect such as a velour, frotte, or the like.
In the textile industry, a practical distinction is drawn between emerizing machines and grinding machines. It is a characteristic of emerizing machines that the fabric web being treated is held against the surface of the emery roller or rollers of the machine by virtue of longitudinal tensioning of the fabric web itself. The emery roller, as aforementioned, includes beater blades about its periphery in parallel relation to its axis and is wound, preferably in a helical fashion, by an emery-covered belt. In contrast, textile grinding machines utilize a grinding roller the surface of which is coated entirely or in a predetermined pattern with a grinding agent. A representative grinding machine of this type is disclosed in West German Offenlegungschrift DE-OS 25 32 459. In a grinding machine, the textile fabric web to be treated is directed to travel through a nip region between the periphery of a grinding roller and a mating roller arranged in parallel peripheral engagement therewith. The present invention is intended for use primarily only with respect to emery-covered rollers utilized in emerizing machines.
In the operation of emerizing machines, the fabric web to be treated is guided by positioning rods or rollers to travel in contact with a predetermined portion of the circumferential periphery of the emery-covered roller, typically for about one-fourth of its circumference. In this manner, the web surface is contacted indirectly by the beater blades through the emery belt wrapped thereabout, whereby the beater blades exercise a wiping-like effect on the web surface.
It is recognized that the height of the nap raised at the web surface by the action of an emery roller in an emerizing machine is directly related to the period of time per unit length of the web during which the web is maintained in contact with the emery roller and, likewise, the density of the nap produced is directly related to the frequency with which the beater blades strike the fabric web per unit time. Accordingly, for any given emery-covered roller in an emerizing machine, relatively shorter and denser naps would be obtained at relatively higher rotational speeds of the roller, while relatively longer but less dense naps would be obtained at relatively lower rotational speeds of the roller. However, a critical rotational speed is associated with each emery roller according to its axial length at which speed the roller tends to oscillate and is incapable of producing a satisfactory working of a textile web. As will be understood, the roller and its mounting structure must be of a substantially stronger design than is required for normal operation if the critical speed is to be exceeded. In this regard, reference may be made to West German Patentschrift DE-PS 27 40 402.
In light of these considerations, it could be attempted to increase the number of beater blades on the circumference of an emery roller in order to achieve an increased number of web contacts per unit of time without increasing the rotational speed of the roller. However, practical limitations exist on the number of beater blades with which any given emery roller can be equipped. Because the roller rotation produces relatively high centrifugal forces, the beater blades must be securely fastened to the central axial body of the roller. Furthermore, while an increase in the number of beater blades would result in a corresponding increase in the number of contacts made by the beater blades with a textile web per unit of time without a change in the rotational speed of the roller, the duration of each individual contact changes only proportionally to the frequency of the contacts.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide an improved emery roller for an emerizing machine which, essentially without changing the rotational speed of the roller, enables achievement of a distinct increase in the frequency of beater blade contacts and a superproportional decrease in the duration of each individual beater blade contact in comparison to the state of the art described above.
Basically, the improved emery roller of the present invention is adapted for use in any emerizing apparatus of the initially-described type wherein the emery-covered roller is equipped with a plurality of beater blades arranged in parallel relation to the axis of rotation of the roller with an emery-covered belt wound outwardly about the beater blades. According to the present invention, the aforementioned objective is achieved by providing each beater blade with a pair of axially extending beater edges spaced apart by an intermediate axially extending recess for successive individual striking of the textile web by the beater edges.
As a result of this construction of each beater blade with two separately-acting longitudinal beater edges, the frequency with which the beater edges strike a textile web is doubled without changing the rotational speed of the emery roller while at the same time the duration of each individual blade contact may be reduced in even greater proportion by configuring the edges to be relatively narrow as measured circumferentially of the roller. In contrast, only the leading edge of beater blades of conventional construction serve to actively make striking contact with the textile web, the trailing edge of the blade being essentially inactive as a beating edge.
A further improvement in the emery roller construction of the present invention may be achieved by configuring the two beater edges of each beater blade to be rounded at a radius of curvature on the order of the height of the nap to be produced on the web surface. As a result, the duration of contact by each beater edge with the textile web may be considerably shorter than a corresponding conventional beater blade having a periphery which follows the emery roller circumference, even when the rotational speed of the roller is reduced by one-half.
Essentially, the radial depth of the recess between the two beater edges of each beater blade can be of any desired dimension. However, the recess must be of a minimum depth sufficient to enable the trailing beater edge to serve a web striking function. As a practical maximum, the recess can extend to approximately the same depth as fasteners which are situated between successive beater blades to secure them to the central body of the emery roller.
According to another feature of the present invention, the recess of each beater blade of the present emerizing roller is configured to be arcuate in cross-section taken radially with respect to the emerizing roller (i.e. in each plane through each beater blade recess which plane is perpendicular to the axis of the roller and intersects each radius thereof) and to be substantially flat (i.e. linear) in cross-section taken axially through the emerizing roller (i.e. in each plane through each beater blade recess which plane intersects the axis of the roller), whereby the recess is essentially concave. With each beater blade having a recess of this configuration and each beater edge being of the aforementioned relatively narrow, rounded configuration, the emerizing roller of the present invention produces advantageous processing results in terms of achieving a desired height and density in the surface nap of the textile web being treated. The arcuate recess is preferably formed in a circular arc of a uniform radius of curvature which can be relatively large, preferably in the range of approximately one-half to one-fourth the overall circumferential dimension of each beater blade. Beater blades according to this construction can be relatively inexpensively manufactured to be sufficiently resistant to breakage. Regardless of the actual configuration of each beater blade, the primary factor is that the leading portion of the trailing beater edge of each beater blade (as viewed in the direction of rotation of the emery roller) be suitably configured to contact a textile web traveling over the emery roller in substantially the same manner as a conventional beater blade.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic radial cross-sectional view of an emery roller in an emerizing apparatus according to the present invention.
FIG. 2 is a schematic axial cross-sectional view taken through one of the beater blades of the emery roller of FIG. 1 along line 2--2 thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawing, an emery roller of an emerizing apparatus according to the preferred embodiment of the present invention is illustrated in radial cross-section and broadly designated in its entirety at 1. The emery roller 1 has a central cylindrical main body 2 to which plurality of beater blades 3 are affixed by intervening threaded bolts 4. The beater blades 3 cover substantially the entire circumference of the central body 2, each beater blade 3 being elongated to extend substantially the length of the central body 2 in parallel relation to the rotational axis 12 thereof. The beater blades 3 are preferably fabricated of wood while the main body 2 is preferably of a tubular configuration fabricated of a suitable metal. The number of threaded bolts 4 utilized to secure the beater blades 3 to the main body 2 is a function of the length and quality of the beater blades 3. An emery-covered belt 14 is wound tightly, preferably in a helical manner, outwardly about the beater blades 3 over the full circumference and length thereof, whereby the emery belt 14 conforms to the peripheral configuration of the beater blades 3 to provide an emery covering over the circumference of the emery roller in the form of multiple polygonal belt sections. As will be understood, the number of corners or edges produced by this conformed configuration of the emery belt is determined by and equal to the number of beating edges formed by the beater blades 3 as hereinafter more fully described.
As viewed in the direction of rotation of the emery roller 1, indicated by the directional arrow 5, each beater blade 3 is configured to have a leading edge 6 and a trailing edge 7, each extending lengthwise along the beater blade 3 in substantially parallel relation to the axis of rotation 12 of the emery roller 1. Of course, as will be understood, if the direction of rotation of the roller 1 were opposite, the edge 7 would act as the leading edge and the edge 6 would act as the trailing edge. In contrast to conventional emery rollers wherein the periphery of each beater blade is configured as a substantially convex arcuate segment conforming to the overall circumference of the emery roller, each emery roller 1 of the present invention is formed with a concave recess 9 between its leading and trailing longitudinal edges 6,7. As a result of the recesses 9 formed in the beater blades 3, the leading and trailing longitudinal edges 6,7 of each beater blade 3 act as separate beating edges on a web of textile material 11 traveling under a downstream tractive force in contact with the outer periphery 10 of the emery roller 1. As aforementioned, the recesses 9 can be formed to substantially any desired radial depth in the beater blades 3, even to substantially the level of the securing bolts 4 if the material from which the beater blades 3 are fabricated is sufficiently stable and strong.
As illustrated in the drawing, the circumferential extent of the emery roller 1 over which the traveling textile web 11 is maintained in contact with the roller periphery 10 can be selectively determined by the provision of guide rods or rollers 13, or other suitable elements, which tension the extent of the textile web 11 therebetween to hold it in contact with the rotating periphery 10 of the emery roller -. In the illustrated embodiment, the textile web 11 is maintained in contact with the emery roller 1 over approximately one-fourth of its overall circumference, i.e., over an angular extent of approximately 90 degrees.
It has been found in practice to be advantageous to the outcome of the emerizing operation of the emery roller 1 to configure the leading and trailing longitudinal edges 6,7 of each beater blade 3 as essentially separate and distinct beating edges each of a substantially rounded configuration. For example, the longitudinal beating edges 6,7 can be formed at a radius of curvature on the order of the height to which the nap of the textile web is to be raised, e.g., on the order of approximately 5 millimeters. It has also proven to be advantageous in practice to achieve an economical manufacture and assembly of the emery roller 1 to configure the recess 9 of each beater blade 3 in the form of a circular arc of a uniform radius of curvature, as viewed in cross-section taken radially with respect to the emery roller 1, and in turn of a substantially flat longitudinal extent, as viewed in cross-section taken axially with respect to the emery roller 1. In the illustrated embodiment, the recess 9 of each beater blade 3 is formed of an arcuate configuration having a radius of curvature on the order of approximately two-thirds of the overall circumferential dimension of each beater blade 3 at the outer periphery 10 of the emery roller 1.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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An emerizing apparatus is equipped with an emergy roller having multiple beater blades about its circumference, the outer periphery of each beater blade being formed with a pair of axially extending longitudinal beater edges and a concave arcuate recess therebetween, whereby each beater edge is adapted to individually strike a textile web traveling in tensioned engagement with the roller periphery to produce a shorter and more dense napped surface on the textile web than can be achieved by a corresponding conventional emery roller operating at the same rotational speed.
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CLAIM OF PRIORITY
This application claims the priority of U.S. Ser. No. 61/777,635 filed on Mar. 12, 2013, the contents of which are fully incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a drilling safety system and more particularly relates to a safety system specially designed to prevent drill shaving and debris from damaging the surrounding equipments and harming the worker.
BACKGROUND OF THE INVENTION
For many manufacturing, maintenance, and repair projects, drilling is an indispensible part of the operation. Under some circumstances, drilling can become hazardous to the person conducting the drilling, the workpiece, and/or the equipments and environment surrounding the drilling site. If essential safety devices cannot be provided, or if proper safety procedures cannot be followed, accidents during drilling may happen, causing significant damages and threatening the worker's wellbeing.
One example for hazardous drilling operations is drilling conducted during electrical work. The electricians are sometimes required to drill on the metal housing of switchgears, which in many instances have to stay “live”—with the electricity still on during the drilling process. Such requirements are not rare, especially for the maintenance and repair work conducted for companies, factories and hospitals, where the continuous provision of electricity is essential. However, the metal shavings and debris resulted from drilling are very hard to collect and such shavings and debris may disperse into the live switchgear, causing short-circuiting or even explosion. Most electricians use make-shift arrangements to collect the shavings and debris. For example, one worker may reach inside the housing of live gear and hold a cardboard box under the drill site while another worker drills through the top. However, such temporary solutions are far from complete and fully effective.
Some devices and systems have been developed to address the danger associated with drilling debris. These designs, however, show shortcomings in one aspect or another. For example, U.S. Pat. No. 6,974,048 ('048 patent) discloses a safety tool that includes magnets and an outer non-conductive sheath encompassing an inner bag. A purpose of the tool is to provide safety for the operator while drilling or cutting into electrical/electronic enclosures, such as switchgear. The tool is constructed so that an operator can perform a task while preventing any conductive debris caused by this task to come in contact with any electrical parts. The top portion of the tool magnetically attaches to the inside of the switchgear structure. The bottom portion of the tool, which is coupled to the top portion by the non-conductive sheath, collects and magnetically contains the debris, such as shavings from drilling into the structure. The debris is collected in the inner bag, which can easily be removed from the tool for disposal of the debris.
This design of the '048 patent, however, has at least two significant disadvantages. First, while much all of the debris is generated on the drilling surface where drilling is initiated, such debris is not properly collected. It should be noted that the majority of the shavings stay at the drilling side and the design taught by the '048 patent does not address these shavings at all. The device disclosed by the '048 patent only collects the shavings after the drill bit has penetrated the workpiece. The shavings on the side of the drill are not collected and these shavings have the potential to cause significant damage to the surrounding equipment as well as the worker himself/herself. More importantly, the tool disclosed by the '048 patent requires the worker to place his/her arm into the housing of live gear to attach the tool to the inner surface of the housing. Similar action is also required to remove the tool from inside the housing of live gear. Such attachment/removal processes significantly increase the chance that the worker would be electrocuted, accidentally drop the bag full of shavings/slugs into the gear, or come in contact with energized parts while holding the bag full of shavings. Therefore, the design by the '048 patent is both unreliable and unsafe.
The hazards of drilling into live electrical equipment involve at least (1) the danger of metal shavings and the slug created by the hole saw entering the housing of the gear during the drilling process and after the drilling process is completed from the drilling side; (2) the danger of the hole saw being released from the drill chuck during the drilling process and falling into the live equipment; (3) the danger of a worker reaching into the live equipment to place equipment inside the housing of live gear under the drilling area to catch debris and removing it, and (4) the danger of dropping the conductive metal shavings accidentally inside the housing of live gear once such shavings are collected.
The current invention addresses all the concerns herein discussed and properly collects all the shavings generated in a drilling process without requiring a worker to reach inside the house of live gear. The devices taught by the current invention may be used in various types of drilling operations and are particularly useful for drilling conducted during electrical work. In summary, various implements are known in the art, but fail to address all of the problems solved by the invention described herein. The preferred embodiments of this invention are illustrated in the accompanying drawings and will be described in more detail herein below.
SUMMARY OF THE INVENTION
The present invention discloses a drill safety system, which may include three parts that can be used individually or in combination. The three parts include: a magnetic unit, a vacuum unit, and an improved hole saw drill set. The magnetic unit may comprise a magnet core and a flexible and openable cover shielding the magnetic core. The vacuum unit may comprise a collecting cup and a connecting tube, wherein the collecting cup and the connecting tube are hollow inside and are connected. The key feature of the hole saw drill set is that it has stopper flange extending from the front periphery of the hole saw arbor, wherein the stopper flange is positioned right behind and abutting the hole saw and blocks advancement of the drill set when the stopper flange abuts a workpiece.
As indicated above, the three parts of the drill safety system may be used individually. However, it is preferable that the parts, especially the magnetic unit and the vacuum unit are utilized in combination. The current invention is particularly useful for drilling on metal workpieces, especially the housing of switchgear, which are often “live” and may be hazardous to work with. Here, for the purpose of providing a clear description, the surface of the workpiece that engages the drill bit is considered a “drilling surface,” and the surface opposite to the drilling surface is defined as “inner surface.” The location on the workpiece that engages the drill bit is the “drilling site.” The terms “shavings” and “debris” generally refer to small pieces of metal or other materials generated by the drilling process. These terms are essentially synonyms and may also refer to “scraps,” “fragments,” “powders,” and “crumbs” that are produced during drilling.
Before drilling starts, the magnetic unit is placed on the drilling surface, and around and/or adjacent to the drilling site. In a preferred embodiment, the magnetic unit has a ring or annulus shape, allowing it to surround the drilling site. The cover of the magnetic unit may comprise a unit base and a flippable top; the magnet core may be placed on the unit base; and the flippable top may be flipped up to allow the magnet core to be removed. During drilling, the metal shavings on the drilling surface are pulled towards the magnetic unit and attach to the cover, which is preferably non-magnetic and non-conductive. After drilling, the flippable top is flipped up, allowing the magnet core to be removed so that the metal shavings can no longer attach to the cover. The user may then easily discard the shavings. To ensure the physical robustness of the magnetic unit, a support structure may be included to provide physical support to the magnetic unit.
The vacuum unit is used to collect the shavings from the inner side. After initial penetration by the drill bit, shavings start to be generated at the inner surface. Such shavings are particularly dangerous because equipment such as switchgear may be damaged if the shavings fall into the equipment. The collecting cup of the vacuum unit may have a lower cup body and a cup rim, wherein the cup rim may fit on the inner surface. The cup covers the drilling site, providing a complete shielding and collecting structure that ensures all shavings from the inner surfaces are properly gathered.
The vacuum unit may further include a first connector, a second connector and a handle element having a handle tube and a handle, wherein the first connector, the second connector, and the handle tube are hollow inside, and the collecting cup, the first connector, the connecting tube, the second connector, and the handle tube are sequentially connected, forming a through channel. Furthermore, the vacuum unit may be connected to a vacuum motor providing suction power, allowing shavings on the inner surface to be collected. In one embodiment, the connecting tube is rigid, ensuring more toughness and robustness. In another embodiment, the connecting tube is flexible, allowing better adjustment. A user may take hold of the handle and manually press the collecting cup to the inner surface. Alternatively, the cup rim may include magnets so that the collecting cup can magnetically attach to the inner surface. The first connector and the second connector are structures that provide more flexibility to the design of the vacuum unit and these structures may have different length and twisting angles. By adjusting the first connector and the second connector, a user may reconfigure the vacuum unit to avoid pressing against the equipments in the workpiece.
The current invention may also include an improved hole saw drill set that includes a stopper flange. The conventional hole saw is a cylinder structure wherein the front end of the cylinder facing the workpiece has sawteeth that may cut through the workpiece to produce a hole. For the conventional hole saw drill set, there is no structure that stops the advancement of the hole saw against the workpiece even after the hole saw has completely passed the drilling surface. Such a design, however, puts performance above safety because while the hole saw can cut holes deeper than its entire length, over-penetration may result in damage to the equipment inside the inner surface by the drill bit. The conventional design is particularly dangerous when drilling on the housing of live switchgears. The current improved hole saw drill set includes a stopper flange attached to the hole saw arbor and positioned right behind and abutting the back end of the hole saw, blocking the advancement of the drill set when the hole saw cylinder has cut into the workpiece. Such a design prevents over-penetration and protects the inner structures of the workpiece.
In general, the present invention succeeds in conferring the following, and others not mentioned, desirable and useful benefits and objectives.
It is an object of the present invention to provide a drill safety system that is safe and easy to use.
It is another object of the present invention to provide a drill safety system having a magnetic unit capable of collecting metal shavings on the drilling surface.
It is another object of the present invention to provide a drill safety system having a magnetic unit with an openable cover that is non-magnetic and non-conductive.
It is another object of the present invention to provide a drill safety system having a magnetic unit that makes disposing the metal shavings easier.
Yet another object of the present invention is to provide a drill safety system having a vacuum unit that can collect the shavings on the inner surface.
Yet another object of the present invention is to provide a drill safety system having a vacuum unit that is easy to adjust and reconfigure.
Yet another object of the present invention is to provide a drill safety system that requires a minimum of maintenance.
It is another object of the present invention to provide a drill safety system that is robust and durable.
Yet another object of the present invention is to provide a drill safety system having an improved drill set with a stopper flange.
Yet another object of the present invention is to provide a drill safety system having an improved drill set with a stopper flange that prevents damages to the structures within the workpiece.
Still another object of the present invention is to provide a drill safety system that is inexpensive.
Still another object of the present invention is to provide drill safety systems having different parts that can be used individually and in combination with one another.
It is a further object of the invention to provide a drill safety system that is easy to manufacture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top perspective view of a vacuum unit of the drill safety system.
FIG. 2 shows a bottom perspective view of the vacuum unit of the drill safety system.
FIG. 3 shows a top perspective view of a magnetic unit of the drill safety system when the flippable top is set in place.
FIG. 4 shows a top perspective view of the magnetic unit of the drill safety system when the flippable top is flipped over.
FIG. 5 shows a top perspective view of the magnetic unit of the drill safety system when the flippable top is flipped over and the magnets are removed.
FIG. 6 shows a top perspective view of an improved drill set of the drill safety system.
FIG. 7 shows a side view of the improved hole saw drill set of the drill safety system.
FIG. 8 shows a side sectional view of all components of the drill safety system when the system is in use.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified, as far as possible, with the same reference numerals. Reference will be made in detail to embodiments of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto without deviating from the innovative concepts of the invention.
FIG. 1 shows a top perspective view of a vacuum unit of the drill safety system. Shown in FIG. 1 is the vacuum unit 50 having a collecting cup 60 , a first connector 70 , a second connector 75 , a connecting tube 80 , and a handle element 85 , wherein the collection cup 60 has a lower cup body 62 and an enlarged cup rim 63 , and the handle element 85 has a handle tube 86 and a handle 87 . The collecting cup 60 , the first connector 70 , the connecting tube 80 , the second connector 75 and the handle tube 86 are all hollow inside and are sequentially connected, forming a through channel for the movement and collection of drill shavings.
FIG. 2 shows a bottom perspective view of the vacuum unit of the drill safety system. Shown in FIG. 2 is the vacuum unit 50 having a collecting cup 60 , a first connector 70 , a second connector 75 , a connecting tube 80 , and a handle element 85 , wherein the collection cup 60 has a lower cup body 62 and an enlarged cup rim 63 , and the handle element 85 has a handle tube 86 and a handle 87 . The collecting cup 60 , the first connector 70 , the connecting tube 80 , the second connector 75 and the handle tube 86 are all hollow inside and are sequentially connected, forming a through channel for the movement and collection of drill shavings.
FIG. 3 shows a top perspective view of a magnetic unit of the drill safety system when the flippable top is set in place. Shown in FIG. 3 is the magnetic unit 10 having an outer cover 20 , wherein the outer cover has a unit base 24 and a flippable top 27 . The inner structures of the magnetic unit 10 are shielded from view. The magnetic unit 10 is generally a ring or annulus structure, especially if viewed from the top.
FIG. 4 shows a top perspective view of the magnetic unit of the drill safety system when the flippable top is flipped over. Shown in FIG. 4 is the magnetic unit 10 having an outer cover 20 , wherein the outer cover has a unit base 24 and a flippable top 27 . The flippable top 27 is flipped up, showing the inner magnets 30 , the magnet connectors 33 , and the support ring 40 . As indicated by FIG. 3 , the magnets 30 are fully covered when the flippable top 27 is flipped down. As shown in FIG. 4 , the magnets 30 are placed around the support ring 40 and on the unit base 24 .
FIG. 5 shows a top perspective view of the magnetic unit of the drill safety system when the flippable top is flipped over and the magnets are removed. Shown in FIG. 5 is the magnetic unit 10 having an outer cover 20 , wherein the outer cover has a unit base 24 and a flippable top 27 . The flippable top 27 is flipped up, showing the inner magnets 30 , the magnet connectors 33 , and the support ring 40 . The magnets 30 are removed from the unit base 24 .
FIG. 6 shows a top perspective view of an improved drill set of the drill safety system. Shown in FIG. 6 is the drill set 90 having a pilot bit 93 , a hole saw arbor 94 , and a hole saw 95 . The key feature for this embodiment is that the hole saw arbor 94 includes a stopper flange 96 positioned right behind and abutting the hole saw 95 .
FIG. 7 shows a side view of the improved drill set of the drill safety system. Shown in FIG. 7 is the drill set 90 having a pilot bit 93 , a hole saw arbor 94 , and a hole saw 95 . The key feature for this embodiment is that the hole saw arbor 94 includes a stopper flange 96 positioned right behind and abutting a back end 98 of the hole saw 95 , defining a hole saw length 99 measured from a front end 97 to the back end 98 of the hole saw 95 . Such an improvement limits the depth of the hole resulted from drilling with the drill set 90 to the hole saw length 99 , preventing unintended over-drilling that may damage the equipment underneath the drilling site.
FIG. 8 shows a side sectional view of all components of the drill safety system when the system is in use. Shown in FIG. 8 is a drill 100 equipped with the improved drill set 90 having a pilot bit 93 and a hole saw 95 , which includes bit stopper flange 96 . Also shown in FIG. 8 are the magnetic unit 10 and the vacuum unit 50 , wherein the magnetic unit 10 comprises an outer cover 20 having a unit base 24 and a flippable top 27 , inner magnets 30 with magnet connectors 33 , and a support ring 40 ; the vacuum unit 50 comprises a collecting cup 60 , a first connector 70 , a second connector 75 , a connecting tube 80 , and a handle element 85 ; and the collection cup 60 has a lower cup body 62 and an enlarged cup rim 63 , and the handle element 85 has a handle tube 86 and a handle 87 . As shown in FIG. 8 , the collecting cup 60 , the first connector 70 , the connecting tube 80 , the second connector 75 and the handle tube 86 are all hollow inside and are sequentially connected, forming a through channel for the movement and collection of drill shavings.
In FIG. 8 , drilling is being conducted on a metal board 200 , which has a drilling surface 210 that engages the pilot bit 93 and the hole saw 95 , as well as an inner surface 220 that is the opposite of the drilling surface 210 . In addition, the location on the board 200 that initially engages the drill bits are generally termed a drill site 240 . The board 200 is intended as an example for the workpieces on which drilling can be conducted. Workpieces having different shapes, sizes, depth, thickness, and texture are all possible.
Referring to FIGS. 1, 2, and 8 , the drill safety system may include a vacuum unit 50 . As indicated above, the vacuum unit 50 is used to collect the shavings from the inner side 220 . The collecting cup 60 of the vacuum unit 50 has a lower cup body 62 and an enlarged cup rim 63 , wherein the cup rim 63 may fit on the inner surface 220 . The collecting cup 60 covers the drilling site 240 , providing a complete shielding and collecting structure that ensures all metal and non-metal shavings on the inner surfaces are properly gathered. Although the collecting cup 60 has a round opening, it should be noted that other shapes, such as square, may also be adopted. In a preferred embodiment, the inner surface 240 is a flat surface and the cup rim 63 may fit on the flat surface.
The collecting cup 60 and the connecting tube 80 are the essential elements of the vacuum unit 50 , which can be connected to a vacuum motor providing suction power, allowing shavings on the inner surface to be collected. The connecting tube 80 may be rigid or flexible. In addition, as indicated by FIGS. 1 and 2 , the vacuum unit 50 may further include a first connector 70 , a second connector 75 , and a handle element 85 , which may include a handle tube 86 and a handle 87 , wherein the collecting cup 60 , the first connector 70 , the connecting tube 80 , the second connector 75 , and the handle tube 86 all hollow inside and are sequentially connected, forming a through channel.
Preferably, a user may take hold of the handle 87 and manually press the collecting cup 60 to the inner surface 240 . Such an embodiment does not require the worker to reach inside the housing of live switchgear and improves safety. Alternatively, the cup rim 63 may include magnets so that the collecting cup 60 can magnetically attach to the inner surface 240 , allowing the person conducting the drilling to do the work alone. The first connector 70 and the second connector 75 are structures that provide more flexibility to the design of the vacuum unit 50 and these structures may have different length and twisting angles. By adjusting the first connector 70 and the second connector 75 , as well as the connecting tube 80 and the handle element 85 , a user may reconfigure the vacuum unit 50 to avoid pressing the various parts of the vacuum unit 50 against the equipment in the workpiece. Various methods can be used to connect the collecting cup 60 , the first connector 70 , the connecting tube 80 , the second connector 75 , and the handle element 85 . These structures can be screwed, molded, welded, or glued together, or using any combination of suitable methods.
Referring to FIGS. 3, 4, 5, and 8 , the magnetic unit 10 is used to collect the metal shavings on the drilling surface 210 . Before drilling, the magnetic unit 10 is placed on the drilling surface 210 , and around and/or adjacent to the drilling site 240 . Since the magnetic unit 10 includes magnets 30 , when the workpiece is metal, the magnetic unit 10 may securely attach to the workpiece without the aid of gravity. This feature is particularly useful when the drilling surface is not horizontal. In a preferred embodiment as shown in FIGS. 3-5 , the magnetic unit has a ring or annulus shape, especially if viewing from the top. The ring shape allows the magnetic unit 10 to surround the drilling site 240 , as shown in FIG. 8 . However, it should be noted that the shape of the magnetic unit 10 may vary according to the specific job to be conducted, the size and shape of the work piece, and surface conditions. For example, the magnetic unit 10 may be an elongated strip that may be flexed and twisted to conform to a specific drilling work. The strip-shaped magnetic unit 10 may even be twisted in a circle to mimic the ring-shape embodiment.
The cover 20 of the magnetic unit may comprise a unit base 24 and a flippable top 27 , wherein the magnet core—the magnets 30 combined with the connector 33 —may be placed on the unit base 24 and be shielded by the flippable top 27 when the flipped top 27 is flipped down. It is possible that the unit base 24 and the flippable top 27 form a single continuous structure. Alternatively, the unit base 24 and the flippable top 27 may be distinct but attached structures that as a whole form a cover 20 shielding the a magnet core. It should also be noted that while the embodiment shown in FIGS. 3-5 show the flippable top 27 to expose the inner structures of the magnetic unit 10 by flipping up, other designs are still possible. The key feature for the cover 20 is that it may be opened so that the magnets may be removed. Specific designs may vary and as long as the general structures fit with the essential concept, such designs are incorporated in the current invention.
When the flippable top 27 is flipped down, no magnet is directly exposed. The metal shavings resulted from drilling on the drilling surface are pulled towards the magnetic unit 10 and attached to the cover 20 , which is preferably non-magnetic and non-conductive. After drilling, as shown in FIGS. 4-5 , the flippable top 27 is flipped up, allowing the magnets 30 to be removed so that the metal shavings can no longer attach to the cover 20 . The user may then easily discard the shavings, put the magnets 30 back, flip down the flippable top 27 , and make the magnetic unit 10 ready to be used again.
To ensure the physical robustness of the magnetic unit 10 , a support structure 40 may be included to provide physical support to the magnetic unit 10 . The support structure 40 is preferred to be rigid and it may conform to the shape of the magnetic unit 10 . As indicated above, the shape of the magnetic unit 10 may vary. Therefore, the size and shape of the support structure 40 may vary accordingly.
The magnets 30 used in the current invention are preferably permanent magnets and may be any type of magnetic material, including but not limited to: metallic magnets, composite magnets, and rare earth magnets, and any combination thereof. The magnet connectors 33 are optional elements used to link two or more magnet pieces together, allowing easier placement and removal. A magnet 30 may have a wrap that covers the magnet 30 , wherein the wrap may directly link with the magnet connector 33 . It is preferred that the magnet connector 33 is flexible, allowing the magnet pieces to bend against one another. The embodiment shown in FIG. 5 includes two magnets sets, each including two magnet pieces linked by a magnet connector 33 . It should be clear that such format may vary according to the size of the magnetic unit 10 , the magnetic power required, and the specific needs of the drilling work.
Referring to FIGS. 6, 7, and 8 , the drill safety system may include an improved hole saw drill set 90 that includes a stopper flange 96 . As indicated above, similar to the conventional hole saw drill bit, the current hole saw 95 is a cylinder structure that can be connected, usually with a threaded section, to a drill arbor 94 , wherein the front end 97 of the cylinder facing the board 200 has sawteeth that may cut through the board 200 to produce a hole at drilling site 240 . In the current improved hole saw drill set 90 , the hole saw arbor 94 includes a stopper flange 96 extending from a periphery of the hole saw arbor 94 and positioned right behind and abutting the back end 98 of the hole saw 95 , blocking the advancement of the hole saw 95 when the entire cylinder of the hole saw 95 has cut into the workpiece.
The length 99 of the hole saw 95 , measured from the front end 97 to the back end 98 , sets a maximum limit for the depth of the hole. To cut a through hole on the board 200 , the thickness of the board 200 must be smaller than the length 99 of the hole saw 95 . Such a design prevents over-penetration, protects the inner structures of the workpiece, and in essence puts more emphasis on the safety of the device. It is a better design compared with placing the stopper flange directly on the back end 98 of the hole saw 95 because the current design allows hole saws with different lengths to be used with the same drill arbor 94 . The user may choose drill bits having different lengths for different projects and use the same drill arbor, ensuring that the drilling can be conducted effectively and protection is provided at the same time.
As indicated above, the various parts of the drill safety device may be used individually and in combination with one another. For example, the user may utilize a conventional hole saw drill bit for drilling that is protected by the magnetic unit 10 and the vacuum unit 50 . The magnetic unit 10 may be used together with traditional make-shift arrangement used by electricians or the device disclosed in U.S. Pat. No. 6,974,048. The magnetic unit 10 and the vacuum unit 50 , when used together, provide a complete solution for debris removal when drilling on metallic workpieces. The inclusion of the improve hole saw drill bit further adds to the level of security that prevents damages and accidents.
In terms of dimension, the sizes of various parts of the drill safety system may vary according to drill beings used, the intended drilling results, and the size and the shape of the workpiece. The collecting cup 60 is preferred to provide sufficient coverage of the drilling site 240 . The covered area of the collecting cup 60 , measure by the area within the cup rim 63 , is preferred to range from 1 cm 2 to 1 m 2 , with the more preferred range of 10 to 200 cm 2 . The overall length of the vacuum unit 50 may range from 10 cm to 5 m, with the preferred range of 30 to 100 cm. When the magnetic unit 10 has a ring shape, as indicated in FIGS. 3-5 , the inner diameter may range from 1 cm to 1 m, with the preferred range of 5 to 30 cm, the outer diameter may range from 1 cm to 1.5 m, with the preferred range of 5 to 50 cm, and the ration of (outer diameter)/(inner diameter) may range from 1.1 to 5, with the preferred range of 1.2 to 2.5. The length 99 of the hole saw 95 may range from 0.5 to 100 cm, with the preferred range of 1 to 20 cm.
It is preferred that various parts of the drill safety system are not too heavy so that they may be held, transported, and used with easy. In particular, the vacuum unit 50 is preferred to be light because in some cases, a user is supposed to hold the vacuum unit 50 during drilling. The overall weight of the vacuum unit 50 may range from 10 g to 20 kg, with the preferred range of 100 g to 5 kg. The overall weight of the magnetic unit 10 may range from 50 g to 20 kg, with the preferred range of 200 g to 10 kg. The overall weight of the drill set 90 may range from 10 g to 5 kg, with the preferred range of 20 g to 2 kg.
In terms of materials, any part of the vacuum unit 50 and the magnetic unit 10 that make contact with the workpiece is preferred to be non-conductive and non-magnetic. The various parts of the vacuum unit 50 may be made from the same or different materials. The material is preferred to be safe, strong, and impermeable to liquid. Moreover, it would be desirable that the material is inexpensive and easy to process during manufacture. The materials that may be used include but are not limited to: rubber, and plastic such as, but not limited to, polyethylene terephthalate (PET), polyethylene (PE), high-density polyethylene, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), high impact polystyrene (HIPS) and polycarbonate (PC), or paperboard coated with a suitable coating such as, but not limited to, polyethylene, or some combination thereof. The various parts of the magnetic unit 10 may be made from the same or different materials. The magnets 30 , as indicated above, are preferred to be permanent magnets. The cover 20 of the magnetic unit 10 is preferred to be non-conductive, non-magnetic, flexible but durable so that the flippable top 27 may be flipped up and down numerous times. The materials suitable to make the cover 20 include but are not limited to rubber, and plastic such as, but not limited to, polyethylene terephthalate (PET), polyethylene (PE), polyvinylidene chloride (PVDC), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), high impact polystyrene (HIPS) and polycarbonate (PC), or paper or fabric coated with a suitable coating such as, but not limited to, polyethylene, or some combination thereof. The preferred material for the cover 20 of the magnetic unit 10 is rubber.
As indicated above, the primary focus of the current invention is to improve safety during the drilling of live equipment. However, the use of the current invention is much broader. For example, with proper arrangement, the vacuum unit, the magnetic unit, and the improved hole saw will also help to save time in new installations. When the workers are doing new installations of switch gear, holes are drilled into the housing. The conventional approach is to use some make-shift arrangement or vacuum out the equipment after drilling has been completed. In systems like data centers each piece of gear may have 8-16 conduits and a significant amount of shavings may be left on top of the gear. The electricians usually need to spend several days vacuuming out all of the gear before it can be energized for the first time. Using the current invention significantly lessens the time and man-power to clean the new gear before energizing it for the first time because the debris is collected while holes are being drilled.
In addition, the current invention may be used to install new circuits underneath raised computer floors sites such as data centers, which have very strict rules about debris caused by new installations in such critical environments. Air conditioning usually moves underneath the floor, creating a strong flow of air that may spread the shavings. This is a situation where the worker is either drilling from underneath equipment and debris would be falling into the clean computer floor or drilling into a junction box that is under the raised floor where the air flow is moving and blowing everything around. The conventional approach is to have a worker hold a shop vacuum nozzle next to the drill site while another worker drills. Then, the floors are vacuumed and coated after a new install before a company moves in. The conventional method gets most of the debris but usually misses whatever is on the side of the drill opposite the vacuum nozzle. Using the current invention properly collects all the shavings while drilling is being conducted, saving a significant amount of time and cost.
Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.
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The present disclosure describes and teaches a drill safety system including a magnetic unit, a vacuum unit, and an improved hole saw drill set. The various parts of the drill safety system may be used individually or in combination with one another. The user may use the magnetic unit to surround the drilling site so that metal drill shavings on the drill surface may be collected by the magnetic unit. In addition, the magnetic unit includes a flippable top mechanism, allowing convenient disposal of the debris. The vacuum unit is fitted to the inner surface of the drilling site, collecting debris that fall through. The improved hole saw prevents over-penetrating by the drill, reducing the likelihood of damaging equipments underneath the drill site. This makes the drill particularly suitable for drilling holes during electrical work.
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RELATED APPLICATIONS
[0001] This application claims priority, under 35 U.S.C. §119, to International Patent Application No.: PCT/PT2007/000048, filed on Nov. 15, 2007, which claims priority to Portuguese patent application No.: PT 103606, filed Nov. 15, 2006, the disclosures of which are incorporated by reference herein in their entireties.
TECHNICAL FIELD
[0002] The present invention relates to electro-optic sensors based on the Surface Plasmon Resonance (SPR) effect, in particular to processes and devices used for the detection of chemical and/or biological events comprising the following elements: (1) a radiation emitter ( 20 ) and a radiation detector ( 30 ); (2) a Detection Zone (DZ) ( 41 ) containing a Detection Surface (DS) ( 42 ) which incorporates a thin conductive layer built to allow for the occurrence of the SPR effect, for at least one angle of incidence and at least one wavelength of the radiation incident onto the DS ( 42 ); (3) a fluidic substrate ( 40 ) including channels ( 43 ) and at least one DZ described in ( 2 ); (4) a fluid control mechanism used to deliver a predefined fluid volume from an initial reservoir into a DZ and from there to a final reservoir; (5) a liquid crystal layer (LCL) ( 80 ), placed between the radiation emitter ( 20 ) and the radiation detector ( 30 ), controlled by electrical, magnetic or optical means, and used in such way that enables the control of the radiation properties and leading to an optimized SPR signal, improving in this way the accuracy and sensitivity of the detection device.
Chemical/Biological Detection Devices
[0003] A Chemical/biological detection device is composed by three major elements: (A) Recognition elements, capable of recognizing a specific chemical and/or biological substance; (B) Transduction mechanisms, capable of converting the chemical/biological recognition events into quantitative information; (C) Fluidic mechanisms, capable of delivering fluid samples to the recognition elements in a controlled manner.
(A) Recognition Element
[0004] Recognition elements are typically based on the key-lock principle, and comprise molecular regions or combinations of the same capable of recognizing specific chemicals or biological substances, from now on referred to analyte. There are different ways to achieve this effect, namely: randomly or oriented enzymes, lectines or antibodies. The performance of this recognition element is dependent on several parameters, namely: (i) the sensitivity (defined by the detection limit); (ii) the specificity (defined by the degree of sensitivity for detecting other substances present in the same medium of the specific analyte to be detected); (iii) its stability over time. In the case of chemical/biological detection devices used for determinations involving proteins or enzymes, the recognition elements usually consist of immobilized layers containing specific and oriented antibodies.
[0005] The chemical/biological recognition element may be obtained using several different mechanisms, namely: (i) chemical adsorption to the surface; (ii) encapsulation on a polymeric matrix; (iii) covalent bonding to a solid substrate. Although the choice of the chemical/biological recognition element is beyond the scope of the present invention, the description presented above serves only has a framework overview of the most common possibilities for building this biosensing element.
(B) Transduction Mechanism
[0006] There are several transduction mechanisms capable of converting chemical/biological events into quantitative information for subsequent treatment and analysis, namely electrochemical, vibratory, magnetic and optic transducers.
[0007] The optical detection of the SPR effect is essentially a measurement technique of the refractive index close to an electrically conductive surface. The most significant difference of SPR detection compared to conventional refractometers relates to the measurement scale and detection process: in conventional techniques, all the fluid volume contributes to the optical response which results in a average measure of the refractive index; On the contrary, in the case of SPR detection, only the volume of the fluid close to a conducting surface is relevant. Moreover, in this later case, the measure corresponds to a weighted average of the refractive index with a decaying weight when moving apart from the conductive layer in which the SPR effect occurs.
SPR Effect
[0008] The SPR effect is an optical phenomenon that results from the local charge density oscillation in an interface between two media of differing dielectric properties. In particular, the SPR effect occurs at the interface between a dielectric medium and a metallic one (see reference 1). In this case, the surface plasmon wave is an electromagnetic wave with polarization TM (magnetic vector of the wave is perpendicular to the propagation direction and parallel to the interfacial plan). The SPR propagation constant β may be described by equation (1):
[0000]
β
=
λ
ɛ
m
ɛ
d
ɛ
m
+
ɛ
d
(
1
)
[0000] in which λ is the incident wavelength, ε m is the dielectric constant of the metal (ε m =ε mr +iε mi ) and ε d is the dielectric constant of the dielectric medium. The SPR only occurs if ε mr <0 and |ε m <ε d . In this case, the SPR effect will propagate at the interface between the two media and will decrease exponentially from the interface to the bulk of each medium. On the other hand, the SPR effect is only detectable for metallic films with thicknesses in the range of tens to hundreds of nanometer (in the case of a gold film, the SPR effect typically occurs with thicknesses between 25 nm and 150 nm).
[0009] Due to these facts and according to equation (1), the propagation constant β of the SPR is extremely sensitive to variations of the refractive index in the dielectric medium close to the interface. As a consequence, the SPR effect may be exploited for sensing applications, e.g. the immobilization of a certain biological material (protein, enzyme, etc.) close to the interface will result in a local variation (at the nanometer length scale) of the refractive index (since typically the refractive index of water-based solutions is around 1.33 and the refractive index of biological compounds is close to 1.54). This change on the refractive index induces a change on the propagation constant of the surface plasmon that may be detected with precision by optical means, as described in the following sections.
SPR Configurations
[0010] There are three basic methods for detecting the SPR effect:
[0000] (i) Measuring the intensity of radiation reflected from the detection surface as a function of the radiation incidence angle; typically, for a given wavelength, the SPR effect is clearly detected at a specific incidence angle in which the reflection is minimal;
(ii) Measuring the intensity of radiation reflected from the detection surface as a function of the radiation wavelength; typically, for a fixed incidence angle, the SPR effect is clearly detected at a specific radiation wavelength in which the reflection is minimal;
(iii) Measuring the phase of radiation reflected from the detection surface as a function of the incidence angle or radiation wavelength. In this case, the SPR effect is clearly detected at a specific incidence angle or radiation wavelength in which the radiation phase variation is maximal.
[0011] Different optical configurations may be used in order to properly detect the SPR effect (see reference 2), using typically an optical system that both creates surface plasmon (using an illumination element, e.g. a laser or a radiation emitting diode or any other appropriate radiation source) and also detects the SPR effect (using an optical measurement element, e.g. CCD, CMOS, photodiode, or any other appropriate element).
[0012] The SPR effect only occurs if the component of the vector of incident wave that is parallel to the interfacial plane is coincident with the component of surface plasmon wave. This specific condition will only exist if there is some coupling mechanism typically provided by (i) a prism; (ii) a wave-guide; (iii) a diffraction grating. The man of the art may rapidly understand these coupling techniques by reading technical literature, namely by reading reference 1.
(C) Fluidic Mechanism
[0013] Different mechanisms may be used for the fluid control, namely conventional fluid pumping using external pumps and tubes, electro pressure control, acoustic/piezoelectric control, electrokinetics, and centrifugal control. The optimization of this element of chemical/biological detection device is beyond the scope of the present invention.
Liquid Crystal Layers
[0014] Liquid crystal (LC) phases, or mesophases, are intermediate phases between liquids and crystals, presenting orientation properties (see reference 3). A specific type of LC, named nematic LC, presents an order on the orientation of its molecules combined with a disorder on the position of its molecules. It is possible to define an average orientation direction of the LC molecules that propagates through long distances, with this direction defined, for example, by a certain alignment surface. Moreover, for certain LC molecules, it is possible to use an external electric field that also induces a specific orientation. In this case, the orientation of the LC molecules depends on the competition between the anchoring surface properties (induced by the alignment surface) and the coupling electric field forces (see reference 4).
[0015] The LC layers present two relevant properties:
[0000] (1) an optical anisotropy resulting in a mismatch on the radiation propagation through the LC layer, in terms of the radiation polarization parallel or perpendicular to the average orientation of the LC molecules;
(2) a gradual change of the average orientation of the LC molecules along an LC layer induces changes on the polarization properties of the radiation passing through the LC layer. In particular, if the LC molecules present a twisting pitch along the LC layer that is much larger than the radiation wavelength, then the system will behave like a waveguide (in which the radiation polarization follows the rotation of the LC molecules). This is the basic principle of the standard LC devices according to the invention of M. Schadt (see reference 5). Now, if the twisting pitch of the LC layer is of the same order as the radiation wavelength, then smaller rotations of the radiation polarization will occur, and/or reflections and/or inverse radiation polarization rotations, depending on the wavelength/pitch ratio.
[0016] There are different types of LC layers with potential use for optical systems. The most common type of LC layer, called twisted nematic LC, is based on the continuous twisted orientation of the average direction of the LC molecules along the LC layer. The LC layer is characterized in that a twisting pitch depends on several parameters, namely the concentration of a chiral dopant that induces the twisting. When subject to an external electric field, the LC molecules tend to be aligned along the field and the twisting is then destroyed. By controlling the applied electric field it is possible to properly adjust the LC layer twisting pitch. For systems in which there is a need to maintain the optical quality (e.g., without radiation diffusion) some types of LC layers are no longer suitable (namely, PDLC layers, or other LC layers with significant radiation diffusion).
Conventional SPR Detection Devices
[0017] Conventional SPR detection devices include an optical system with pre-defined and fixed properties, namely in terms of incidence angles, polarization and wavelength.
[0018] FIG. 1A is a schematic illustration of a conventional SPR detection device according to the prior art, in the prismatic configuration. A radiation emitter ( 20 ) produces a radiation beam ( 101 ) focused through a prism ( 90 ) into a detection surface DS ( 42 ) situated in a detection zone DZ ( 41 ). The DS includes a thin conductive layer in close proximity with the fluid. The radiation reflected ( 102 ) is directed to the radiation detector ( 30 ). The analysis of the radiation signal observed in the radiation detector ( 30 ) is used for the quantitative measurement of the concentration of substances or of chemical and/or biological events occurring in the vicinity of the DS ( 42 ). In this configuration, the device presents fixed and predefined optical properties, namely in terms of radiation wavelengths, phase and incidence angles.
[0019] FIG. 1B is a schematic illustration of a conventional SPR detection device according to the prior art, in the grating coupling configuration. A radiation emitter ( 20 ) produces a radiation beam ( 101 ) focused through a prism ( 90 ), into a detection surface DS ( 42 ) situated in a Detection Zone DZ ( 41 ). The DS includes a thin conductive layer behaving like a diffraction grating. The radiation reflected ( 102 ) is directed to the radiation detector ( 30 ). The analysis of the radiation signal observed in the radiation detector ( 30 ) is used for the quantitative measurement of the concentration of substances or of chemical and/or biological events occurring in the close proximity of the DS ( 42 ). Again, in this configuration, the device presents fixed and predefined optical properties, namely in terms of radiation wavelengths, phase and incidence angles.
[0020] In this configuration, the radiation emitter ( 20 ) has fixed and pre-defined optical properties, namely in terms of:
the wavelength spectra, this parameter may be pre-defined by using a laser for the radiation emitter ( 20 ), or by using a radiation emitter ( 20 ) with a continuous emission spectra, such as a LED or any other source of continuous spectra; the range of incident angles of the radiation incident on the DS ( 42 ), defined by the optical elements used, namely by the optical lenses setup the radiation emitter ( 20 ); the polarization of the incident radiation, typically fixed linear or circular, when using lasers in the radiation emitter ( 20 ), or non-polarized radiation when using LEDs; the phase of the incident radiation. If a laser is used for the radiation emitter, typically the radiation is coherent in the radiation cone incident on the DS ( 42 ); the focal point of the radiation incident on the DS ( 42 ); the refractive index of the material used as substrate in contact with the DS ( 42 ); the refractive index of the standard fluid used to perform the SPR measurements.
[0028] These different parameters are pre-defined and fixed in conventional SPR detection devices, and this fact presents a limitation on their potential use. In particular, it is a limiting factor in terms of detection range of the fluid refractive index in contact with the DS ( 42 ). Moreover, the limitations, associated with detection noise and angular resolution of the radiation detector ( 30 ) sensor (i.e. the relation between angular aperture of the incident radiation and number of detection elements in the sensor), are also a limiting factor of the resolution and sensitivity of conventional SPR detection devices.
[0029] These facts limit both the sensitivity and the application range of SPR detection. In particular, conventional SPR detection devices present the following limitations:
[0000] (1) difficulty in eliminating optical defects (mechanical fatigue, radiation diffusion, refractive index changes), resulting in a noise signal higher than desired. This fact is particularly relevant when detecting small biological substances;
(2); difficulty in distinguishing the SPR sensor signal due to receptor-analyte binding and refractive index changes of either the fluid or the DS ( 42 ) substrate due to temperature changes. This fact limits the extrapolation of SPR measurements into quantitative information regarding analyte concentration present near the DS ( 42 ) (see reference 6);
(3) difficulty in adjusting the detection parameters for maximum sensitivity at the DS ( 42 ) for the desired thickness corresponding to the size of the analyte;
[0030] In order to overcome these limitations, the present invention considers the use of a LC layer ( 80 ) placed between the radiation emitter ( 20 ) and the radiation detector ( 30 ), controlled by electric, magnetic or optical means, in order to adjust the radiation properties and in this way amplify the SPR signal observed at the radiation detector ( 30 ).
[0031] The patent US2003103208 refers to a SPR sensor with a prismatic configuration, using an LC layer placed between the radiation emitter and a conductive layer defining the DS, in order to rotate the radiation polarization by 90°. In this case, the radiation incident on the DS may have two polarization states: (i) TM polarization (parallel to the interface) or (ii) TE polarization (perpendicular to the interface). The patent mentioned above only applies to SPR sensors in the prismatic configuration and to devices wherein the radiation polarization is rotated by 90°.
[0032] The patent EP1157266 refers to an SPR detection device, mentioning that it would be possible to use a LC layer behaving like a controllable polarizer. The referred patent applies to SPR sensor devices based on diffractive reflective optical elements. Moreover, in the above-mentioned patent there is no mention on the possible embodiment of the referred LC layer.
[0033] Patents EP1068511 and US2003206290 concern an SPR detection device in which LC layers are used as controllable diaphragms by electric means, in order to select the time period and placement of the radiation beam necessary for the SPR effect.
[0034] The following publications are included here for reference:
1. Homola, J. Et al. Sensors and Actuators 54, 3-15 (1999); 2. Homola, J. Anal Bioanal Chem 377, 528-539 (2003); 3. P. G. de Gennes, J. Prost, The Physics of Liquid Crystals (2nd ed. Clarendon, Oxford 1993) 4. Fonseca, J G, PhD Thesis, Strasbourg 2001 5. Helfrich, W., Schadt, M. patent CH19710005260 6. G. Vertogen, W. H. de Jeu: Thermotropic Liquid Crystals: Fundamentals (EPSinger-Verlag, Berlin, 1988) 7. Hecht, E. Optics, Addison Wesley Longman (1998). 8. Gordon D. Love. Proc. Soc. Foto.-Opt. Instrum. Eng. 2566: 43-47 (1995). 9. H. Ren et al, Appl. Phys. Lett. 84, 4789 (2004). 10. Born, M. and Wolf, E. Principles of Optics: Electromagnetic Theory of Propagation, Interference, and Diffraction of Light, Pergamon Press (1989).
OBJECT OF THE PRESENT INVENTION
[0045] We have come to the conclusion that it would be relevant to dynamically adjust some parameters significant for the SPR effect, in order to optimize the respective SPR detection device performance. In this frame, LC layers are found to be appropriate and advantageous, since it is possible to adjust the radiation properties (reflected radiation or transmitted radiation) by controlling a LC layer using simple electric or optic means. This adjustment of the radiation properties, when coupled to a detection device based on the SPR effect, may be explored in order to enhance its overall performance.
[0046] In a first aspect, the present invention comprises an optical system consisting of a radiation emitter ( 20 ) and a radiation detector ( 30 ) both used for detecting events occurring in the close proximity of a DS ( 42 ), which includes a thin electrically conductive layer in a fluidic substrate, containing channels ( 43 ) and at least a DZ ( 42 ). The DZ ( 42 ) is built in such a way that it enables the occurrence of the SPR effect, which is used for the detection of chemical and/or biological events. The detection device also includes a LC layer ( 80 ) placed in between the radiation emitter ( 20 ) and the radiation detector ( 30 ), controlled by electrical or optical means. The LC layer ( 80 ) is controlled in such a way that enables the controlled adjustment of the radiation properties in order to optimize the accuracy and sensitivity of the detection device.
[0047] In a second aspect, the present invention consists of a SPR sensor ( 10 ) capable of detecting chemical and/or biological events in the close proximity of a DS ( 42 ), comprising a fluidic substrate ( 40 ) and an optical system, wherein the optical system comprises a radiation emitter ( 20 ) and a radiation detector ( 30 ) and a LC layer ( 80 ) placed in the radiation path between the radiation emitter ( 20 ) and the radiation detector which is capable of adjusting the radiation properties. The SPR sensor ( 10 ) is capable of detecting:
(i) the presence of a specific substance, and/or (ii) the occurrence of a specific chemical and/or biological event in one of the detection zones of the fluidic substrate,
[0050] The arrangement of the radiation emitter ( 20 ) and radiation detector ( 30 ) with respect to the fluidic substrate ( 40 ) is fixed in such a way that the radiation beam incident on the DS ( 42 ) contains at least one incident angle for which there is a coupling on the thin electrically conductive layer resulting in the SPR effect. This configuration is influenced by several properties and parameters, in particular:
The wavelength of the radiation incident on the DS ( 42 ); The refractive index, extinction coefficient and thickness of the electrically conductive layer; The incidence angle; The radiation polarization; The refractive index and extinction coefficient of the fluid present at the DZ ( 41 ).
[0056] In this sense, and having all parameters fixed, it is possible to observe a change in the radiation pattern of the SPR sensor ( 10 ) and from this information to quantify the change on the refractive index in the close proximity of the DS ( 42 ). This determination is then used in order to quantify the surface immobilization of a certain substance or the reaction of two types of molecules in the proximity of the DS ( 42 ).
[0057] The embodiments of the present invention enable proper adjustment of the different parameters mentioned above, in a dynamic way and during the detection process, by using an additional LC layer ( 80 ), also placed in the radiation path between the radiation emitter ( 20 ) and the radiation detector ( 30 ). The different embodiments described in the following sections correspond to different solutions for existing problems of conventional SPR detection devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] FIG. 1A is a schematic illustration of a conventional SPR detection device according to the prior art, in the prismatic configuration.
[0059] FIG. 1B is a schematic illustration of a conventional SPR detection device according to the prior art, in the grating coupling configuration.
[0060] FIG. 2A is a schematic illustration of the average orientation of the molecules in a twisted nematic LC layer. In the rest condition the molecules present a rotation of 90° along the LC layer (left) and when subject to an external electric field above a certain threshold (V_th) the twist is minimized and the molecules became aligned along the electric field (right).
[0061] FIG. 2B is a schematic illustration of the behaviour of the total twisting angle of the LC layer illustrated in FIG. 2A as a function of the applied voltage, for high enough voltages the twisting angle tends to zero.
[0062] FIG. 3A is a schematic illustration of a SPR detection device in the grating coupling configuration and using a LC layer to control the polarization of the radiation incident in the detection surface.
[0063] FIG. 3B is a schematic illustration of the embodiment of the device described in FIG. 3A , after acquiring two signals (S 1 and S 2 ) with different polarizations being possible to minimize the acquisition noise by dividing the two signals and obtain a final signal (S_SPR) with optimized signal to noise ratio.
[0064] FIG. 4A is a schematic illustration of the behaviour of SPR effect in terms of radiation intensity (dashed line) and radiation relative phase (solid line) both as a function of the incidence angle on the detection surface.
[0065] FIG. 4B is a schematic illustration of the average orientation of the molecules in a uniform nematic LC layer. In the rest condition, the molecules average orientation is uniform and aligned along the alignment surface direction (left), and when subject to an externally applied electric field above a certain threshold (V_th) the molecules become aligned with the electric field.
[0066] FIG. 4C is a schematic illustration of the behaviour of the total phase difference (de-phasing between the ordinary and extraordinary polarization directions of the radiation with respect to the LC average orientation direction) of the LC layer described in FIG. 4B as a function of the applied voltage. For high enough voltages the phase difference tends to zero.
[0067] FIG. 5A is a schematic illustration of an SPR detection device in the grating coupling configuration and according to the second example of the present invention, where a LC layer is used to control the de-phasing of the radiation incident on the detection surface.
[0068] FIG. 5B is a schematic illustration of the evolution of the de-phasing of radiation as a function of the incidence angle on the detection surface for the detection device described in FIG. 5A .
[0069] FIG. 5C is a schematic illustration of the SPR signal detected by the radiation detector of a conventional SPR sensor (dashed line) and the sensor for the device described in FIG. 5A (solid line)
[0070] FIG. 5D is a schematic illustration of the evolution of the distance between the two angles at which the minimum of intensity of the SPR optical signal occur (W), as a function of the de-phasing of radiation for the detection device described in FIG. 5A , and in which the LC layer ( 80 ) induces a de-phasing perpendicular to the incidence direction.
[0071] FIG. 6 is a schematic illustration of the optical sub-system of radiation emission for a SPR detection device according to the present invention, in which a collimating lens is positioned after the emitter, followed by a polarizer and an LC layer placed in the collimated radiation path, and finally a focusing lens is used for directing the radiation to the detection surface.
[0072] FIG. 7A is a schematic illustration of the resulting refractive index of the LC layer described in FIG. 4B as a function of the applied voltage.
[0073] FIG. 7B is a schematic illustration of the average orientation of the molecules inside the LC layers. In the rest condition (V<V_TH) the LC molecules present uniform average orientation (left). Depending on the applied voltage (for V>V_TH), it is possible to create spatial patterns of refractive index.
[0074] FIG. 7C is a schematic illustration of the equivalent focal distance of the LC layer illustrated in FIG. 7B , as a function of the applied voltage.
[0075] FIG. 7D is a schematic illustration of the optical sub-system of radiation emission for a SPR detection device according to the present invention, in which a group of two LC layers are used to act as focusing lens of variable amplification with constant focal length.
[0076] FIG. 8 is a schematic illustration of a detection device according to the present invention, in which a group of two LC layers is placed in between the detection surface and the radiation detector in order to control the radiation signal amplification.
DETAILED DESCRIPTION OF THE INVENTION
[0077] In a first aspect, the present invention consists of an SPR sensor ( 10 ) used for detecting chemical and/or biological events, comprising a radiation emitter ( 20 ) and a radiation detector ( 30 ) used for detecting events occurring in the close proximity of a DS ( 42 ) of a DZ ( 41 ) of a fluidic substrate ( 40 ), comprising channels ( 43 ), and at least one DZ ( 41 ). The DZ ( 41 ) contains a DS ( 42 ), which includes a thin electrically conductive layer, built in such a way that enables the occurrence of the SPR effect. The SPR sensor ( 10 ) includes a LC layer ( 80 ), positioned in the radiation path between the radiation emitter ( 20 ) and the radiation detector ( 30 ), and controlled by electrical or optical means, enabling the proper adjustment of the radiation properties, to optimise the SPR optical signal. The proper adjustment of the radiation properties using the LC layer ( 80 ) leads to enhanced sensitivity and accuracy of the SPR detection device.
[0078] In a second aspect, the present invention consists of a SPR sensor ( 10 ) capable of detecting chemical and/or biological events occurring in the close proximity of a DS ( 42 ), comprising a fluidic substrate ( 40 ) and an optical system, wherein the optical system comprises a radiation emitter ( 20 ) and a radiation detector ( 30 ) and an LC layer positioned between the radiation emitter ( 20 ) and the radiation detector ( 30 ). The LC layer ( 80 ) is capable of adjusting the radiation properties.
[0000] The SPR sensor ( 10 ) is capable of detecting:
(i) the presence of a specific substance, and/or (ii) the occurrence of a specific chemical and/or biological event in one of the detection zones.
[0081] The embodiments of the present invention enable proper adjustment of the different parameters mentioned above, in a dynamic way and during the detection process, by using an additional LC layer ( 80 ), positioned in the radiation path between the radiation emitter ( 20 ) and the radiation detector ( 30 ). The different embodiments described in the following correspond to different solutions for existing problems of conventional SPR detection devices.
First Example
[0082] The SPR effect occurs in the component of the radiation polarization that is parallel to the interface (TM polarization) between a thin electrically conductive layer and a dielectric layer. Conventional SPR sensors typically maximize the intensity of the incident radiation in this polarization in order to maximize the SPR signal. The absence of a reference signal is considered problematic for the detection. In particular, the lack of reference signal results in a high (higher than desired) signal noise, due to different sources, namely the lack of stability and uniformity of the radiation source and of the substrate used for the detection. One simple way to eliminate this problem consists in rotating, in a controlled and systematic way, the polarization of the incident radiation. Since the noise is, in a first analysis, independent of the radiation polarization, one may then eliminate a significant part of the acquisition noise by acquiring two signals of different polarizations. For example, by acquiring two signals with TE and TM polarizations and dividing (TM/TE) or subtracting (TM−TE) the two signals it is possible to isolate only the contribution of the SPR effect. This process may the performed using a LC layer ( 80 ) with well-known properties.
[0083] FIG. 2A is a schematic illustration of the average orientation of the molecules in a twisted nematic LC layer. In the rest condition (V<Vth) the average orientation of the LC molecules ( 83 ) present a rotation of 90° along the LC layer (left). For sufficiently high applied voltages (V>Vth) the LC molecules ( 83 ) tend to be aligned along the electric field and the twist is gradually minimized.
[0084] FIG. 2B is a schematic illustration of the behaviour of the total twisting angle of the LC layer described in FIG. 2A , as a function of the applied voltage. If the twisting pitch is sufficiently large when compared with the electromagnetic radiation wavelength, then the LC layer ( 80 ) behaves like a wave-guide, so that the incident radiation polarization is rotated along the LC rotation.
[0085] Using, for example, a LC layer ( 80 ) with a twisting pitch of eight times its thickness, the LC layer ( 80 ) will then show two typical states depending on the applied voltage:
[0000] (i) when the applied voltage is sufficiently low (e.g., for a planar orientation, the applied voltage is below the Frederiks threshold, see reference 3) then the LC layer ( 80 ) induces a rotation of 90° of the incident radiation polarization. The incident radiation may then be selected and aligned in order to have a 90° rotation of its polarization when passing through the LC layer ( 80 ) and then be incident on the DS ( 42 ) with the TM or TE polarizations while maintaining its relative intensity;
(ii) when subjected to a sufficiently high voltage, the rotation of the LC molecules ( 83 ) is destroyed as they tend to be aligned with the applied electric field. In this case, the radiation incident on the DS ( 42 ) will only have one polarization component (e.g. TM).
[0086] The novelty of the present invention consists of a device comprising:
(i) a fluidic substrate ( 40 ) including at least one DZ ( 41 ) with a DS ( 42 ) built in such a way that it enables the occurrence of the SPR effect; (ii) a group of radiation emitter ( 20 ) and radiation detector ( 30 ) arranged in such a way that the radiation incident onto the DS ( 42 ) includes a range of angles in which the SPR effect occurs; (iii) a LC layer ( 80 ) positioned in the radiation path between the radiation emitter ( 20 ) and the radiation detector ( 30 ) built in such a way that it behaves like a wave-guide, so that the polarization of radiation passing through the LC layer ( 80 ) is also rotated, enabling the SPR sensor 10 to accomplish the following sequence of events.
(1) Reference Tension Control. The LC controller ( 84 ) applies a sufficiently low voltage on the LC layer ( 80 ) so that the LC molecules ( 83 ) impose a rotation of the polarization of radiation incident on the DS ( 42 ).
(2) Reference Signal Acquisition. The first signal S 1 is acquired by the radiation detector ( 30 ) corresponding to a condition in which the two polarization components (TE and TM) are present in the radiation incident on the DS ( 42 ). The acquisition of the signal S 1 must occur after a certain time from the applied reference tension (typically in the order of ms) in order to have all the LC molecules out of the transitory orientation regime.
(3) Tension Measurement Control. The LC controller ( 84 ) applies a sufficiently high voltage on the LC layer ( 80 ) so the LC molecules ( 83 ) are aligned with the applied electric field destroying the natural twisting. Due to this alignment, there is no rotation of the polarization of radiation incident on the DS ( 42 ).
(4) Signal Measurement Acquisition. The second signal S 2 is acquired by the radiation detector ( 30 ) that corresponds to a condition in which only one polarization component (e.g. TM) is present in the radiation incident on the DS ( 42 ). The acquisition of the signal S 2 must occur after a certain time from the applied reference tension (typically in the order of ms) in order to have all the LC molecules out of the transitory orientation regime.
(5) Signal Processing. Finally the SPR signal is extracted from the two optical signals using the relation:
[0000]
S
SPR
=
S
2
2
S
1
-
S
2
(
2
)
[0090] FIG. 3A is a schematic illustration of a SPR detection device ( 10 ) in the grating coupling configuration and using a LC layer ( 80 ) to control the polarization of the radiation incident in the DS ( 42 ). The radiation emitter ( 20 ) irradiates a light beam ( 101 ) incident on the LC layer ( 80 ) that presents in its initial state a total twist of 45° of the average orientation of the LC molecules ( 83 ). The LC layer ( 80 ) presents a large twisting pitch when compared to the radiation wavelength behaving like a wave-guide. The LC layer ( 80 ) is connected to controller ( 84 ) able to apply electric tensions and in this way fine-tune the total twist of the incident radiation polarization ( 101 ) on the DS ( 42 ). Analyzing the signals detected on the radiation detector ( 30 ) corresponding to the different applied voltages, enables the determination of real-time reference signals, eliminating in this way a significant part of the SPR signal acquisition noise. After passing the LC layer ( 80 ), the radiation beam is transmitted over a transparent substrate ( 44 ) and is incident on the DS ( 42 ) that includes a thin electrically conductive layer behaving like a diffraction grating. The DS ( 42 ) is in direct contact with a fluid. The reflected signal ( 102 ) is then incident on the radiation detector ( 30 ). From the analysis of the optical signals on the radiation detector ( 30 ) it is possible to quantitatively determine the concentration of the analyte in the close proximity of the DS ( 42 ).
[0091] FIG. 3B is a schematic illustration of the embodiment of the device described in FIG. 3A . An initial signal S 1 , corresponding to a linear polarization of the incident radiation ( 101 ) at 45° (with respect to the TM polarization direction) contains a significant optical noise that prevents a precise measurement. By applying the proper electric voltages to the LC layer ( 80 ) it is possible to obtain a second optical signal S 2 , corresponding to the TM polarization of the incident radiation ( 101 ) (0°). This second signal still contains a significant noise level. By properly dividing both signals one determines the SPR signal and eliminates almost all the noise, since this noise is mostly polarization-independent.
[0092] One should note that this concretization only enables the proper measurement of the SPR effect if the delay between the two signals S 1 and S 2 is small compared to the dynamics of the acquisition noise, since this approach is only valuable for polarization-independent noise.
[0093] The radiation incident ( 101 ) on the LC layer ( 80 ) should preferably be collimated in order to have a uniform and constant rotation of the radiation polarization. In this case, the optical elements used for focusing the radiation incident on the DS ( 42 ) should be placed between the LC layer ( 80 ) and the fluidic substrate ( 40 ) that contains the DS ( 42 ). Alternatively, the man of the art may place the LC layer ( 80 ) in a region in which the radiation is not collimated, as long as the dependency of the polarization rotation as a function of the incident angle is taken into account. This example may easily be extended to other similar situations wherein the rotation of the LC layer is smaller or higher than 45°, or if the polarization of the incident radiation is different. As a general rule, the SPR signal S_SPR is obtained from the relation:
[0000]
S
SPR
=
a
1
S
2
b
1
S
1
-
c
1
S
2
(
3
)
[0000] in which a 1 , b 1 and c 1 are parameters that depend on the initial rotation angle of the LC molecules ( 83 ), on the total initial twist of the LC layer ( 80 ), its thickness and the applied electric voltages.
[0094] Other methods for controlling the LC layer ( 80 ) may be considered, as long as it is still possible to control the degree of rotation of the LC molecules ( 83 ). For example, is it possible to use a magnetic actuator, and in this case one must consider that typically LC molecules tend to align perpendicularly to the direction of the applied magnetic field. One may also consider a variation of the present embodiment, in which the LC controller ( 84 ) keeps the electric voltage amplitude constant and only the electric signal frequency is varied. In this case the man of the art must select the proper frequency range in which the LC molecules response is strongly dependent of the applied electric signal frequency.
Second Example
[0095] Conventional SPR detection devices based on the detection of reflected radiation intensity are based on the measurement of radiation intensity levels of the reflected radiation as a function of the incidence angle. In this case, the SPR effect is clearly identified by a strong decrease of the reflected radiation intensity for a specific incidence angle. So the SPR detection is based on the determination of the temporal evolution of the reflected radiation minimum. In an alternative approach, it is possible to measure the variation of the relative phase of the reflected radiation, since this latter shows a much sharper transition in the SPR effect than the transition observed in radiation intensity, as illustrated on FIG. 4A .
[0096] FIG. 4A is a schematic illustration of the behaviour of SPR effect in terms of radiation intensity (dashed line) and radiation relative phase (solid line) both as a function of the incident angle on the DS ( 42 ). The relative phase shows a much sharper transition at the SPR coupling than the radiation intensity. This fact may be explored in order to build SPR detection devices with better resolution.
[0097] Although there are intrinsic advantages in the phase-measurement configuration, its implementation in conventional SPR detection devices is particularly difficult. On the other hand, it is possible to use a LC layer ( 80 ), built in such a way that it enables the proper adjustment of the radiation de-phasing, according to FIGS. 4B and 4C .
[0098] FIG. 4B is a schematic illustration of the average orientation of the LC molecules ( 83 ) in a uniform nematic LC layer ( 80 ). Due to the anisotropic nature of the LC molecules a de-phasing between the TE and TM polarization components of the radiation is observed. In the rest condition (V<Vth) the molecules average orientation is uniform and parallel to the surface, and when subject to sufficiently high external electric fields (V>Vth) the LC molecules ( 83 ) tend to be aligned along the electric field.
[0099] FIG. 4C is a schematic illustration of the behaviour of the total phase difference (de-phasing between the ordinary and extraordinary polarization directions of radiation with respect to the LC average orientation direction) of the LC layer ( 80 ) described in FIG. 4B as a function of the applied voltage. For sufficiently low voltages (V<Vth) and due to the optical anisotropy the total de-phasing of the LC molecules is fixed and defined by the total LC layer ( 80 ) thickness and the average orientation of the LC molecules ( 83 ). For high enough voltages (V>Vth) the phase difference tends to zero and is defined by relation (4).
[0100] Knowing the properties of the LC layer ( 80 ) it is then possible to determine with precision the induced de-phasing δ by the relation:
[0000]
δ
=
n
o
∫
-
d
/
2
d
/
2
[
n
e
n
o
2
sin
2
θ
(
z
)
+
n
e
2
cos
2
θ
(
z
)
-
1
]
z
(
4
)
[0000] in which n o and n e are the ordinary and extraordinary refractive indexes of the LC and θ(z) is the average orientation of the LC molecules ( 83 ) along the LC layer ( 80 ).
[0101] In this example, we have considered a SPR sensor ( 10 ) with fixed wavelength and a range of incidence angles, and having a LC layer ( 80 ) placed in the radiation path between the radiation emitter ( 20 ) and the radiation detector ( 30 ). The SPR sensor ( 10 ) enables the detection of radiation intensities as a function of the incidence angle, the LC layer ( 80 ) being built and placed in such a way that it enables the adjustment of the optical phase difference between the TM and TE components of the radiation polarization through optical or electric means.
[0102] FIG. 5A is a schematic illustration of an SPR detection device in the grating coupling configuration according to this second embodiment of the present invention. The radiation emitter ( 20 ) irradiates a light beam that passes through an LC layer ( 80 ) presenting in its rest condition a phase variation between the TM and TE components of the radiation polarization, given by δ=Δn*D, in which Δn is the birefringence of the LC and D the total thickness of the LC layer ( 80 ). The LC layer ( 80 ) is connected to an LC controller ( 84 ) that enables to control the electric voltages applied to the LC layer ( 80 ). The amplitude of the applied electric voltages enables the fine tuning of the phase difference between the TM and TE components of the radiation polarization that is incident on the DS ( 42 ). The optical signal from the DS ( 42 ) passes through a polarizer ( 31 ) and arrives to the radiation detector ( 30 ). The analysis of the optical signal in the radiation detector ( 30 ) enables the quantitative determination of the analyte concentration in the close proximity of the DS ( 42 ).
[0103] In this case it is considered favourable that the radiation incident on the DS ( 42 ) contains both non-zero polarization components (TM and TE). The TE component does not change in terms of radiation intensity or phase, independently of the incidence angle (besides the classic changes expressed by the Fresnel relations and resulting from the refractive index and extinction coefficients, see reference 7) and depends only on the incident angles and on the refractive indexes of the substrate and the fluid. On the contrary, the TM polarization component changes sharply at a specific incidence angle due to the SPR effect. For example, the phase of the TM polarization component of the radiation shows an abrupt transition, typically over 180° in a range of incidence angles smaller than 10°.
[0104] FIG. 5B is a schematic illustration of the evolution of the radiation de-phasing as a function of the incident angle on the DS ( 42 ) for the detection surface of the device described in FIG. 5A . The phase φ_TE of the TE polarization component from the DS ( 42 ) does not show significant changes. The phase φ_TM of the TM polarization component changes sharply close to a specific incidence angle in which the SPR effect occurs. Initially the total phase difference between the TE and TM polarization components is typically high. By using an LC layer ( 80 ), that induces an additional phase difference φ_LC as a function of the applied voltage, it is then possible to properly adjust the phase difference between the two TE and TM polarization components of the radiation incident ( 101 ) on the DS ( 42 ), in order to have a phase difference of zero at the incidence angle at which the SPR effect occurs.
[0105] The detection polarizer ( 31 ) is placed in a perpendicular direction to the polarization direction of the incident radiation ( 102 ) and between the DS ( 42 ) and the radiation detector ( 30 ). In this way, when the de-phasing between the two polarization components is zero, one observes a total extinction of light after the detection polarizer and, on the other hand, one observes a maximum of radiation intensity after the detector polarizer ( 31 ) for a de-phasing of 90° (quarter-wave). This fact comes from the effect induced by the linear polarizer ( 31 ), since the intensity of radiation passing through the polarizer follows the relation (5):
[0000] I=I 0 cos 2 α (5)
[0000] in which I 0 is the intensity of the radiation incident on the polarizer and α is the angle between the linear polarization of the incident radiation ( 102 ) and the major direction of the polarizer.
Due to the sharp change on the relative phase of the TM component, one may observe two extinctions of light for two incidence angles corresponding to null or 180° de-phasing. Between these two radiation extinctions there is a local maximum of radiation intensity that corresponds to a de-phasing of 90°, according to FIG. 5C .
[0107] FIG. 5C is a schematic illustration of the SPR signal detected by the radiation detector for a conventional SPR detection device (dashed line) and for the device described in FIG. 5A (solid line), in which the detection polarizer ( 31 ) is placed approximately parallel to the SPR angle. Due to the sharp change of the TM component relative phase of the radiation coming from the DS ( 42 ), after passing through the detection polarizer ( 31 ) the signal presents a sharp intensity transition. One observes two minima of radiation intensity spaced by an angular distance W, with a local maximum between them. The angles of minimum intensity correspond to linear polarizations perpendicular to the major direction of the detection polarizer ( 31 ). The distance W is found to be minimized when the de-phasing (Δφ=φ_TE+φ_LC−φ_TM) is null for the angle of incidence in which the SPR effect occurs.
[0108] By applying an electric voltage to the LC layer ( 80 ) in order to vary the phase difference between the TM and TE components of the radiation polarization, it is then possible to adjust the angular position of the two light extinctions. The angular distance W between these extinctions increases when moving apart from and decreases when moving closer to the incidence angle at which the SPR effect occurs. Thus, it is possible to control the applied voltage on the LC layer ( 80 ) in order to minimize this angular distance W and determine in this way the minimum angular distance that corresponds to the angle at which the SPR effect occurs.
[0109] It is then possible, using this invention, to detect simultaneously the phase difference change of the radiation incident and also the angle in which the SPR occurs. The proper control of the total de-phasing induced by the LC layer ( 80 ) is feasible since the average orientation of the LC molecules ( 83 ) depends on the applied voltage. By combining these two effects (the de-phasing induced by the LC layer and the effect induced by the detection polarizer) it is then possible to obtain a SPR signal with much better contrast when compared with conventional SPR sensors.
[0110] The result of the this second embodiment would only be achieved in a conventional SPR sensor using a fixed quarter-wave or another element that would introduce a fixed de-phasing between TM and TE polarization components of the radiation incident on the DS ( 42 ), but nevertheless unable to dynamically adjust the de-phasing between both polarization components.
[0111] This example may be extended for SPR sensors ( 10 ) with different configurations, namely in the prismatic configuration and in the diffraction coupling configuration. It is also possible to obtain the same result when using other means for controlling the LC layer ( 80 ) as long as it is possible to properly adjust the average orientation of the LC molecules ( 83 ).
[0112] It is also possible to use an alternative configuration, in which the polarizer ( 31 ) is aligned in perpendicularly to the linear polarization direction for the incidence angle at which the SPR effect occurs. In this case one observes a similar signal to the one presented in FIG. 5C , but with two local maxima spaced by the angular distance W and having a minimum at the incidence angle at which the SPR effect occurs.
[0113] One other alternative configuration consists in using a LC layer ( 80 ) with a gradient of de-phasing φ_LC in a perpendicular direction to the direction of variation of the incident angles. In this case, the optical signal acquired by the radiation detector ( 30 ) is two-dimensional, with each line exhibiting the same behaviour described in FIG. 5C .
[0114] FIG. 5D is a schematic illustration of the evolution of the angle for the minimum of intensity of the SPR optical signal as a function of the radiation de-phasing for the detection device described in FIG. 5A , and in which the LC layer ( 80 ) induces a de-phasing in the perpendicular direction to the variation of the incident angles. In this case, the detection is performed using a two-dimensional radiation detector ( 30 ) of matrix type, in which is observed in each line a similar behaviour as described in FIG. 5C . The gradual change of the de-phasing enables the determination in real time of the line corresponding to the minimal distance W between the two local minima of the radiation intensity.
[0115] The man of the art may find several advantages when adopting this method, since the proper adjustment of the voltages applied to the LC layer ( 80 ) may be applied between signal acquisitions, contrarily to the other configurations previously presented.
[0116] All the previous configurations have considered an LC layer ( 80 ) placed in between the radiation emitter ( 20 ) and the DS ( 42 ). This is usually considered preferable due to its simplicity, since it enables the use of a collimated radiation beam and then placing the focusing elements after the LC layer ( 80 ).
[0117] FIG. 6 is a schematic illustration of the optical sub-system of radiation emission for an SPR detection device according to the present invention, in which a collimating lens ( 22 ) is used after the radiation emitter ( 20 ), and a emitter polarizer ( 23 ) placed between the lens and the LC layer ( 80 ) in the collimated radiation path. The emitter polarizer ( 23 ) is used in order to optimize the linear polarization of the incident radiation beam. After passing through the LC layer ( 80 ), the radiation is focused on the DS ( 42 ) by means of a focusing lens ( 24 ).
[0118] The configuration described in FIG. 6 is one of the possible configurations for the emitter sub-system, but other possible combinations might be used in order to obtain the same results previously described. For example, the emitter polarizer ( 23 ) might be eliminated when using a laser as the emission element ( 21 ), since laser typically emit polarized light. The collimating lens ( 22 ) may also be eliminated if the data processing takes into account the effect of the variable incident angle on the polarizer ( 23 ) and on the LC layer ( 80 ). The elimination of this collimating lens may introduce additional noise, although the man of the art is capable of properly taking into account this last effect on the signal processing algorithms.
[0119] It is also possible to consider an alternative configuration in which the LC layer ( 80 ) is placed in the optical path between the DS ( 42 ) and the radiation detector ( 30 ). In this latter case, there will be again the effect of the variable incident angle on LC layer ( 80 ) and on the detection polarizer ( 31 ) so this effect must be properly considered.
Third Example
[0120] Conventional SPR detection devices typically use a radiation beam incident on the DS ( 42 ) in a fixed range of incident angles. This fact may also be a limiting factor in terms of sensitivity and detection range of the SPR detection device. It would then be interesting to use an SPR detection device having the possibility of controlling, in an easy way, the sensitivity limit and/or the detection range by acting on the range of incident angles of the radiation incident on the DS ( 42 ).
[0121] The third embodiment of the present invention consists of using two LC layers ( 85 ) and ( 86 ), controlled by an LC controller ( 84 ) and placed in between the radiation emitter ( 20 ) and the DS ( 42 ) in order to properly adjust the incidence angles of the radiation beam incident on the DS ( 42 ). A LC layer may behave as a lens due to the effect of local refractive index variation, namely as a function of an external applied voltage (see reference 8).
[0122] FIG. 7A is a schematic illustration of the resulting refractive index of the LC layer ( 80 ) described in FIG. 4B as a function of the applied voltage. The average refractive index of the LC layer ( 80 ) changes between the ordinary refractive index n o for low applied voltages (V<V_TH) and the extraordinary refractive index n e for sufficiently high applied voltages.
[0123] FIG. 7B is a schematic illustration of an LC layer behaving like an optical lens. In the rest condition (V<V_TH), the average orientation of the LC molecules ( 83 ) is uniform and parallel to the top and bottom LC substrates. For sufficiently high electric voltages, the LC molecules tend to be aligned along the electric field and thus present a spatial pattern. It is possible to build an LC Layer ( 80 ) that, for a fixed applied voltage, at its center presents a higher alignment of its molecules with respect to the applied electric field when compared to more external regions of the LC layer ( 80 ). The gradual change of the average orientation of the LC molecules ( 83 ) results in a spatial pattern of the effective refractive index of the LC layer ( 80 ) and so this latter behaving like an optical lens.
[0124] FIG. 7C is a schematic illustration of the equivalent focal distance of an LC layer ( 80 ) illustrated in FIG. 7B , as a function of the applied voltage. The equivalent focal distance of the LC layer ( 80 ) decreases when increasing the applied voltage. Within certain limits, the equivalent focal distance shows a linear dependency with the applied electric voltage.
[0125] There are several possible configurations that exploit this effect and enable the use of LC layers as optical lenses (see references 8 and 9 ). Given the SPR sensor ( 10 ) characteristics, it is considered favourable to have a constant and fixed focal length for the radiation incident on the DS ( 42 ). The resulting focal length of the association of two thin lenses is given by the relation ( 6 ):
[0000]
f
=
f
2
(
d
-
f
1
)
d
-
(
f
1
+
f
2
)
(
6
)
[0000] in which d is the distance between the two lenses, f 1 and f 2 are the focal lengths of the lens 1 and lens 2 , respectively (see reference 7). The total range of incident angles is defined by Δα.
[0126] FIG. 7D is a schematic illustration of the optical sub-system of radiation emission for an SPR detection device according to the present invention, characterized in that two LC layers ( 85 ) and ( 86 ) are used, in order to have it working like a focusing lens of variable amplification with constant focal length. The radiation emitter ( 20 ) irradiates a collimated radiation beam onto a first LC layer ( 85 ) characterized by an equivalent focal length f 1 . A second LC layer ( 86 ), placed at a distance d from the first LC layer ( 85 ) and is characterized by a focal length f 2 . The group of these two LC layers is built and placed in such a way that it presents a constant focal length f and a controllable range of incident angles Δθ, simply by adjusting the electric voltages applied on the LC layers ( 85 ) and ( 86 ).
[0127] The group of LC layers ( 85 ) and ( 86 ) shows a constant equivalent focal length f and obeys the relation ( 6 ). The total range of incident angles Δθ is controllable through the applied electric voltages on the LC layers ( 85 ) and ( 86 ) and follows the relation (7):
[0000]
Δ
θ
≈
arctan
(
h
1
2
d
2
-
f
1
(
d
+
f
2
)
f
2
(
d
-
f
1
)
)
(
7
)
[0128] This relation (7) is only valid if the LC layers ( 85 ) and ( 86 ) were much thinner than the distance d. This is the typical case, since common LC layers have a thickness between 1 μm and 100 μm and d is typically between 1 mm and 10 mm. The exact relation for the range of incident angles Δθ and may also be determined when the distance d is of the same order of the LC layer thickness, but in this latter case it becomes difficult to maintain the condition of constant focal length.
[0129] The control on the equivalent focal lens of an LC layer may be obtained by applying an external electric voltage, with a typical signal frequency between 1 KHz and 100 KHz, and voltage amplitudes between 0 V and 50 V. The effective refractive index of the LC layer may change with the applied voltage, depending on several parameters, namely: the structure of the LC layer, its thickness, the relation between the elastic, optical and dielectric constants of the LC molecules, the anchoring strength between the LC molecules and the LC substrates, among others. In a simplified approach, and within certain limits, it is possible to observe a linear dependency of the equivalent focal length of an LC layer when varying the applied voltage.
[0130] Let us consider, for example, two LC layer ( 85 ) and ( 86 ), built in such a way that each layer may vary linearly its equivalent focal length between 1 mm and 10 mm, depending on the applied voltage. For example, having 10 V of applied voltages induces an equivalent focal length of 10 mm and 20 V yields 1 mm of focal length). The two LC layers are placed at a distance of 10 mm, and the collimated radiation beam has 5 mm of diameter when arriving to the first LC layer ( 85 ). In this example, the radiation incident on the DS ( 42 ) will have a total focal length of 20 mm. Now, maintaining this total focal length at 20 mm and according to equations (6) and (7), it is possible to vary the total range of incident angles Δθ from 48° (with V 1 =20.000 V and V 2 =14.215 V) to 1.8° (with V 1 =12.222 V and V 2 =19.091 V).
[0131] The practical use of this example of the present invention may require the man of the art a special care in the measure and control of optical aberrations and distortions induces by the group of LC layers behaving like a variable amplification lens with constant focal length. This determination and control may the obtained with precision (see reference 10) in order to minimize the noise associated to the detection based on the SPR effect.
[0132] This third embodiment of the present invention may be extended to other configurations of detection devices based on the SPR effect, namely in the cases of the prismatic configuration or the grating coupling configuration. It may also be considered with advantage other means for controlling the average orientation of the LC molecules ( 83 ) of the LC layers ( 85 ) and ( 86 ), wherein the applied voltage amplitude is kept constant and only the signal frequency is varied. In this case, the man of the art may choose a suitable frequency range wherein the LC molecules ( 83 ) response is strongly dependent on the signal frequency.
[0133] Another alternative configuration of this embodiment consists in using two LC layers ( 85 ) and ( 86 ) placed in the optical path between the DS ( 42 ) and the radiation detector ( 30 ). This last configuration may be considered with advantage since all the elements with high optical quality are placed in the proximity of the radiation emitter ( 20 ), and so it may optimize the SPR effect on the DS ( 42 ). This latter case may imply the use of an additional detection lens ( 32 ), placed in between the DS ( 42 ) and the LC layers ( 85 ) and ( 86 ), in order to have a collimated beam before the first LC layer ( 85 ).
[0134] FIG. 8 is a schematic illustration of a detection device according to the present invention, in which a group of two LC layers is placed in between the detection surface ( 42 ) and the radiation detector ( 30 ) in order to control the radiation signal amplification. The incident radiation ( 101 ) is reflected at the DS ( 42 ) and the reflected radiation ( 102 ) is transmitted through detection lens ( 32 ) and then passes through the LC layers ( 85 ) and ( 86 ) and arrives to the radiation detector ( 30 ). The LC layers ( 85 ) and ( 86 ) are controlled by the LC controlled ( 84 ). By properly adjusting the applied voltages on the LC layers ( 85 ) and ( 86 ) it is possible to control the diverging angle of the reflected radiation ( 102 ). This control enables the adjustment of the detection range and sensitivity limit of the SPR sensor ( 10 ).
[0135] In this case the group of LC layers ( 85 ) and ( 86 ) enable the control of optical signal amplification around the angle in which the SPR effect occurs. For example, it is possible to defined a minimum acceptable contrast of the SPR optical signal and then gradually adjust the amplification of the group of LC layers ( 85 ) and ( 86 ) in order to maximize the resolution of the detection device, keeping a signal to noise rate rather constant.
[0136] These examples demonstrate some different possible embodiments of the present invention in order to build and use an SPR sensor ( 10 ) using LC layers that enables the detection of chemical and/or biological events, with a better performance when compared to conventional SPR detection devices.
Summary of the Abbreviations
[0000]
SPR sensor 10
Radiation emitter 20
Emission element 21 Collimating Lens 22 Emitter Polarizer 23 Focusing Lens 24
Radiation Detector 30
Detection Polarizer 31 Detection Lens 32
Fluidic Channels 40
Detection Zone (DZ) 41 Detection Surface (DS) 42 Channels 43 Substrate 44
Liquid Crystal (LC) Layer 80
Bottom LC substrate 81 Top LC substrate 82 LC Molecules 83 LC Controller 84 First LC Lens Layer 85 Second LC Lens Layer 86
Prism 90 Incident Radiation 101 Outgoing Radiation 102
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A detection device based on the surface plasmon resonance effect, including a radiation emitter and a radiation detector, a fluidic substrate, a liquid crystal layer and respective control mechanism.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of copending U.S. application Ser. No. 10/956,316 filed Oct. 1, 2004, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed to emitter electrodes for gas ionizers and, more specifically, to a gas ionizer emitter electrode formed of or coated with a carbide material such as silicon carbide.
[0003] Ion generators are related generally to the field of devices that neutralize static charges in workspaces to minimize the potential for electrostatic discharge. Static elimination is an important activity in the production of technologies such as large scale integrated circuits, magnetoresistive recording heads, and the like. The generation of particulate matter by corona-producing electrodes in static eliminators competes with the equally important need to establish environments that are free from particles and impurities. Metallic impurities can cause fatal damage to such technologies, so it is desirable to suppress those contaminants to the lowest possible level.
[0004] It is known in the art that when metallic ion emitters are subjected to corona discharges in room air, they show signs of deterioration and/or oxidation within a few hours and the generation of fine particles. This problem is prevalent with needle electrodes formed of copper, stainless steel, aluminum, and titanium. Corrosion is found in areas under the discharge or subjected to the active gaseous species NO x . NO 3 ions are found on all the above materials, whether the emitters had positive or negative polarity. Also, ozone-related corrosion is dependent on relative humidity and on the condensation nuclei density. Purging the emitter electrodes with dry air can reduce NH 4 NO 3 as either an airborne contaminant or deposit on the emitters.
[0005] Surface reactions lead to the formation of compounds that change the mechanical structure of the emitters. At the same time, those reactions lead to the generation of particles from the electrodes or contribute to the formation of particles in the gas phase.
[0006] Silicon and silicon dioxide emitter electrodes experience significantly lower corrosion than metals in the presence of corona discharges. Silicon is known to undergo thermal oxidation, plasma oxidation, oxidation by ion bombardment and implantation, and similar forms of nitridation. Some have tried to improve silicon emitters by using 99.99% pure silicon that contains a dopant such as phosphorus, boron, antimony and the like. For example, U.S. Pat. No. 5,650,203 (Gehlke) discloses silicon emitters containing a dopant material. However, even such high purity doped silicon emitters suffer from corrosion and degradation.
[0007] Another approach is to form emitter electrodes from nearly pure germanium or from germanium with a dopant material. For example, U.S. Pat. No. 6,215,248 (Noll), the contents of which are incorporated by reference herein, discloses germanium needles or emitter electrodes for use in low particle generating gas ionizers and static eliminators. While such germanium emitter electrodes have proven to be less susceptible to corrosion and degradation than metallic emitter electrodes and silicon emitter electrodes with a dopant, there is a need for an emitter electrode that produces or causes even less metallic and/or non-metallic contamination with enhanced resistance to erosion.
BRIEF SUMMARY OF THE INVENTION
[0008] Briefly stated, in one embodiment, the present invention comprises an ionizer emitter electrode formed of or coated with a carbide material, wherein the carbide material is selected from the group consisting of germanium carbide, boron carbide, silicon carbide and silicon-germanium carbide. The present invention also comprises a corona-producing ionizer emitter electrode substantially formed of silicon carbide. In another aspect, the present invention is a corona-producing ionizer emitter electrode formed of an electrically conductive metal base, the metal base being coated at least partially with silicon carbide. In yet another aspect, the present invention is a corona-producing ionizer emitter electrode that ionizes gas when high voltage is applied thereto, and the emitter electrode is formed substantially of silicon carbide with the necessary dopant to achieve a resistivity of less than or equal to about one hundred ohms-centimeter (100 Ω-cm).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention and its applications are not limited to the precise arrangements and instrumentalities shown.
[0010] In the drawings:
[0011] FIG. 1 is a side elevational view of an emitter electrode formed or coated with a carbide material in accordance with some preferred embodiments of the present invention;
[0012] FIG. 2A is a schematic view of a point-to-plane corona producing apparatus in accordance with a first preferred embodiment of the present invention;
[0013] FIG. 2B is a schematic view of a point-to-point corona producing apparatus in accordance with a second preferred embodiment of the present invention;
[0014] FIG. 2C is a schematic view of a wire-to-plane corona producing apparatus in accordance with a third preferred embodiment of the present invention;
[0015] FIG. 2D is a schematic view of a wire to cylinder corona producing apparatus in accordance with a fourth preferred embodiment of the present invention;
[0016] FIG. 2E is a schematic view of a point-to-room corona producing apparatus in accordance with a fifth preferred embodiment of the present invention; and
[0017] FIG. 3 is a schematic diagram of a gas ionizer which utilizes the preferred embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Certain terminology is used in the following detailed description for convenience only and is not limiting. The words “right,” “left,” “lower” and “upper” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the described device and designated parts thereof. The terminology includes the words above specifically mentioned, derivatives thereof and words of similar import. Additionally, the word “a,” as used in the claims and in the corresponding portions of the specification means “one” or “at least one.”
[0019] Referring to the drawings in detail, wherein like numerals represent like elements throughout, there is shown in FIG. 1 an emitter electrode 12 formed or coated with a carbide material, such as silicon carbide (SiC), in accordance with some preferred embodiments of the present invention. The emitter electrode has a generally cylindrically-shaped body and a generally conically-shaped tip 18 ending with a rounded end 17 . Alternatively, the rounded end 17 is sharply tapered or pointed. The rear end has a chamfer 19 . The shape of the emitter electrode 12 of FIG. 1 is merely exemplary and should not be construed as limiting to this invention. Other shapes, sizes or proportions may be utilized without departing from the present invention.
[0020] Pure and ultra-pure SiC has been found, by experimentation, to outlast other electrode materials such as metallic, doped silicon and even pure germanium electrodes. SiC has been found to have superior chemical, plasma and erosion resistance with phenomenal thermal properties as compared to the other mentioned electrode materials. Chemical vapor deposition (CVD) manufacturing produces chemical vapor deposition (CVD) SiC that is highly pure and is commercially available. For example, purities of about 99.9995% CVD SiC can be obtained by CVD manufacturing. Because of the high purity of CVD SiC, the potential for unwanted metallic and non-metallic contamination is drastically reduced and nearly eliminated in gas ionization applications. CVD SiC emitter electrodes 12 also exhibit greater mechanical strength and reduced breakage as compared to similarly designed semiconductive counterparts. Experimentation has demonstrated that SiC, particularly CVD SiC, emitter electrodes are cleaner—with respect to fine particulates—than polycrystalline germanium emitters and single crystal silicon emitter electrodes. Other carbide materials exhibiting physical properties may be utilized such as germanium carbide, boron carbide, silicon carbide, silicon-germanium carbide and the like.
[0021] Preferably, the emitter electrode 12 is formed of at least 99.99% pure silicon carbide. Preferably, the silicon carbide is chemical vapor deposition (CVD) silicon carbide. Preferably, the emitter electrode 12 is a corona-producing ionizer emitter electrode 12 that is substantially formed of silicon carbide.
[0022] Doping of the carbide material may be necessary to achieve the desired conductivity. For example, in the case of silicon carbide, nitrogen is typically introduced to control the conductivity (resistivity). Preferably, the carbide material is doped to achieve predetermined conductivity characteristics.
[0023] Alternatively, the emitter electrode 12 is a corona-producing ionizer emitter electrode 12 formed of an electrically conductive metal base that is at least partially coated with silicon carbide. The metal base may be formed of copper, stainless steel, aluminum, titanium and the like, so long as silicon carbide material coats at least a substantial portion or all of the tip 18 . Preferably, silicon carbide material coats all of exposed surfaces of the metal base to reduce the potential for corrosion and degradation.
[0024] Referring to FIG. 3 , a typical gas ionizer 100 is schematically shown which utilizes the preferred embodiments of the present invention. Gas ionizers 100 typically deliver ionized gas to a clean room, such as a Class 10 clean room or other high cleanliness mini-environment. A high-voltage power supply 22 is electrically coupled to the emitter electrode 12 . A corona is produced by application of high voltage to the electrode 12 . The gas ionizer 100 may comprise a plurality of emitter electrodes 12 all connected to an AC voltage for generating both positive and negative ions (not shown). Alternatively, the gas ionizer 100 comprises two separately connected sets of electrical emitter electrodes 12 used in conjunction with bipolar DC voltage that allows one set of emitter electrodes 12 to be operated at a positive voltage and a second set of emitter electrodes 12 to be operated at a negative voltage for generating positive and negative ions (not shown).
[0025] The high-voltage power supply 22 is typically supplied with electrical power conditioned at between about seventy (70 V) and about two hundred forty (240 V) volts AC at between about fifty (50 Hz) and about sixty (60 Hz) hertz. The high-voltage power supply 22 can include a circuit (not shown in detail), such as a transformer, capable of stepping up the voltage to between about three thousand (3 KV) and ten thousand (10 KV) volts AC at between about fifty (50 Hz) and about sixty (60 Hz) hertz. Alternatively, high-voltage power supply 22 can include a circuit, such as a rectifier that includes a diode and capacitor arrangement, capable of increasing the voltage to between about five thousand (5 KV) and ten thousand (10 KV) volts DC of both positive and negative polarities. Alternatively, the high-voltage power supply 22 is supplied with electrical power conditioned at about twenty-four (24 V) volts DC. The high-voltage power supply 22 can include a circuit, such as a free standing oscillator or switching type arrangement that is used to drive a transformer whose output is rectified, capable of conditioning the voltage to between about three thousand (3 KV) and ten thousand (10 KV) volts DC of both positive and negative polarities. Other power supplies using other voltages may be utilized without departing from the present invention.
[0026] FIG. 2A is a schematic view of a point-to-plane corona producing apparatus in accordance with a first preferred embodiment of the present invention. The emitter electrode 12 is arranged in a point geometry and a counter-electrode 20 is arranged in a plane geometry. The power supply 22 is electrically coupled to the emitter electrode 12 to generate a corona. The counter-electrode 20 may be connected to ground (i.e., Earth ground) in the case of high voltage AC or to an opposite polarity of the power supply 22 than the emitter electrode 12 in the case of high-voltage DC.
[0027] FIG. 2B is a schematic view of a point-to-point corona producing apparatus in accordance with a second preferred embodiment of the present invention. Two or more emitter electrodes 12 are arranged in a point geometry where the electrodes have opposite voltage polarity. The power supply 22 is electrically coupled to each emitter electrode 12 to generate a corona.
[0028] FIG. 2C is a schematic view of a wire-to-plane corona producing apparatus in accordance with a third preferred embodiment of the present invention. A wire electrode 23 formed of SiC is arranged in a thin-wire geometry and a counter-electrode 20 is arranged in a plane geometry. The power supply 22 is electrically coupled to the emitter electrode 12 to generate a corona. The power supply 22 is electrically coupled to the emitter electrode 12 to generate a corona. The counter-electrode 20 may be connected to ground in the case of high voltage AC or to an opposite polarity of the power supply 22 than the emitter electrode 12 in the case of high-voltage DC.
[0029] FIG. 2D is a schematic view of a wire to cylinder corona producing apparatus in accordance with a fourth preferred embodiment of the present invention. The wire electrode 23 formed of SiC is arranged in a thin-wire geometry and the counter-electrode 21 is arranged in a plane geometry. The power supply 22 is electrically coupled to the emitter electrode 12 to generate a corona. The power supply 22 is electrically coupled to the emitter electrode 12 to generate a corona. The counter-electrode 21 may be connected to ground in the case of high voltage AC or to an opposite polarity of the power supply 22 than the emitter electrode 12 in the case of high-voltage DC.
[0030] FIG. 2E is a schematic view of a point-to-room corona producing apparatus in accordance with a fifth preferred embodiment of the present invention. The emitter electrode 12 is arranged in a point geometry and there is no counter-electrode 20 , 21 . The power supply 22 is electrically coupled to the emitter electrode 12 to generate a corona. The power supply 22 is also connected to ground (i.e., Earth ground).
[0031] From the foregoing, it can be seen that the present invention comprises an emitter electrode formed or coated with silicon carbide (SiC) or CVD SiC for use with gas ionizers. It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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A method is provided for forming a corona-producing emitter electrode by depositing substantially pure silicon carbide by CVD and forming a corona-producing emitter electrode with the deposited silicon carbide. In addition, a method of forming a corona-producing gas ionizer is provided by providing a corona electrode formed from CVD silicon carbide, electrically coupling the corona electrode to a high voltage power supply, and providing an AC or DC voltage from the high voltage power supply to the corona electrode. Furthermore, a method of ionizing gas in an environment is provided by providing a corona-producing ionizer emitter electrode formed substantially of CVD silicon carbide, electrically coupling the electrode to a high voltage power supply, and providing an AC or DC voltage from the high voltage power supply to the electrode.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of co-pending patent application, application Ser. No. 10/147,630, filed May 16, 2002, the contents of which are expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Field
[0003] The present invention relates to power driven cycles, and more specifically, to frames for electric motor driven cycles.
[0004] Background
[0005] Recently, due to the shortage of gasoline and the ecological consequences of such use, various proposals have been created dealing with alternative power sources for motor vehicles. One of the most popular and promising proposals relates to electric powered vehicles. The difficulty encountered with electric powered vehicles, however, is the inability to deliver sufficient power for long-range operation without utilizing an extremely large number of heavy batteries. This is due largely to the weight requirements of conventional automobiles. The cycle, on the other hand, is substantially lighter than the automobile, and therefore, tends to have significantly lower power requirements. As a result, cycles, such as motorcycles and bicycles, are ideal for electric power applications.
[0006] Conventional electric motor driven cycles have typically employed heavy tube frame structures with an array of brackets to support the batteries and the electric motor. This construction often results in a mass fraction for the electric motor driven cycle that is less than optimal. “Mass fraction” refers to the percentage that the batteries contribute to the overall weight of the electric motor driven cycle. Increased performance in terms of extended range can often be obtained by increasing the mass fraction. One way to increase the mass fraction is to reduce the weight of the frame. This tends to increase the range of the electric motor driven cycle for a given battery weight. Accordingly, a lightweight frame construction is needed with sufficient rigidity to support the weight of the batteries and motor.
SUMMARY
[0007] In one aspect of the present invention, an electric motor driven cycle includes front and rear wheels, a monocoque frame suspended between the front and rear wheels, and electric motor coupled to one of the wheels, the electric motor being a load-bearing member of the frame.
[0008] In another aspect of the present invention, an electric motor driven vehicle includes front and rear wheels, a monocoque frame suspended between the front and rear wheels, a handle bar extending from the frame, and an electric motor coupled to one of the wheels, the electric motor being a load-bearing member of the frame.
[0009] It is understood that other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only exemplary embodiments of the invention by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF DRAWINGS
[0010] Aspects of the present invention are illustrated by way of example, and not by way of limitation, in the accompanying drawings, wherein:
[0011] [0011]FIG. 1 is a perspective view of an exemplary electric motor driven cycle
[0012] [0012]FIG. 2 is a side view of an exemplary machined cut metal sheet for either the right or left side of the frame for an electric motor driven cycle;
[0013] [0013]FIG. 3 is a perspective view of two exemplary machined cut metal sheets illustrating the assembly of the right and left portions of the frame for an electric motor driven cycle;
[0014] [0014]FIG. 4 is a cross-section top view of an exemplary mounting configuration for the electric motor; and
[0015] [0015]FIG. 5 is a perspective view of an exemplary electric motor driven cycle with a cosmetic overlay around the frame.
DETAILED DESCRIPTION
[0016] The detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments in which the present invention can be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details. In some instances, well-known structures and devices are shown generally in order to avoid obscuring the concepts of the present invention.
[0017] [0017]FIG. 1 is a perspective view of an exemplary electric motor driven cycle. The electric motor driven cycle 102 is based on a fully suspended and dampened monocoque frame design. A monocoque frame is a type of construction in which the outer surface bears all or a major portion of the stresses. The monocoque frame 104 can be formed as a unitary structure with one or more compartments to house the internal components of the electric motor driven cycle 102 . The internal components include an electric motor 106 powered by dual batteries 108 a and 108 b , and a battery charger 110 to periodically charge the batteries 108 a and 108 b.
[0018] The monocoque frame 104 has a lightweight construction with sufficient rigidity to support the internal components. As a result, the mass fraction of the electric motor driven cycle 102 can be optimized for higher performance in terms of extended range capability. In addition, the monocoque frame provides a high degree of design flexibility with respect to the location of the internal components within the frame. As a result, the designer can strategically position the internal components for optimal performance. By way of example, the batteries 108 a and 108 b can positioned within the frame 104 to provide good weight distribution to improve handling during operation. The electric motor 106 can be positioned within the frame 104 to optimize power delivery to the electric motor driven cycle 102 . The electric motor 106 can also be strategically positioned to provide a structural support member for the frame. In the exemplary embodiment of FIG. 1, the electric motor 104 serves as a load bearing element that supports the weight of the passenger while withstanding the bending stresses created by the electric motor driven cycle 102 during turns during operation. By using the electric motor 106 , or any other internal component, as a structural element of the frame 104 , the weight of the frame can be further reduced thereby increasing the mass fraction of the electric motor driven cycle 102 . In contrast, the conventional tube frame construction may have severe limitations with regard to the location of the internal components due to the bracket arrangements needed to support those components.
[0019] The frame 104 can be coupled to a front wheel 112 with a front fork assembly 114 . The front, fork assembly 114 includes a bifurcated member 116 with right and left spring loaded damping tubes 118 a and 118 b extending downward to form a front fork. The axle of the front wheel 112 can be inserted into the front fork. A steered tube 120 extending upward from the center of the bifurcated member 116 can be rotatably inserted through the frame 104 with upper and lower bearings (not shown). Right and left cross-members 122 a and 122 b can be secured to the frame 104 to prevent buckling due to compressive loading between the two bearing points. A clamp 124 can be used to couple the steered tube 120 to a handle bar 126 .
[0020] The frame 104 can be coupled to a rear wheel 128 with a rear suspension system 130 . The rear suspension system 130 includes a swing arm 132 connecting the axle of the rear wheel 128 to the drive shaft of the motor 106 . Alternatively, the swing arm 132 can be connected between the frame 104 and the rear wheel axle. A shock absorber 134 can be connected across the frame 104 and the swing arm 132 to absorb the energy produced by sudden bumps in the road.
[0021] Power can be delivered to the rear wheel 128 with a belt drive assembly between the electric motor 106 and the rear wheel 128 . A drive belt 135 can be connected between a toothed pulley 136 at the end of the motor drive shaft and a toothed drive wheel 138 extending from the rear wheel axle. The toothed configuration of both the pulley and drive wheel tends to reduce slippage during rapid accelerations and decelerations. A drive belt can be used instead of a drive chain in applications where noise suppression is desirable. In applications where the swing arm 132 is connected between the frame 104 and the rear wheel axle, an idler tensioner (not shown) may be used to regulate the tension of the drive belt 135 as the swing arm moves in response to sudden bumps in the road.
[0022] The frame can be constructed from a pair of machined metal sheets which are shaped and connected together to form a monocoque structure. An exemplary machined cut metal sheet for either the right or left side of the frame is shown in FIG. 2. The metal sheet can be mild steel, stainless steel, chrome-molly steel, titanium, aluminum, or any other suitable material known in the art.
[0023] As shown in FIG. 2, the metal sheet 202 can be formed with a circular machined cutout 204 to accommodate the electric motor. Two rectangular machined cutouts 206 a and 206 b can also be formed in the metal sheet 202 . Each rectangular machined cutout 206 a and 206 b is surrounded by four tabs 208 a - d extending from respective bending breaks 210 a - d in the metal sheet 202 . During the manufacturing process, the tabs 208 a - d can be bent inward to form the battery compartments. The battery charger compartment can be formed in a similar manner with a rectangular cutout 212 surrounded by four tabs 214 a - d extending from respective bending breaks 216 a - d . Various other compartments can be formed in the metal sheet 202 depending on the particular application. The metal sheet 202 may also be formed with one or more exterior tabs 218 a - f extending from respective bending breaks 220 a - f along the periphery of the metal sheet 202 . The exterior tabs 218 a - f once bent inward, can be used to connect the left and right members of the frame together. The metal sheet 202 may also have various screw hole cutouts (not shown) for supporting the internal components. Threaded inserts can be pressed or welded into the screw holes at a later stage during the manufacturing process.
[0024] The machining of the metal sheet can be achieved in a variety of ways. By way of example, the sheet metal pattern can be formed by laser cutting, chemical machining, water jet cutting, electron beam cutting, or any other conventional machining method. Once the sheet metal pattern is formed, the metal sheet can be shaped by manually bending the tabs, or by using a hydroforming or similar process. Alternatively, a progressive die stamp process can be used to perform both the cutting of the metal sheet and the bending of the tabs in an automated fashion. Either way, the two shaped metal sheets can then be brought together to form the frame as shown in FIG. 3. The exterior tabs 218 a - f can be formed such that they butt up against, or overlap, their counterpart tabs extending from the other metal sheet. The exterior tabs from one metal sheet can then be connected to the exterior tabs from the other metal sheet by various processes including laser welding, automated welding, pinch welding, mig welding, or any other suitable process. Once the two metal sheets are connected together to form the frame, other structural members may be added. By way of example, the right and left cross-members 122 a and 122 b (see FIG. 1), and bearing support surfaces (not shown) can be added to support the front fork assembly 114 (see FIG. 1). The frame exterior can then be galvanized, zinc plated, painted, powder coated, or treated in any conventional manner to prevent corrosion.
[0025] [0025]FIG. 4. is a cross-sectional top view showing the electric motor secured to the frame. In the exemplary embodiment shown, the electric motor 106 serves as a structural support member of the frame 104 . The electric motor 106 can be held between the two frame members 104 a and 104 b with a motor support tube 402 bolted to the frame 104 . The back end 106 a of the electric motor extends outward through the circular machined cutout of one frame member 104 a . The drive shaft 106 b of the electric motor 106 extends outward through the circular machined cutout of the other frame member 104 b . The pulley 134 can be connected to the distal end of the drive shaft 106 b . A motor support ring 404 can be bolted to the electric motor 106 to achieve a face mount.
[0026] [0026]FIG. 5 is a side view of an exemplary electric motor driven cyclic with a cosmetic overlay around the frame. The overlay 502 can be plastic or any other suitable material. The use of a cosmetic overlay allows various overlay designs to be used without having to modify the frame. This approach may provide a very economical solution to support the evolution of aesthetic designs as the electric motor driven cycle industry continues to expand its penetration into the marketplace. The overlay 502 may include one or more bulges 504 a and 504 b to accommodate the internal components of electric motor driven cycle. A drive belt cover 506 in combination with the overlay 502 gives the electric motor driven cycle an overall aesthetically pleasing look.
[0027] The electric motor driven cycle 102 may also include a front fender 508 to house the bifurcated member 116 of the front fork assembly 114 (see FIG. 1). A pod 510 can be used to house the clamp 124 connection between the steered tube 120 and the handle bar 126 (see FIG. 1). The pod 510 may also be used to carry various displays and controls depending on the particular design requirements and the intended consumer market. The pod 510 may also provide a convenient surface to support a headlight (not shown). The electric motor driven cycle 102 may also include a passenger seat 512 and front and rear foot pegs 514 a and 514 b.
[0028] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles, defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
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An electric motor driven cycle having front and rear wheels, a monocoque frame suspended between the front and rear wheels, and an electric motor coupled to one of the wheels, the electric motor being a load-bearing member of the frame. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or the meaning of the claims.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Application No. 61/702,698, filed Sep. 18, 2012, which is incorporated herein by reference in its entirety.
FIELD
Certain embodiments of the disclosure relate generally to authentication of a device.
BACKGROUND
Devices such as mobile phones, computers, laptops, tablets, personal digital assistants, etc., have become ubiquitous, particularly in the workplace. Such devices may be used to receive, transmit, store, and generate confidential information. Furthermore, such devices are highly portable and may be carried into and out of secure facilities or may be used to gain access to those facilities. An unauthorized person interested in accessing confidential information or in gaining access to secure facilities may do so by replacing an authentic device with a cloned counterfeit device or by inserting additional electronic equipment into the device.
Current authentication procedures focus primarily in validating a user of a device. Authentication of a device is typically limited to visual authentication. For example, verification of serial number, make, and/or model of the device. However, as discussed above, this authentication may not be sufficiently strong for certain applications.
BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES
Exemplary embodiments are described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the left most digit(s) of a reference number identifies the drawing in which the reference number first appears.
FIG. 1 is a diagram of an environment for authenticating a device, according to an exemplary embodiment.
FIG. 2 is a flow diagram of a method for authenticating a device, according to an exemplary embodiment.
FIG. 3 is a flow diagram of a method for authenticating a device, according to another exemplary embodiment.
FIG. 4 is a flow diagram of a method for authenticating a device, according to yet another exemplary embodiment.
DETAILED DESCRIPTION
The following Detailed Description refers to accompanying drawings to illustrate various exemplary embodiments. References in the Detailed Description to “one exemplary embodiment,” “an exemplary embodiment,” “an example exemplary embodiment,” etc., indicate that the exemplary embodiment described may include a particular feature, structure, or characteristic, but every exemplary embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same exemplary embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an exemplary embodiment, it is within the knowledge of those skilled in the relevant art(s) to affect such feature, structure, or characteristic in connection with other exemplary embodiments whether or not explicitly described.
The various exemplary embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge of those skilled in relevant art(s), readily modify and/or adapt for various applications such exemplary embodiments, without undue experimentation, without departing from the spirit and scope of the invention. Therefore, such adaptations and modifications are intended to be within the meaning and plurality of equivalents of the exemplary embodiments based upon the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by those skilled in relevant art(s) in light of the teachings herein.
Users can access information using a wide variety of devices including mobile phones, computers, laptops, personal digital assistants, tablets, etc. These devices are made of a plurality of materials, and at least some of these materials emit a unique measurable reaction when being exposed to a particular energy. This unique measurable reaction is referred hereinafter as the device's hardware DNA.
A device's hardware DNA may be used as a factor to authenticate the device. For example, in a workplace environment, an exemplary embodiment can authenticate an organization-issued device by comparing the device's hardware DNA to a corresponding enrolled hardware DNA signature for the device.
FIG. 1 is a diagram of an environment 100 for authentication of device 120 using a hardware DNA signature, according to various embodiments of the present disclosure. Environment 100 includes an authenticating unit 110 , one or more devices 120 , a network 130 , and a database 140 . As would be appreciated by a person of ordinary skill in the art, embodiments of the disclosure may be used in any environment incorporating authentication of a device.
Device 120 includes at least one material that reacts to energy transmitted from authenticating unit 110 . As would be appreciated by a person of ordinary skill in the art, a device 120 may be a computer, laptop, tablet, personal digital assistant, or any device which may be subject to authentication. Device 120 may further include measuring unit 122 , communication interface 123 , motion sensor 124 , and energy unit 125 , which will be described in further detail below with respect to other exemplary embodiments.
Authenticating unit 110 is configured to illuminate device 120 with a laser, visible light, an electromagnetic field, or other form of energy, and to monitor hardware DNA signature of device 120 . Authenticating unit 110 includes an energy transmitting unit 111 to transmit the form of energy used to illuminate device 120 and a receiving unit 112 to monitor the response to the form of energy (i.e., the hardware DNA signature of device 120 ).
Authenticating unit 110 further includes a processor 113 to control circuits and/or elements of authenticating unit 110 to perform at least some of the operations of the present embodiment. Authenticating unit 110 also includes a user interface 114 to receive operating instructions and information from a user and to provide authentication status information to the user. For example, user interface 114 may be used to input unique identification information of a device being authenticated, initiate an authentication process, and indicate to the user the results of the authentication process. Authenticating unit 110 further includes a communication interface 115 , which will be described in further detail below with respect to other exemplary embodiments.
Database 140 includes computer data storage for storing data within supporting data structures. In the present embodiment, database 140 stores authentication information, including an enrolled hardware DNA for a plurality of devices. The authentication information may be stored in database 140 through an enrollment process initiated by the manufacturer of a corresponding device, an end user, or another entity.
In the present embodiment, a user seeking to authenticate device 120 obtains a unique identification of device 120 , for example, the device's serial number. In an embodiment, the unique identification is entered through user interface 114 . As would be appreciated by persons of ordinary skill in the art, other methods for entering the device ID may be used with the present invention. Authenticating unit 110 may use this identification to query database 140 for authentication information corresponding to device 120 . Authenticating unit may also use this information to determine the type of energy to transmit towards device 120 for authentication, the energy's intensity, or some other parameter related to the authentication of device 120 .
Note that in the environment illustrated in FIG. 1 , authenticating unit 110 communicates with database 140 through communication network 130 to obtain authentication information for device 120 . A person of ordinary skill in the art would understand that authenticating unit 110 may communicate with database 140 using a direct physical link or through multiple networks using wired or wireless means. Accordingly, in various exemplary embodiments a database for storing authentication information may be co-located with a corresponding authenticating unit or be located remotely.
FIG. 2 is a flow diagram 200 of a method for authenticating a device according to an exemplary embodiment of the disclosure. The flowchart is described with continued reference to the embodiment of FIG. 1 . However, the flowchart is not limited to that embodiment.
At block 210 , device 120 is enrolled in authentication database (DB) 140 . In particular, device 120 is illuminated with energy, for example a laser beam, at a predetermined intensity, and the device's response is measured, i.e., its baseline hardware (HW) DNA. The response may be converted into a different form (e.g., digital representation) for storage. The baseline hardware DNA is stored in a database, such as database 140 .
The enrollment step may be performed by the manufacturer 150 of the device. Alternatively, the enrollment step may be performed by an owner of a device (e.g., a corporate or government entity). This may allow the device's owner to enroll new devices or re-enroll a device (i.e., generate and store a new hardware DNA) whenever the device undergoes a hardware change affecting its hardware DNA.
At block 220 , the device ID is entered into authentication unit 110 . The device ID may be obtained, for example, from a user entering the device ID into the authenticating unit.
At block 230 , authenticating unit 110 illuminates device 120 with a corresponding energy using transmitting unit 111 .
At block 240 , authentication unit 110 measures a response from device 120 using receiving unit 112 . The response may include a visible change in the surface of device 120 , such as a change in color or displaying a particular pattern, in which case receiving unit 112 may include a lens and image processing circuitry for detecting, processing, and recording the visible change. Authentication unit 110 may convert the monitored response into a digital representation.
At block 250 , authenticating unit 110 queries authentication DB 140 for authentication information, including the device's enrolled hardware DNA, based on the unique device ID.
At block 260 , authentication unit 110 compares the measured response, i.e., the device's hardware DNA, to the baseline hardware (HW) DNA.
Device 120 is deemed authentic if the measured response matches the baseline hardware DNA of the authentication information (block 270 ). On the other hand, device 120 is deemed not authentic if the measured response does not match the baseline hardware DNA (block 280 ).
Although in the present embodiment the authentication unit queries the database for the baseline hardware DNA and performs the comparison locally, the comparison may be performed remotely. For example, authenticating unit 110 may provide the unique device ID and the measured response to a centralized server, and the centralized server may use the information to query database 140 and compare the measured response to the device's baseline hardware DNA.
FIG. 3 is a flow diagram 300 of a method for authenticating a device according to another exemplary embodiment of the disclosure. The flowchart is described with continued reference to the embodiment of FIG. 1 . However, the flowchart is not limited to that embodiment.
In exemplary embodiments described above, during authentication, the hardware DNA of device 120 is measured by authenticating unit 110 , which is separate from device 120 . However, in various exemplary embodiments device 120 may measure its hardware DNA and may transmit its hardware DNA to a corresponding authenticating unit via short range wireless communication. Specifically, returning to FIG. 1 , in the present exemplary embodiment, authenticating unit 110 includes a communication interface 115 to communicate via short range wireless communication with devices such as device 120 , and device 120 includes a measuring unit 122 for measuring a reaction to a corresponding energy and a communication interface 123 to communicate via short range wireless communication with devices such as authenticating unit 110 . Such a configuration allows device 120 to generate a hardware DNA by measuring a response to incident energy locally. This may facilitate measurement of a reaction to incident energy that is not visual, such as a measurement of a resistance of a material within device 120 .
At block 310 , device 120 is enrolled in authentication database (DB) 140 . In an embodiment, the device 120 is illuminated with energy, for example an electromagnetic signal, at a predetermined intensity. Measuring unit 122 , instead of an external measuring unit, measures the device's response to the incident energy and communication interface 123 transmits data including the measured response. For example, the incident energy may affect the resistance of at least one material within device 120 , and measuring unit 122 may perform a resistance test on the at least one material to determine the resistance of the at least one material in view of the incident energy. In such case, the measured resistance becomes the baseline hardware DNA.
Measuring unit 122 then provides the hardware DNA signature to communication interface 123 for transmission towards a corresponding communication interface (not shown in FIG. 1 ) of the device manufacturer. The baseline hardware DNA signature is enrolled for the device in authentication database (DB) 140 . A person of ordinary skill in the art would understand that resistance may be measured in multiple ways. For example, measuring unit 122 may apply a voltage across a portion of the material and measure the flow of current across.
At block 320 , the device ID is entered into authentication unit 110 . The device ID may be obtained, for example, from a user entering the device ID into the authenticating unit.
At block 330 , authenticating unit 110 illuminates device 120 using transmitting unit 11 .
At block 340 , measuring unit 122 within device 120 measures the resistance of the at least one material in view of the incident energy and provides the measurement to communication interface 123 for transmission towards authenticating unit 110 . Device 120 may be triggered to measure the response of the at least one material in multiple ways. For example, a measurement may be triggered by a direct instruction transmitted via short range communication towards device 120 , a manual switch, an electronic user interface, etc., operable by the user to request such measurement.
At block 350 , authenticating unit 110 receives data from device 120 including the measured response.
At block 360 , authenticating unit 110 queries authentication DB 140 for authentication information, including the device's baseline hardware DNA, based on the unique device ID.
At block 370 , authentication unit 110 compares the measured response, i.e., the device's hardware DNA, to the baseline hardware DNA.
Device 120 is deemed authentic if the measured response matches the baseline hardware DNA of the authentication information (block 380 ). On the other hand, device 120 is deemed not authentic if the measured response does not match the baseline hardware DNA (block 390 ).
FIG. 4 is a flow diagram 400 of a method for authenticating a device according to yet another exemplary embodiment of the disclosure. The flowchart is described with continued reference to the embodiment of FIG. 1 . However, the flowchart is not limited to that embodiment.
In the various exemplary embodiments described above, a hardware DNA signature includes only one dimension for authentication. In alternative embodiments, a hardware DNA signature may include multiple elements/dimensions. For example, one or more dimensions can be characterized by the inclination of a device relative to a horizontal axis when the device is exposed to incident energy, the incidence angle of the energy relative to a surface of the device, the intensity of the incident energy, the type of emitted energy, or a combination thereof. Accordingly, during authentication, device measurements may need to match some, all or a combination of the corresponding measurements in its baseline hardware DNA to be deemed authentic.
At block 410 , device 120 is enrolled in authentication database (DB) 140 . In particular, a multi-dimensional device hardware DNA profile is generated by directing an energy, for example a laser beam, at a predetermined intensity towards device 120 when device 120 is positioned at multiple predetermined orientations relative to the laser beam, and measuring the device's response for each orientation.
At block 420 , the device ID is entered into authentication unit 110 . The device ID may be obtained, for example, from a user entering the device ID into the authenticating unit.
At block 430 , authenticating unit 110 illuminates device 120 using transmitting unit 111 . The user will then position device 120 in one of the multiple predetermined orientations relative to the laser beam to get a measurement for the particular dimension. The predetermined orientation may be previously known to the user or may be provided to the user through user interface of authentication unit 110 .
At block 440 , authenticating unit 110 measures the response corresponding to the particular orientation and records the response in association with the orientation.
At block 450 , authenticating unit 110 determines if there are additional dimensions, i.e., orientations, at which a response from device 120 needs to be measured. If there are more incidence angles at which a response needs to be measured, authenticating unit indicates that the device should be re-positioned for measuring a corresponding response and operation returns to step 440 .
If there are no more incidence angles at which a response needs to be measured, operation proceeds to step 460 where authenticating unit 110 queries authentication DB 140 for authentication information, including the device's baseline hardware DNA, based on the unique device ID.
At block 470 , authenticating unit 110 compares the measured responses to the multi-dimensional baseline hardware DNA. Device 120 is deemed authentic if the measured response matches the baseline hardware DNA of the authentication information (block 480 ). On the other hand, device 120 is deemed not authentic if the measured response does not match the baseline hardware DNA (block 490 ).
Although in the present embodiment the multiple dimensions are predetermined orientations relative to the laser beam, the present disclosure is not so limited. Other multi-dimensional schemes include multiple responses to energy incident to corresponding surfaces of the device, multiple responses corresponding to multiple intensities of incident energy into one or more surfaces of the device, multiple measurements of resistance corresponding to multiple materials of the device when the device is exposed to a form of energy, etc., without departing from the scope of the present teachings.
CONCLUSION
it is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the invention as contemplated by the inventor(s), and thus, are not intended to limit the invention and the appended claims in any way.
The invention has been described above with the aid of functional building blocks illustrating the implementation of specified functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for the convenience of the description. Alternate boundaries can be defined so long as the specified functions and relationships thereof are appropriately performed.
It will be apparent to those skilled in the relevant art(s) that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus the invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
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Methods and systems for authentication of a device are disclosed. An exemplary method includes transmitting an energy towards the device including a material, monitoring a response of the device to the transmitted energy, generating a signature of the device based on the response of the device to the transmitted energy, comparing the device signature to an enrolled signature for the device, and indicating that authentication of the device is successful when the generated signature matches the enrolled signature. An exemplary system includes a transmitter configured to transmit an energy towards the device, a receiver configured to monitor a response of the device, and a processor configured to generate a signature of the device based on the response of the device, compare the device signature to an enrolled signature for the device, and indicate that authentication of the device is successful when the generated signature matches the enrolled signature.
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CROSS-REFERNCE TO RELATED APPLICATION
[0001] This is a CIP application of U.S. patent application Ser. No. 10/039,557 filed on Jan. 8, 2002, and for which priority is claimed under 35 U.S.C.sctn.120.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates aminothiol compounds which perform as superior catalysts in the asymmetric addition reactions of organic zinc and aldehyde.
[0004] 2. Description of the Related Technology
[0005] For preparing secondary alcohols, one of the most important methods is to react organic zinc with aldehyde in addition reactions. In order to accelerate this reaction, chiral aminoalcohols are usually added as ligands to combine with organic zinc. Such chiral aminoalcohol create an asymmetric reaction environment, so that one of the produced chiral secondary alcohols is produced more than its stereoisomer, i.e., the asymmetric addition reactions. Apparently, the crux of obtaining a high chemical yield as well as enantioselectivity in the above reactions is to select proper chiral compounds which can provide excellent asymmetric environment for catalytical process.
[0006] Though many chiral compounds used in the addition reactions regarding organic zinc and aldehyde can achieve good enantioselectivity, however, these compounds have to be added at an amount at least 1% of the main reactants, and usually around 20%. Additionally, the enantioselectivity always decays with decreasing amount of the chiral ligands used. In general, the enantioselectivity is reduced below 90% enantiomeric excess (e.e.) when the chiral ligands are descended under 5%, so that most of above reactions are not good enough for industrial usage.
[0007] Aminoalcohols with optical activity, such as N,N-dibutylnorephe-edine, are frequently applied to accelerating the asymmetric addition reactions of organic zinc and aldehyde as chiral ligand catalysts. By adding aminoalcohols, enantioselectivity of the above reactions can be reached as high as 99% e.e., but an amount 10-20% of chiral aminoalcohols is need. Therefore, it's an important issue how to reduce the necessary amount of the chiral ligands used in the catalysis, so that it can be an economically efficient process
SUMMARY OF THE INVENTION
[0008] The object of the present invention is to provide aminothiol compounds with two chiral centers, which can increase enantioselectivity of asymmetric addition of organic zinc and aldehyde.
[0009] In order to achieve the above object, the present invention discloses an aminothiol compound having a general formula I;
[0010] wherein R 1 -R 5 are substitutable ligands.
[0011] According to the present invention, the aminothiol compounds can perform as superior catalysts in asymmetric addition reactions wherein organic zinc and aldehyde are involved. In such reactions, though the catalysts are added only 0.1% or even 0.02%, enantioselectivity higher than 98% e.e. can always be obtained. Such catalyses are economically useful for industries.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] In the present invention, aminothiol compounds have a general formula I,
[0013] wherein R 1 is aryl or alkyl of C1-C9;
[0014] R 2 is aryl or alkyl of C1-C9;
[0015] R 3 is aryl or alkyl of C1-C9;
[0016] R 4 is aryl or alkyl of C1-C9; or
[0017] R 3 , R 4 and N can form a three-to-eight-membered heterocycle; and
[0018] R 5 can be H or alkyl of C1-C6.
[0019] [Preparation Mode]
[0020] In general, the aminothiol compounds can be prepared through procedures shown in Scheme A.
[0021] Scheme A includes steps of: (a) reacting amino-alcohol with bromo-compound and carbonate of alkaline metal to form the specific ligand of R 3 , R 4 and N; (b) replacing —OH with —SAc by adding MeSO 2 Cl and NEt 3 (c) adding LiAlH 4 to form —SH.
[0022] The following EXAMPLEs indicate procedures for preparing representative aminothiol compounds of the present invention. Table 1 lists codes of different ligands shown in the compound of formula (I), so that the aminothiol compounds of the present invention can be simply represented with combinations of such codes.
TABLE 1 R 1 R 2 N-R 3 -R 4 R 5 code ligand code ligand code ligand code ligand 2 methyl b methyl 2 Bu n c H (n-butyl) 3 Bu n c Bu n 3 Bn (n-butyl) (n-butyl) (benzyl) 4 i-butyl f i-propyl 4 pyrro- lidinyl 5 Bn g Ph 5 piperidyl (benzyl) (phenyl) 6 i-propyl 6 morpho- linyl 7 Ph (phenyl)
[0023] For example, compound (2b4c) is an aminothiol compound of the present invention, wherein R 1 is methyl; R 2 is methyl; N, R 3 and R 4 form a membered membered heteorocycle, pyrrolidinyl; and R 5 is H. As for the middle product obtained in step (a), the last code “a” represents the alcohol ligand, —OH.
EXAMPLES 1 and 2
Preparation of (2R,3S)-4-Methyl-3-(1-pyrrolidinyl) Pentane-2-thiol (6b4c) and (3R,4S)-2-Methyl-4-(1-pyrrolidinyl) pentane-3-thiol (2f4c)
[0024] Step (a): Preparing (2R,3S)-4-Methyl-3-(1-pyrrolidinyl) pentan-2-ol (6b4a)
[0025] To a three-necked flask, (2R,3S)-3-amino-4-methylpentan-2-ol (0.585g, 5.0 mmol), Na 2 CO 3 (1.16g, 11.0 mmol) and CH 3 CN (20 mL) are added under the nitrogen system and then heated with refluxing. Next, Br 2 C 4 H 8 (1.295g, 6.0 mmol) is injected into the solution. After complete reaction for 12 hours, H 2 O (20 mL) is added to terminate the reaction. The product is repeatedly extracted with EtOAc (20 mL), wherein the organic phase is dehydrated with Na 2 SO 4 . A coarse product is obtained after filtration and concentration. Column chromatography (Silica gel 50 g, eluent is n-Hexane:EtOAc=1:1) is used to purify the coarse product and a slightly-yellow liquid (0.85 g) is obtained. The yield is 85% and the other analysis includes:
[0026] [0026] 1 H NMR (400 MHz, CDCl 3 ) δ 0.87 (d, J=6.4 Hz, 3H, CH(CH 3 ) 2 ), 0.96 (d, J=6.4 Hz, 3H, CH(CH 3 ) 2 ), 1.05 (d, J=6.4 Hz, 3H, CHOHCH 3 ), 1.72-1.79 (m, 4H, —(CH 2 ) 2 —), 1.82-2.00 (m, 1H, CH(CH 3 ) 2 ), 2.48 (dd, J 1 =4.8 Hz, J 2 =10.0 Hz, 1H, NCH), 2.80-2.92 (m, 4H, NCH 2 —), 3.70-3.80 (m, 1H, CHOH)
[0027] [0027] 13 C NMR (100 MHz, CDCl 3 ) δ 18.59 (CHOHCH 3 ), 19.80 (CH(CH 3 ) 2 ), 21.38 (CH(CH 3 ) 2 ), 23.93 (—CH 2 —) 27.30 (CH(CH 3 ) 2 ), 50.91 (NCH 2 —), 65.64 (NCH), 69.50 (CHOH)
[0028] Element analysis: C 10 H 21 NO theoretical: C, 70.12; H, 12.36; N, 8.18 experimental: C, 71.16; H, 12.28; N, 8.14
[0029] High-resolution MS (70 eV) m/e theoretical: 171.1623 experimental: 172.1699
[0030] [α] 25 D =+42.1 (c=1.45, CDCl 3 )
[0031] Step (b): Preparing (2R,3S)-4-Methyl-3-(1-pyrrolidinyl)-2-thioacetylpentane (6b4b)
[0032] and (3R,4S)-2-Methyl-4-(1-pyrrolidinyl)-3-thioacetylpentane (2f4b)
[0033] To a three-necked flask, compound (6b4a) (0.855g, 5.0 mmol), CH 2 Cl 2 (20 mL) and NEt 3 (1.01 g, 10.0 mmol) are added under nitrogen system. Next, MeSO 2 Cl (0.69 g, 6.0 mmol, dissolved in 20 mL CH 2 Cl 2 ) is added dropwisely at 0° C. After complete reaction for 2 hours, a coarse product is obtained through repeated depressing concentration and adding benzene therein. The coarse product is then added into benzene (20 mL) with refluxing, and MeCOSH (0.46 g, 6.0 mmol) and NEt 3 (1.01 g, 10.0 mmol) dissolved in 20 mL benzene are injected into the above solution under the nitrogen system. After 12 hours, H 2 O (20 mL) is added to terminate the reaction. The product is repeatedly extracted with EtOAc (20 mL), wherein the organic phase is dehydrated with Na 2 SO 4 . A coarse product is obtained after filtration and concentration. Column chromatography (Silica gel 70 g, eluent is n-Hexane:NEt 3 =100:1) is used to purify the coarse product and two orange liquids, compound (6b4b) (0.229 g) and compound (2f4b) (0.458 g), are obtained. The yields of compound (6b4b) and compound (2f4b) are 20% and 40%, respectively. The other analysis for compound (6b4b) includes:
[0034] [0034] 1 H NMR (400 MHz, CDCl 3 ) δ 0.92 (d, J=7.2 Hz, 3H, CH(CH 3 ) 2 ), 0.94 (d, J=7.2 Hz, 3H, CH(CH 3 ) 2 ), 1.27 (d, J=6.8 Hz, 3H, SCHCH 3 ), 1.66-1.73 (m, 4H, —(CH 2 ) 2 —), 1.90-2.05 (m, 1H, CH(CH 3 ) 2 ), 2.27 (s, 3H, SCOCH 3 ), 2.41 (dd, J 1 =3.2 Hz, J 2 =8.0 Hz, 1H, NCH), 2.67-2.74 (m, 2H, NCH 2 —), 2.75-2.81 (m, 2H, NCH 2 —), 3.86-4.05 (m, 1H, SCH)
[0035] [0035] 13 C NMR (100 MHz, CDCl 3 ) δ 18.38 (SCHCH 3 ) 20.37 (CH(CH 3 ) 2 ), 21.18 (CH(CH 3 ) 2 ), 24.20 (—CH 2 —), 29.40 (CH(CH 3 ) 2 ), 30.66 (SCOCH 3 ), 43.29 (NCH) 51.06 (NCH 2 —), 69.61 (SCHCH 3 ), 196.77 (SCOCH 3 )
[0036] Element analysis C 12 H 23 NOS theoretical: C, 62.83; H, 10.11; N, 6.11 experimental: C, 62.90; H, 10.10; N, 6.02
[0037] High-resolution MS (70 eV) m/e theoretical: 229.1500 experimental: 229.1523
[0038] [α]25D=+48.1 (c=1 0.05, CDCl 3 )
[0039] The other analysis for compound (2f4b) includes:
[0040] [0040] 1 H NMR (400 MHz, CDCl 3 ) δ 0.91 (d, J=6.8 Hz, 3H, CH(CH 3 ) 2 ), 0.96 (d, J=7.2 Hz, 3H, CH(CH 3 ) 2 ), 1.03 (d, J=6.8 Hz, 3H, NCHCH 3 ), 1.68-1.73 (m, 4H, —(CH 2 ) 2 —), 1.86-2.11 (m, 1H, CH(CH 3 ) 2 ), 2.33 (s, 3H, SCOCH 3 ), 2.42-2.64 (m, 4H, NCH 2 —), 2.42-2.64 (m, 1H, NCH), 3.60 (dd, J 1 =4.8 Hz, J 2 =8.0 Hz, 1H, SCH),
[0041] [0041] 13 C NMR (100 MHz, CDCl 3 ) δ 13.78 (NCHCH 3 ) 19.81 (CH(CH 3 ) 2 ), 20.78 (CH(CH 3 ) 2 ), 23.26 (—CH 2 —), 30.25 (CH(CH 3 ) 2 ), 30.72 (SCOCH 3 ), 50.64 (NCH 2 —), 54.84 (NCH), 58.89 (SCHCH 3 ), 195.56 (SCOCH 3 )
[0042] Element analysis C 12 H 23 NOS theoretical: C, 62.83; H, 10.11; N, 6.11 experimental: C, 62.56; H, 10.25; N, 5.97
[0043] High-resolution MS (70 eV) m/e theoretical: 299.1500 experimental: 299.1508
[0044] [α]25D=+41.7 (c=0.99, CDCl 3 )
[0045] Step (c): Preparing (2R,3S)-4-Methyl-3-(1-pyrrolidinyl)pentane-2-thiol (6b4c)
[0046] and (3R,4S)-2-Methyl-4-(1-pyrrolidinyl)pentane-3-thiol (2f4c)
[0047] To a three-necked flask, LAH (LiAlH 4 , 0.076 g, 2.0 mmol) and ether (10 mL) are added under nitrogen system. Next, compound (6b4b) (0.229 g, 1.0 mmol) or compound (2f4b) (0.229 g, 1.0 mmol) dissolved in 10 mL ether is slowly added into the flask within 30 min at 0° C. After reaction for 1 hour, 15% NaOH is added to the flask until a white solid is present complete. The solid is filtered and repeatedly washed with a solvent. The filtrate is then concentrated to obtain a coarse product. Column chromatography (Silica gel 40 g, eluent is n-Hexane:NEt 3 =100:1) is used to purify the coarse product and two orange liquids, compound (6b4c) (0.15 g) and compound (2f4c) (0.15 g), are obtained. The yields of compound (6b4c) and compound (2f4b) are 80% and 80%, respectively. The other analysis for compound (6b4c) includes:
[0048] [0048] 1 H NMR (400 MHz, CDCl 3 ) δ 0.88 (d, J=6.8 Hz, 3H, CH(CH 3 ) 2 ), 0.93 (d, J=6.4 Hz, 3H, CH(CH 3 ) 2 ), 1.35 (d, J=6.8 Hz, 3H, CHSHCH 3 ), 1.65-1.73 (m, 4H, —(CH 2 ) 2 —), 1.98-2.10 (m, 1H, CH(CH 3 ) 2 ), 2.55 (dd, J 1 =3.6 Hz, J 2 =7.2 Hz, 1H, NCH), 2.70-2.75 (m, 2H, NCH 2 —), 2.76-2.82 (m, 2H, NCH 2 —), 3.03-3.20 (m, 1H, CHOH)
[0049] [0049] 13 C NMR (100 MHz, CDCl 3 ) δ 20.75 (CH(CH 3 ) 2 ), 21.24 (CHSHCH 3 ), 22.26 (CH(CH 3 ) 2 ), 24.49 (—CH 2 —) 29.17 (CH(CH 3 ) 2 ), 38.44 (NCH), 51.18 (NCH 2 —), 70.87 (SCH)
[0050] Element analysis C 10 H 21 NS theoretical: C, 64.11; H, 11.30; N, 7.48 experimental: C, 64.35; H, 11.12; N, 7.65
[0051] High-resolution MS (70 eV) m/e theoretical: 187.1395 experimental: 187.1366
[0052] [α]25D=+17.4° (c=0.83, CDCl 3 )
[0053] The other analysis for compound (2f4c) includes:
[0054] [0054] 1 H NMR (400 MHz, CDCl 3 )
[0055] δ 0.92 (d, J=6.8 Hz, 3H, CH(CH 3 ) 2 ), 1.01 (d, J=6.4 Hz, 3H, CH(CH 3 ) 2 ), 1.04 (d, J=6.4 Hz, 3H, NCHCH 3 ), 1.69-1.75 (m, 4H, —(CH 2 ) 2 —), 1.69-1.75 (m, 1H, CH(CH 3 ) 2 ), 2.35-2.41 (m, 1H, NCH), 2.43-2.49 (m, 2H, NCH 2 —), 2.52-2.58 (m, 2H, NCH 2 —), 2.84 (dd, J 1 =4.0 Hz, J 2 =9.6 Hz, 1H, SHCH)
[0056] [0056] 13 C NMR (100 MHz, CDCl 3 ) δ 12.08 (NCHCH 3 ), 20.47 (CH(CH 3 ) 2 ), 21.71 (CH(CH 3 ) 2 ), 23.27 (—CH 2 —) 31.24 (CH(CH 3 ) 2 ), 50.95 (NCH 2 —), 52.17 (NCH), 60.54 (SCH)
[0057] Element analysis C 10 H 21 NS theoretical: C, 64.11; H, 11.30; N, 7.48 experimental: C, 63.98; H, 11.25; N, 7.45
[0058] High-resolution MS (70 eV) m/e theoretical: 187.1395 experimental: 187.1386
[0059] [α]25D=+23.7° (c=1.51,CDCl 3 )
EXAMPLES 3 and 4
Preparation of (3S,4R)-2-Methyl-3-(1-pyrrolidinyl) octane-4-thiol (6c4c) and (3R,4S)-2-Methyl-4-(1-pyrrolidinyl) octane-3-thiol (3f4c)
[0060] Step (a): Preparing (3S,4R)-2-Methyl-3-(1-pyrrolidinyl)octan-4-ol (6c4a)
[0061] Repeat Step (a) of EXAMPLE 1, but (2R,3S)-3-amino-4-methyl pentan-2-ol is replaced with (3S,4R)-3-amino-2-methyloctan-4-ol. The analysis for compound
[0062] (6c4a) includes:
[0063] [0063] 1 H NMR(400 MHz, CDCl 3 ) δ 0.77-0.92 (m, 3H, (CH 2 ) 3 CH 3 ), 0.77-0.92 (m, 6H, CH(CH 3 ) 2 ), 1.06-1.62 (m, 6H, (CH 2 ) 3 CH 3 ), 1.62-1.81 (m, 4H, —(CH 2 ) 2 —), 1.89-2.05 (m, 1H, CH(CH 3 ) 2 ), 2.47 (dd, J 1 =4.8 Hz, J 2 =9.6 Hz, 1H, NCH), 2.74-2.86 (m, 4H, NCH 2 —), 3.45-3.52 (m, 1H, CHOH),
[0064] [0064] 13 CNMR(100 MHz, CDCl 3 ) δ 13.99 (CH 2 CH 2 CH 2 CH 3 ), 20.20 (CH(CH 3 ) 2 ), 21.81 (CH(CH 3 ) 2 ), 22.66 (CH 2 CH 2 CH 2 CH 3 ), 24.23 (—CH 2 —), 27.48 (CH(CH 3 ) 2 ), 29.23 (CH 2 CH 2 CH 2 CH 3 ), 32.21 (CH 2 CH 2 CH 2 CH 3 ), 50.85 (NCH 2 —), 69.11 (NCH), 70.58 (CHOH)
[0065] Element analysis C 13 H 27 NO theoretical: C, 73.18; H, 12.76; N, 6.56 experimental: C, 73.20; H, 12.63; N, 6.51
[0066] High-resolution MS (70 eV) m/e theoretical: 213.2093 experimental: 214.2165
[0067] [α]25D=+53.3° (c=1.03, CDCl 3 )
[0068] Step (b): Preparing (3S,4R)-2-Methyl-3-(1-pyrrolidinyl)-4-thioacetyloctane (6c4b)
[0069] and (3R,4S)-2-Methyl-4-(1-pyrrolidinyl)-3-thioacetyloctane (3f4b)
[0070] Repeat Step (b) of EXAMPLE 1, but replace compound (6b4a) with compounds (6c4a) or (3f4a). Analysis for product (6c4b) includes:
[0071] [0071] 1 H NMR (400 Mz CDCl 3 ) δ 0.85 (t, J=7.2 Hz, 3H, (CH 2 ) 3 CH 3 ), 0.86 (d, J=5.6 Hz, 3H, CH(CH 3 ) 2 ), 0.95 (d, J=5.6 Hz, 3H, CH(CH 3 ) 2 ), 1.20-1.50 (m, 6H, (CH 2 ) 3 CH 3 ), 1.64-1.72 (m, 4H, —(CH 2 ) 2 —), 1.85-2.12 (m, 1H, CH(CH 3 ) 2 ), 2.28 (s, 3H, SCOCH 3 ), 2.43 (dd, J 1 =2.8 Hz, J 2 =8.0 Hz, 1H, NCH), 2.58-2.66 (m, 2H, NCH 2 —), 2.68-2.77 (m, 2H, NCH 2 —), 3.80-3.88 (m, 1H, SCH),
[0072] [0072] 13 C NMR (100 MHz, CDCl 3 ) δ 14.00 (CH 2 CH 2 CH 2 CH 3 ), 20.50 (CH(CH 3 ) 2 ), 21.19 (CH(CH 3 ) 2 ), 22.56 (CH 2 CH 2 CH 2 CH 3 ), 23.99 (—CH 2 —), 29.54 (CH(CH 3 ) 2 ), 29.58 (CH 2 CH 2 CH 2 CH 3 ), 30.53 (SCOCH 3 ), 32.16 (CH 2 CH 2 CH 2 CH 3 ), 47.53 (NCH), 50.79 (NCH 2 —), 70.19 (SCH), 196.26 (SCOCH 3 )
[0073] Element analysis C 15 H 29 NOS theoretical: C, 66.37; H, 10.77; N, 5.16 experimental: C, 66.14; H, 10.85; N, 5.22
[0074] High-resolution MS (70 eV) m/e theoretical: 271.1970 experimental: 271.1971
[0075] [α]25D=+39.6° (c=1.03, CDCl 3 )
[0076] Analysis for product (3f4b) includes:
[0077] [0077] 1 HNMR(400 MHz CDCl 3 ) δ 0.82-0.90 (m, 3H, (CH 2 ) 3 CH 3 ), 0.82-0.90 (m, 3H, CH(CH 3 ) 2 ), 0.93 (d, J=6.4 Hz, 3H, CH(CH 3 ) 2 ), 1.20-1.60 (m, 6H, (CH 2 ) 3 CH 3 ), 1.65-1.73 (m, 4H, —(CH 2 ) 2 —), 1.91-2.05 (m, 1H, CH(CH 3 ) 2 ), 2.31 (s, 3H, SCOCH 3 ), 2.50-2.63 (m, 4H, NCH 2 —), 2.50-2.63 (m, 1H, NCH), 3.63 (t, J=6.0 Hz, 1H, SCH),
[0078] [0078] 13 C NMR (100 MHz, CDCl 3 ) δ 13.91 (CH 2 CH 2 CH 2 CH 3 ), 19.07 (CH(CH 3 ) 2 ), 20.83 (CH(CH 3 ) 2 ), 22.98 (CH 2 CH 2 CH 2 CH 3 ), 23.56 (—CH 2 —), 30.26 (CH(CH 3 ) 2 ), 30.49 (CH 2 CH 2 CH 2 CH 3 ), 30.70 (SCOCH 3 ), 30.79 (CH 2 CH 2 CH 2 CH 3 ), 49.33 (NCH 2 —), 53.70 (NCH), 61.89 (SCH), 195.68 (SCOCH 3 )
[0079] Element analysis C 15 H 29 NOS theoretical: C, 66.37; H, 10.77; N, 5.16 experimental: C, 66.23; H, 10.71; N, 5.02
[0080] High-resolution MS (70 eV) m/e theoretical: 271.1970 experimental: 271.1991
[0081] [α]25D=+48.2° (c=1.24, CDCl 3 )
[0082] Step (c): Preparing (3S,4R)-2-Methyl-3-(1-pyrrolidinyl)octane-4-thiol (6c4c)
[0083] and (3R,4S)-2-Methyl-4-(1-pyrrolidinyl) octane-3-thiol (3f4c)
[0084] Repeat Step (c) of EXAMPLE 1, but replace compound (6b4b) with compounds (6c4b) or (3f4b). Analysis for product (6c4c) includes:
[0085] [0085] 1 H NMR (400 MHz, CDCl 3 ) δ 0.84-1.00 (m, 6H, CH(CH 3 ) 2 ), 0.84-1.00 (m, 3H, (CH 2 ) 3 CH 3 ), 1.16-1.35 (m, 4H, CH 2 (CH 2 ) 2 CH 3 ), 1.48-1.78 (m, 2H, CH 2 (CH 2 ) 2 CH 3 ), 1.48-1.78 (m, 4H, —(CH 2 ) 2 —), 2.00-2.13 (m, 1H, CH(CH 3 ) 2 ), 2.43 (dd, J 1 =3.6 Hz, J 2 =8.4 Hz, 1H, NCH), 2.71-2.93 (m, 4H, NCH 2 —), 2.71-2.963 (m, 1H, SHCH),
[0086] [0086] 13 C NMR (100 MHz, CDCl 3 ) δ 14.07 (CH 2 CH 2 CH 2 CH 3 ), 20.88 (CH(CH 3 ) 2 ), 21.39 (CH(CH 3 ) 2 ), 22.49 (CH 2 CH 2 CH 2 CH 3 ), 24.39 (—CH 2 —), 28.90 (CH(CH 3 ) 2 ), 30.54 (CH 2 CH 2 CH 2 CH 3 ), 34.56 (CH 2 CH 2 CH 2 CH 3 ), 44.95 (NCH), 51.01 (NCH 2 —), 70.85 (CHSH)
[0087] Element analysis C 13 H 27 NS theoretical: C, 68.06; H, 11.86; N, 6.11 experimental: C, 68.21; H, 11.55; N, 6.35
[0088] High-resolution MS (70 eV) m/e theoretical: 229.1864 experimental: 229.1857
[0089] [α]25D=+54.3° (c=10.01, CDCl 3 )
[0090] Analysis for product (3f4c) includes:
[0091] [0091] 1 H NMR (400 MHz, CDCl 3 ) δ 0.86-1.00 (m, 3H, (CH 2 ) 3 CH 3 ), 0.86-1.00 (m, 6H, CH(CH 3 ) 2 ), 1.23-1.50 (m, 4H, CH 2 (CH 2 ) 2 CH 3 ), 1.52-1.73 (m, 2H, CH 2 (CH 2 ) 2 CH 3 ), 1.52-1.73 (m, 4H, —(CH 2 ) 2 —), 1.75-1.92 (m, 1H, CH(CH 3 ) 2 ), 2.33 (dd, J 1 =4.4 Hz, J 2 =8.0 Hz, 1H, NCH), 2.47-2.62 (m, 4H, NCH 2 —), 2.85 (dd, J 1 =4.4 Hz, J 2 =8.0 Hz, 1H, SHCH),
[0092] [0092] 13 C NMR (100 MHz, CDCl 3 ) δ 13.92 (CH 2 CH 2 CH 2 CH 3 ), 20.13 (CH(CH 3 ) 2 ), 21.23 (CH(CH 3 ) 2 ), 23.21 (CH 2 CH 2 CH 2 CH 3 ), 23.43 (—CH 2 —), 29.30 (CH 2 CH 2 CH 2 CH 3 ), 30.65 (CH(CH 3 ) 2 ), 31.42 (CH 2 CH 2 CH 2 CH 3 ), 50.24 (NCH 2 —), 51.99 (NCH), 64.56 (CHSH)
[0093] Element analysis C 13 H 27 NS theoretical: C, 68.06; H, 11.86; N, 6.11 experimental: C, 68.21; H, 11.56; N, 6.01
[0094] High-resolution MS (70 eV) m/e theoretical: 229.1864 experimental: 229.1857
[0095] [α]25D=+38.8° (c=0.99, CDCl 3 )
EXAMPLE 5
Preparation of (3R,4S)-2,5-Dimethyl-4-(1-pyrrolidinyl)hexane-3-thiol (6f4c)
[0096] Step (a): Preparing (3R,4S)-2,5-Dimethyl-4-(1-pyrrolidinyl)hexan-3-ol (6f4a)
[0097] Repeat Step (a) of EXAMPLE 1, but replace (2R,3S)-3-amino-4-methylpentan-2-ol with (3R,4S)-4-amino-2,5-dimethylhexan-3-ol. Analysis for compound (6f4a) includes:
[0098] [0098] 1 H NMR (400 MHz, CDCl 3 ) δ 0.83 (d, J=6.8 Hz, 3H, NCHCH(CH 3 ) 2 ), 0.97 (d, J=6.8 Hz, 3H, NCHCH(CH 3 ) 2 ), 1.02 (d, J=1.2 Hz, 3H, CHOHCH(CH 3 ) 2 ), 1.04 (d, J=1.2 Hz, 3H, CHOHCH(CH 3 ) 2 ), 1.63-1.73 (m, 4H, —(CH 2 ) 2 —), 1.74-1.83 (m, 1H, NCHCH(CH 3 ) 2 ), 2.05-2.12 (m, 1H, CHOHCH(CH 3 ) 2 ), 2.21 (dd, J 1 =3.2 Hz, J 2 =4.0 Hz, 1H, NCH), 2.55-2.63 (m, 2H, NCH 2 —), 2.65-2.72 (m, 2H, NCH 2 —), 3.41 (dd, J 1 =4.4 Hz, J 2 =9.2 Hz, 1H, CHOH)
[0099] [0099] 13 C NMR (100 MHz, CDCl 3 ) δ 19.20 (NCHCH(CH 3 ) 2 ), 19.30 (NCHCH(CH 3 ) 2 ), 19.62 (CHOHCH(CH 3 ) 2 ), 22.68 (CHOHCH(CH 3 ) 2 ), 23.40 (—CH 2 —) 26.99 (NCHCH(CH 3 ) 2 ), 30.59 (CHOHCH(CH 3 ) 2 ), 51.59 (NCH 2 —), 68.34 (NCH), 77.60 (CHOH)
[0100] Element analysis C 12 H 25 NO theoretical: C, 72.31; H, 12.64; N, 7.03 experimental: C, 72.18; H, 12.73; N, 6.89
[0101] High-resolution MS (70 eV) m/e theoretical: 199.1936 experimental: 200.2011
[0102] [α]25D=+45.7° (c=1.21, CDCl 3 )
[0103] Step (b): Preparing (3R,4S)-2,5-Dimethyl-4-(1-pyrrolidinyl)-3-thioacetylhexane (6f4b)
[0104] Repeat Step (b) of EXAMPLE 1, but replace compound (6b4a) with compound (6f4a). Analysis for product (6f4b) includes:
[0105] [0105] 1 H NMR (400 MHz, CDCl 3 ) δ 0.88 (d, J=6.8 Hz, 3H, NCHCH(CH 3 ) 2 ), 0.90-0.98 (m, 3H, NCHCH(CH 3 ) 2 ), 0.90-0.98 (m, 6H, SCHCH(CH 3 ) 2 ), 1.66-1.71 (m, 4H, —(CH 2 ) 2 —), 1.88-2.00 (m, 1H, NCHCH(CH 3 ) 2 ), 2.01-2.12 (m, 1H, SCHCH(CH 3 ) 2 ), 2.34 (s, 3H, SCOCH 3 ), 2.62-2.70 (m, 2H, NCH 2 —), 2.71-2.77 (m, 2H, NCH 2 —), 2.62-2.77 (m, 1H, NCH), 3.79 (dd, J 1 =5.2 Hz, J 2 =6.4 Hz, 1H, SCH)
[0106] [0106] 13 C NMR (100 MHz, CDCl 3 ) δ 18.62 (NCHCH(CH 3 ) 2 ), 19.99 (NCHCH(CH 3 ) 2 ), 21.10 (SCHCH(CH 3 ) 2 ), 21.59 (SCHCH(CH 3 ) 2 ), 24.01 (—CH 2 —) 30.44 (NCHCH(CH 3 ) 2 ), 30.54 (SCHCH(CH 3 ) 2 ), 30.70 (SCOCH 3 ), 49.24 (NCH 2 —), 50.80 (NCH), 64.73 (SCH), 195.37 (SCOCH 3 )
[0107] Element analysis C 14 H 27 NOS theoretical: C, 65.32; H, 10.57; N, 5.44 experimental: C, 65.20; H, 10.81; N, 5.14
[0108] High-resolution MS (70 eV) m/e theoretical: 257.1813 experimental: 257.1859
[0109] [α]25D=+53.9° (c=1.23, CDCl 3 )
[0110] Step (c): Preparing (3R,4S)-2,5-Dimethyl-4-(1-pyrrolidinyl)hexane-3-thiol (6f4c)
[0111] Repeat Step (c) of EXAMPLE 1, but replace compound (6b4b) with compound (6f4b). Analysis for product (6f4c) includes:
[0112] [0112] 1 H NMR (400 MHz, CDCl 3 ) δ 0.89 (d, J=6.4 Hz, 3H, NCHCH(CH 3 ) 2 ), 0.92-1.06 (m, 3H, NCHCH(CH 3 ) 2 ), 0.92-1.06 (m, 6H, SHCHCH(CH 3 ) 2 ), 1.62-1.72 (m, 4H, —(CH 2 ) 2 —), 1.89-1.95 (m, 1H, NCHCH(CH 3 ) 2 ), 2.13-2.25 (m, 1H, SHCHCH(CH 3 ) 2 ), 2.52 (dd, J 1 =4.4 Hz, J 2 =8.0 Hz, 1H, NCH), 2.64-2.73 (m, 4H, NCH 2 —), 2.92 (dd, J 1 =4.4 Hz, J 2 =7.6 Hz, 1H, CHSH)
[0113] [0113] 13 C NMR (100 MHz, CDCl 3 ) δ 17.63 (NCHCH(CH 3 ) 2 ), 19.56 (NCHCH(CH 3 ) 2 ), 21.57 (CHSHCH(CH 3 ) 2 ), 21.79 (CHSHCH(CH 3 ) 2 ), 24.14 (—CH 2 —) 29.40 (NCHCH(CH 3 ) 2 ), 29.69 (CHSHCH(CH 3 ) 2 ), 48.77 (NCH), 50.03 (NCH 2 —), 66.19 (CHSH)
[0114] Element analysis C 12 H 25 NS theoretical: C, 66.91; H, 11.70; N, 6.50 experimental: C, 66.38; H, 10.91; N, 6.28
[0115] High-resolution MS (70 eV) m/e theoretical: 215.1708 experimental: 215.1712
[0116] [α]25D=+13.7° (c=0.99, CDCl 3 )
EXAMPLE 6
Preparation of (1R,2S)-3-Methyl-1-phenyl-2-(1-pyrrolidinyl) Butane-1-thiol (6g4c)
[0117] Step (a): Preparing (1R,2S)-3-Methyl-1-phenyl-2-(1-pyrrolidinyl)butan-1-ol (6g4a)
[0118] Repeat Step (a) of EXAMPLE 1, but replace (2R,3S)-3-amino-4-methylpentan-2-ol with (1R,2S)-2-amino-3-methyl-1-phenylbutan-1-ol, and replace Na 2 CO 3 (1.16 g, 11.0 mmol) with K 2 CO 3 (1.52 g, 11.0 mmol). Column chromatography (Silica gel, eluent is n-Hexane:EtOAc=10:1) is used to purify the coarse product and a slightly-yellow liquid (1.00 g) is obtained. The yield is 86% and the other analysis includes:
[0119] [0119] 1 H NMR (400 MHz, CDCl 3 ) δ 0.80 (d, J=6.8 Hz, 3H, CH(CH 3 ) 2 ), 0.96 (d, J=6.8 Hz, 3H, CH(CH 3 ) 2 ), 1.62-1.70 (m, 4H, —(CH 2 ) 2 —), 1.72-1.82 (m, 1H, CH(CH 3 ) 2 ), 2.54 (dd, J 1 =4.4 Hz, J 2 =8.0 Hz, 1H, NCH), 2.57-2.64 (m, 2H, NCH 2 —), 2.68-2.74 (m, 2H, NCH 2 —), 4.92 (d, J=4.0 Hz, 1H, CHOH), 7.14-7.34 (m, 5H, ArH)
[0120] [0120] 13 C NMR (100 MHz, CDCl 3 ) δ 20.28 (CH(CH 3 ) 2 ), 21.81 (CH(CH 3 ) 2 ), 23.78 (—CH 2 —), 27.88 (CH(CH 3 ) 2 ), 51.47 (NCH 2 —), 72.29 (NCH), 72.51 (CHOH), 126.08, 126.62, 127.79, 142.88 (Ph)
[0121] Element analysis C 15 H 23 NO theoretical: C, 77.21; H, 9.93; N, 6.00 experimental: C, 77.11; H, 9.73; N, 6.23
[0122] High-resolution MS (70 eV) m/e theoretical: 233.1780 experimental: 234.1865
[0123] [α]25D=−41.3° (c=1.38, CDCl 3 )
[0124] Step (b): Preparing (1R,2S)-3-Methyl-1-phenyl-2-(1-pyrrolidinyl)-1-thioacetyl butane (6g4b)
[0125] Repeat Step (b) of EXAMPLE 1, but replace compound (6b4a) with compound (6g4a). Column chromatography (Silica gel, eluent is n-Hexane:NEt 3 =100:1) is used to purify the coarse product and a slightly-yellow liquid (1.09g) is obtained. The yield is 75% and the other analysis includes:
[0126] [0126] 1 H NMR (400 MHz, CDCl 3 ) δ 0.90 (d, J=6.8 Hz, 3H, CH(CH 3 ) 2 ), 0.99 (d, J=6.4 Hz, 3H, CH(CH 3 ) 2 ), 1.45-1.55 (m, 4H, —(CH 2 ) 2 —), 1.92-2.04 (m, 1H, CH(CH 3 ) 2 ), 2.26 (s, 3H, SCOCH 3 ), 2.60-2.69 (m, 4H, NCH 2 —), 2.97 (t, J=6.4 Hz, 1H, NCH), 4.99 (d, J=6.4 Hz, 1H, SCH), 7.14-7.41 (m, 5H, ArH)
[0127] [0127] 13 C NMR (100 MHz, CDCl 3 ) δ 19.82 (CH(CH 3 ) 2 ), 21.62 (CH(CH 3 ) 2 ), 24.31 (—CH 2 —), 30.57 (CH(CH 3 ) 2 ), 30.59 (SCOCH 3 ), 49.69 (NCH), 50.42 (NCH 2 —), 69.33 (SCH), 126.73, 127.86, 128.70, 141.80 (Ph), 194.60 (SCOCH 3 )
[0128] Element analysis C 17 H 25 NOS theoretical: C, 70.06; H, 8.65; N, 4.81 experimental: C, 69.68; H, 8.80; N, 4.63
[0129] High-resolution MS (70 eV) m/e theoretical: 291.1657 experimental: 291.1661
[0130] [α]25D=−240.8° (c=1.02, CDCl 3 )
[0131] Step (c): Preparing (1 R,2S)-3-Methyl-1-phenyl-2-(1-pyrrolidinyl)butane-1-thiol (6g4c)
[0132] Repeat Step (c) of EXAMPLE 1, but replace compound (6b4b) with compound (6g4b). A slightly-yellow liquid (0.401g) is obtained through pumping concentration. The yield is 85% and other analysis includes:
[0133] [0133] 1 H NMR (400 MHz, CDCl 3 ) δ 0.95 (d, J=7.2 Hz, 3H, CH(CH 3 ) 2 ), 0.99 (d, J=6.4 Hz, 3H, CH(CH 3 ) 2 ), 1.37-1.48 (m, 4H, —(CH 2 ) 2 —), 2.06-2.15 (m, 1H, CH(CH 3 ) 2 ), 2.54-2.70 (m, 4H, NCH 2 —), 3.00 (dd, J 1 =5.2 Hz, J 2 =7.6 Hz, 1H, NCH), 4.30 (d, J=7.6 Hz, 1H, SHCH), 7.12-7.40 (m, 5H, ArH)
[0134] [0134] 13 C NMR(100 MHz, CDCl 3 ) δ 18.95 (CH(CH 3 ) 2 ), 21.67 (CH(CH 3 ) 2 ), 24.46 (—CH 2 —), 30.42 (CH(CH 3 ) 2 ), 50.60 (NCH 2 —), 70.03 (NCH), 77.20 (CHSH), 126.73, 127.9, 128.1, 144.57 (Ph)
[0135] Element analysis C 15 H 23 NS theoretical: C, 72.23; H, 9.29; N, 5.62 experimental: C, 72.01; H, 9.88; N, 5.32
[0136] High-resolution MS (70 eV) m/e theoretical: 249.1551 experimental: 249.1554
[0137] [α]25D=−489.0° (c=1.01, CDCl 3 )
EXAMPLE 7
Preparation of (1R,2S)-1,2-Diphenyl-2-piperidin-1-yl-ethanethiol (6g5c) Step (a): Preparing (6g5a)
[0138] [0138]
[0139] Repeat Step (a) of EXAMPLE 6, but replace 1,4-dibromobutane with 1,5-dibromopentane. Column chromatography (Silica gel, eluent is n-Hexane:EtOAc=10:1) is used to purify the coarse product and a slightly-yellow liquid (1.00 g) is obtained. The yield is 86% and the other analysis includes:
[0140] [0140] 1 H NMR (400 MHz, CDCl 3 ) δ 0.80 (d, J=6.8 Hz, 3H, CH(C H 3 ) 2 ), 0.96 (d, J=6.8 Hz, 3H, CH(C H 3 ) 2 ), 1.62-1.70 (m, 4H, —(C H 2 ) 2 —), 1.72-1.82 (m, 1H, C H (CH 3 ) 2 ), 2.54 (dd, J 1 =4.4 Hz, J 2 =8.0 Hz, 1H, NCH), 2.57-2.64 (m, 214, NCH 2 —), 2.68-2.74 (m, 2H, NCH 2 —), 4.92 (d, J=4.0 Hz, 1H, C H OH), 7.14-7.34 (m, 5H, ArH)
[0141] [0141] 13 C NMR (100 MHz, CDCl 3 ) δ 20.28 (CH( C H 3 ) 2 ), 21.81 (CH( C H 3 ) 2 ), 23.78 (—CH 2 —), 27.88 ( C H(CH 3 ) 2 ), 51.47 (NCH 2 —), 72.29 (N C H), 72.51 ( C HOH), 126.08, 126.62, 127.79, 142.88 (Ph)
[0142] Element analysis C 18 H 21 NO theoretical: C, 77.21; H, 9.93; N, 6.00 experimental: C, 77.11; H, 9.73; N, 6.91
[0143] High-resolution MS (70 eV) m/e theoretical:233.1780 experimental: 234.1865
[0144] [α] 25 D =−41.3 (c=1.38, CHCl 3 )
[0145] Step (b): Preparing (1R,2S)-Thioavcetic acidS-(3-methyl-1-phenyl-2-pyrrolidin-1-yl-butyl)ester (6g5b)
[0146] Repeat Step (b) of EXAMPLE 6, but replace compound (6g4a) with compound (6g5a). Column chromatography (Silica gel, eluent is n-Hexane:NEt 3 =100:1) is used to purify the coarse product and a slightly-yellow liquid (1.09 g) is obtained. The yield is 75% and the other analysis includes:
[0147] [0147] 1 H NMR(40 MHz, CDCl 3 ) δ 0.90 (d, J=6.8 Hz, 3H, CH(C H 3 ) 2 ), 0.99 (d, J=6.4 Hz, 3H, CH(C H 3 ) 2 ), 1.45-1.55 (m, 4H, —(C H 2 ) 2 —), 1.92-2.04 (m, 1H, C H (CH 3 ) 2 ), 2.26 (s, 3H, SCOC H 3 ), 2.60-2.69 (m, 4H, NCH 2 —), 2.97 (t, J=6.4 Hz, 1H, NCH), 4.99 (d, J=6.4 Hz, 1H, SCH), 7.14-7.41 (m, 5H, ArH)
[0148] [0148] 13 C NMR (100 MHz, CDCl 3 ) δ 19.82 (CH( C H 3 ) 2 ), 21.62 (CH( C H 3 ) 2 ), 24.31 (—CH 2 —), 30.57 ( C H(CH 3 ) 2 ), 30.59 (SCO C H 3 ), 49.69 (NCH), 50.42 (NCH 2 —), 69.33 ( C HSCOCH 3 ), 126.73, 127.86, 128.70, 141.80 (Ph), 194.60 (S C OCH 3 )
[0149] Element analysis C 21 H 25 NOS theoretical: C, 70.06; H, 8.65; N, 4.81; S 11.00 experimental: C, 69.68; H, 8.80; N, 4.63; S11.13
[0150] High-resolution MS (70 eV) m/e theoretical: 291.1657 experimental: 291.1661
[0151] [α] 25 D =−240.8 (c=1, CHCl 3 )
[0152] Step (c): Preparing (1R,2S)-3-Methyl-1-phenyl-2-pyrrolidin-1-yl-butane-1-thiol (6g5c)
[0153] Repeat Step (c) of EXAMPLE 6, but replace compound (6g4b) with compound (6g5b). A slightly-yellow liquid (0.401 g) is obtained. The yield is 85%, and the other analysis includes:
[0154] [0154] 1 H NMR (400 MHz, CDCl 3 ) δ 0.95 (d, J=7.2 Hz, 3H, CH(C H 3 ) 2 ), 0.99 (d, J=6.4 Hz, 3H, CH(C H 3 ) 2 ), 1.37-1.48 (m, 4H, —(C H 2 ) 2 —), 2.06-2.15 (m, 1H, C H (CH 3 ) 2 ), 2.54-2.70 (m, 4H, NCH 2 —), 3.00 (dd, J 1 =5.2 Hz, J 2 =7.6 Hz, 1H, NCH), 4.30 (d, J=7.6 Hz, 1H, SHC H ), 7.12-7.40 (m, 5H, ArH)
[0155] [0155] 13 C NMR (100 MHz, CDCl 3 ) δ 18.95 (CH( C H 3 ) 2 ), 21.67 (CH( C H 3 ) 2 ), 24.46 (—CH 2 —), 30.42 ( C H(CH 3 ) 2 ), 50.60 (NCH 2 —), 70.03 (N C H), 77.20 ( C HSH), 126.73, 127.9, 128.1, 144.57 (Ph),
[0156] Element analysis C 24 H 33 NOS theoretical: C, 72.23; H, 9.29; N, 5.62 experimental: C,72.01; H, 9.88; N, 5.32
[0157] High-resolution MS (70 eV) m/e theoretical: 249.1551 experimental: 249.1554
[0158] [α] 25 D =−489.0 (c=1, CHCl 3 )
EXAMPLE 8
Preparation of (1R,2S)-1,2-Diphenyl-2-piperidin-1-yl-ethanethiol (7g4c) Step (a): Preparing (1R,2S)-1,2-Diphenyl-2-pyrrolidine-1-yl-ethanol (6g5a)
[0159] [0159]
[0160] Repeat Step (a) of EXAMPLE 6, but replace (1R,2S)-2-amino-1-phenyl-3-methyl-butanol with (1R,2S)-2-amino-1,2-diphenyl-ethanol. Column chromatography (Silica gel, eluent is n-Hexane:EtOAc=5:1) is used to purify the coarse product and a white solid (1.24 g) is obtained. The yield is 93% and the other analysis includes:
[0161] [0161] 1 H NMR(400 MHz, CDCl 3 ) δ 1.82-1.85 (m, 4H, N(CH 2 C H 2 ) 2 ), 2.59-2.62 (m, 2H, NCH 2 ), 2.74-2.76 (m, 2H, NCH 2 ), 3.30 (d, J=3.2 Hz, 1H, NCH), 5.24 (d, J=3.0 Hz, 1H, C H OH), 6.97-7.25 (m, 10H, ArH)
[0162] [0162] 13 C NMR(100 MHz, CDCl 3 ) δ 23.47 (N(CH 2 C H 2 ) 2 ), 52.94 (N(CH 2 ) 2 ), 73.99 (NCH), 77.31 (CHOH), 126.08, 126.70, 127.02, 127.19, 127.42, 129.25, 137.47, 140.69 (2Ph)
[0163] Element analysis C 18 H 21 NO theoretical: C,80.86; H,7.91; N,5.24 experimental: C,81.06; H,7.65; N,5.11
[0164] High-resolution MS (70 eV) m/e theoretical: 267.3649 experimental: 267.3688
[0165] [α] 25 D =−87.5 (c=1, CHCl 3 )
[0166] melt point: 113.65±0.45° C.
[0167] Step (b): Preparing (1R,2S)-1,2-Diphenyl-2-pyrrolidine-1-yl-1-thioacetyl-ethane (7g4b)
[0168] Repeat Step (c) of EXAMPLE 6, but replace compound (6g4b) with compound (7g4a). Column chromatography (Silica gel, eluent is n-Hexane:NEt 3 =100:1) is used to purify the coarse product and a yellow liquid (1.33 g) is obtained. The yield is 82% and the other analysis includes:
[0169] [0169] 1 H NMR (400 MHz, CDCl 3 ) δ 1.74-1.78 (m, 4H, N(CH 2 C H 2 ) 2 ), 2.28 (s, 3H, COCH 3 ), 2.50-2.57 (m, 4H, N(CH 2 ) 2 ), 3.48 (d, J=4.8 Hz, 1H, NCH), 5.25 (d, J=5.2 Hz, 1H, SCH), 6.88-7.26 (m, 10H, ArH)°
[0170] [0170] 13 C NMR (100 MHz, CDCl 3 ) δ 23.33 (N(CH 2 C H 2 ) 2 ), 30.83 (COCH 3 ), 52.62 (N(CH 2 ) 2 ), 52.85 (NCH), 74.99 (SCH), 126.88, 127.48, 127.59, 128.88, 129.00, 138.64, 140.33 (2Ph), 196.58 (S C OCH 3 )
[0171] Element analysis C 20 H 23 NOS theoretical: C, 73.81; H, 7.12; N, 4.30 experimental: C, 73.55; H, 7.26; N, 4.38
[0172] High-resolution MS (70 eV) m/e theoretical: 325.4737 experimental: 325.4245
[0173] [α] 25 D =−32.5 (c=1, CHCl 3 )
[0174] Step (c): Preparing (1R,2S)-1,2-Diphenyl-2-pyrrolidine-1-yl-ethane-1-thiol (7g4c)
[0175] Repeat Step (c) of EXAMPLE 6, but replace compound (6g4b) with compound (7g4b). A slightly-yellow liquid (0.43 g) is obtained. The yield is 76%, and the other analysis includes:
[0176] [0176] 1 H NMR (400 MHz, CDCl 3 ) δ 1.72-1.79 (m, 4H N(CH 2 C H 2 ) 2 ), 2.29(s, 1H, SH), 2.45-2.51 (m, 2H, NCH 2 ), 2.55-2.61 (m, 2H, NCH 2 ), 3.46 (d, J=5.6 Hz, 1H, NCH), 4.70 (d, J=5.2 Hz, 1H, CHSH), 6.96-7.36 (m, 10 H, ArH)
[0177] [0177] 13 C NMR (100 MHz, CDCl 3 ) δ 23.47 (N(CH 2 C H 2 ) 2 ), 48.60 (NCH), 52.30(N(CH 2 ) 2 ), 75.70 (CHSH), 127.05, 127.09, 127.35, 127.72, 128.63, 129.79, 137.40, 140.85 (2Ph)
[0178] Element analysis C 18 H 21 NS theoretical: C,76.28; H,7.47; N,4.94 experimental: C,76.06; H,7.28; N,5.23
[0179] High-resolution MS (70 eV) m/e theoretical: 283.4369 experimental: 283.4348
[0180] [α] 25 D =−162.0 (c=1, CHCl 3 )
EXAMPLE 9
Preparation of (1R,2S)-1,2-Diphenyl-2-piperidin-1-yl-ethanethiol (7g5c)
[0181] Step (a): Preparing (1R,2S)-1,2-Diphenyl-2-piperidin-1-yl-ethanol (7g5a)
[0182] Repeat Step (a) of EXAMPLE 6, but replace (1R,2S)-2-amino-1-phenyl-3-methyl-butanol with (1R,2S)-2-amino-1,2-diphenyl-ethanol, and replace 1,4-dibromobutane with 1,5-dibromopentane. Column chromatography (Silica gel 50g, eluent is n-Hexane:EtOAc=5:1) is used to purify the coarse product and a white solid (1.28 g) is obtained. The yield is 91% and the other analysis includes:
[0183] [0183] 1 H NMR (400 MHz, CDCl 3 ) δ 1.45-1.49 (m, 2H, ((CH 2 ) 2 CH 2 (CH 2 ) 2 )), 1.55-1.62 (m, 4H, N(CH 2 CH 2 ) 2 ), 2.47-2.55 (m, 2H, NCH 2 ), 2.62 (br, 2H, NCH 2 ), 3.38 (d, J=4.0 Hz, 1H, NCH), 5.38 (d, J=4.0 Hz, 1H, CHOH), 6.98-7.26 (m, 10H, ArH)
[0184] [0184] 13 C NMR (100 MHz, CDCl 3 ) δ 24.60 ((CH 2 ) 2 CH 2 (CH 2 ) 2 ), 26.28 (N(CH 2 CH 2 ) 2 ), 52.51 (N(CH 2 ) 2 ), 71.55 (NCH), 76.42 (CHOH), 126.14, 126.58, 127.01, 127.42, 129.43, 136.64, 141.38 (2Ph)
[0185] IR ν max (cm −1 ) 3131 (OH)
[0186] Element analysis C 19 H 23 NO theoretical: C,81.10; H,8.24; N,4.98; 0,5.68 experimental: C,81.65; H,8.41; N,4.72; 0,5.22
[0187] High-resolution MS (70 eV) m/e theoretical: 281.1780 experimental: 281.1770
[0188] [α] 25 D =−74.2 (c=1.2, CHCl 3 )
[0189] melting point: 93-95° C.
[0190] Step (b): Preparing (1R,2S)-1,2-Diphenyl-2-piperidin-1-yl-1-thioacetyl-ethane (7g5b)
[0191] Repeat Step (b) of Example 6, but the compound (6g4a) is replaced with the compound (7g5a). Column chromatography (Silica gel 70g, eluent is n-Hexane:NEt 3 =160:1) is used to purify the coarse product and an orange solid (1.46g) is obtained. The yield is 86% and the other analysis includes:
[0192] [0192] 1 H NMR (400 MHz, CDCl 3 ) δ 1.20 (br, 2H, ((CH 2 ) 2 CH 2 (CH 2 ) 2 )), 1.26 (br, 2H, NCH 2 CH 2 ), 1.31 (br, 2H, NCH 2 CH 2 ), 2.14 (s, 3H, COCH 3 ), 2.14 (br, 2H, NCH 2 ), 2.41 (br, 2H, NCH 2 ), 3.82 (d, J=10.4 Hz, 1H, NCH), 5.31 (d, J=10.4 Hz, 1H, SCH), 7.10-7.31 (m, 10H, ArH)
[0193] [0193] 13 C NMR (100 MHz, CDCl 3 ) δ 24.42 ((CH 2 ) 2 CH 2 (CH 2 ) 2 ), 26.04 (N(CH 2 CH 2 ) 2 ), 30.49 (COCH 3 ), 48.78 (NCH) 50.71 (N(CH 2 ) 2 ), 73.28 (SCH), 126.67, 127.32, 127.59, 127.81, 128.25, 128.72, 136.03, 141.72 (2Ph)
[0194] Element analysis C 21 H 25 NOS theoretical: C,74.29; H,7.42; N,4.13; 0,4.71; S9.45 experimental: C,74.19; H,7.10; N,4.49; 0,4.52; S9.70
[0195] high-resolution MS (70 eV) m/e theoretical: 339.5005 experimental: 339.5436
[0196] Step (c): Preparing (1R,2S)-1,2-Diphenyl-2-piperidin-1-yl-ethanethiol (7g5c)
[0197] Repeat Step (c) of EXAMPLE 1, but compound (6g4b) is replaced with compound (7g5b). A transparent liquid (0.505 g) is obtained. The yield is 85% and the other analysis includes:
[0198] [0198] 1 H NMR (400 MHz, CDCl 3 ) δ 1.16-1.29 (m, 6H, (C H 2 (C H 2 CH 2 ) 2 N), 2.01 (SH), 2.18(br, 2H, CH 2 (CH 2 C H 2 ) 2 N), 2.34 (br, 2H, CH 2 (CH 2 C H 2 ) 2 N), 3.78 (d, J=4.8 Hz, 1H, NCH), 4.68 (d, J=4 Hz, 1H, SCH), 7.14-7.30 (m, 10H, ArH)
[0199] [0199] 13 C NMR (100 MHz, CDCl 3 ) δ 24.42 ((CH 2 ) 2 C H 2 (CH 2 ) 2 ), 26.12 (N(CH 2 C H 2 ) 2 ), 44.75(NCH) 50.86 (N(CH 2 ) 2 ), 76.36 (SCH), 126.84, 127.32, 127.61, 127.89, 128.03, 129.22, 135.75, 142.03 (2Ph)
[0200] Element analysis C 18 H 21 NS theoretical: C, 76.72; H, 7.79; N, 4.71; S, 10.78 experimental: C, 76.85; H, 7.83; N, 4.75; S, 10.82
[0201] High-resolution MS (70 eV) m/e theoretical: 297.1551 experimental: 298.0035
[0202] [α] 25 D =−122.0 (c=1, CHCl 3 )
EXAMPLE 10
Preparation of (1R,2S)-1,2-Diphenyl-2-morpholin-4-yl-ethane-1-thiol (7g6c)
[0203] Step (a): Preparing (1R,2S)-1,2-Diphenyl-2-morpholin-4-yl-ethanol (7g6a)
[0204] Repeat Step (a) of EXAMPLE 6, but replace (1R,2S)-2-amino-1-phenyl-3-methyl-butanol with (1R,2S)-2-amino-1,2-diphenylethanol, and replace 1,4-dibromobutane with (BrC 2 H 4 ) 2 O. Column chromatography (Silica gel 50 g, eluent is n-Hexane:EtOAc=4:1) is used to purify the coarse product and a white solid (1.34 g) is obtained. The yield is 95% and the other analysis includes:
[0205] [0205] 1 H NMR (400 MHz, CDCl 3 ) δ 2.51-2.56 (m, 2H, N(CH 2 ) 2 ), 2.66 (br, 2H, N(CH 2 ) 2 ), 3.30 (s, 1H, OH), 3.36 (d, J=4.0 Hz, 1H, NCH), 3.70-3.76 (m, 4H, O(CH 2 ) 2 ), 5.33 (d, J=4.0 Hz, 1H, CHOH), 6.94-7.26 (m, 10H, ArH)
[0206] [0206] 13 C NMR (100 MHz, CDCl 3 ) δ 51.96 (N(CH 2 ) 2 ), 67.11 (O(CH 2 ) 2 ), 71.18 (NCH), 76.44 (CHOH), 126.11, 126.87, 127.40, 127.56, 127.60, 129.54, 135.56, 140.81 (2Ph)
[0207] IR ν max (cm −1 ) 3127 (OH)
[0208] Element analysis C 18 H 21 NO 2 theoretical: C,76.33; H,7.46; N,4.93; O, 11.28 experimental: C,76.38; H,7.36; N,4.90; O,11.36
[0209] High-resolution MS (70 eV) m/e theoretical: 283.1573 experimental: 283.1570
[0210] [α] 25 D =−140.7 (c=1.4, CHCl 3 )
[0211] melting point: 123-125° C.
[0212] Step (b): Preparing (1R,2S)-1,2-Diphenyl-2-morpholin-4-yl-1-thioacetyl-ethane (7g6b)
[0213] Repeat Step (b) of EXAMPLE 6, but replace compound (6g4a) with compound (7g6a). Column chromatography (Silica gel 70 g, eluent is n-Hexane:NEt 3 =100:1) is used to purify the coarse product and an orange solid (1.57 g) is obtained. The yield is 92% and the other analysis includes:
[0214] [0214] 1 H NMR (400 MHz, CDCl 3 ) δ 2.20 (s, 3H, COCH 3 ), 2.31-2.35 (m, 2H, N(CH 2 ) 2 ), 2.46 (m, 2H, N(CH 2 ) 2 ), 3.51(m, 4H, O(CH 2 ) 2 ), 3.72 (d, J=8.8 Hz, 1H, NCH), 5.28 (d, J=8.4 Hz, 1H, SCH), 7.05-7.27 (m, 10H, ArH)
[0215] [0215] 13 C NMR (100 MHz, CDCl 3 ) δ 30.58(COCH 3 ), 48.88(NCH), 50.49 (N(CH 2 ) 2 ), 66.95(O(CH 2 ) 2 ), 73.63(SCH), 126.93, 127.72, 127.78, 127.86, 128.43, 128.94, 135.88, 140.87 (2Ph)
[0216] Element analysis C 20 H 23 NO 2 S theoretical: C,70.35; H,6.79; N,4.10; O,9.37; S9.39 experimental: C,70.85; H,6.14; N,4.69; O,6.17; S9.15
[0217] High-resolution MS (70 eV) m/e theoretical: 341.4727 experimental: 341.4794
[0218] Step (c): Preparing (1R,2S)-1,2-Diphenyl-2-morpholin-4-yl-ethane-1-thiol (7g6c)
[0219] Repeat Step (c) of EXAMPLE 6, but replace compound (6g4b) with compound (7g6b). Column chromatography (Silica gel 40 g, eluent is n-Hexane:NEt 3 =300:1) is used to purify the coarse product and a white solid (0.31 g) is obtained. The yield is 53% and the other analysis includes:
[0220] [0220] 1 H NMR (400 MHz, CDCl 3 ) δ 1.96(s, 1H, SH), 2.39-2.46 (m, 4H, N(CH 2 ) 2 ), 3.48-3.56 (m, 4H, O(CH 2 ) 2 ), 3.71 (d, J=8.4 Hz, 1H, NCH), 4.70 (d, J=8.4 Hz, 1H, CHSH), 7.12-7.30 (m, 10H, ArH)
[0221] [0221] 13 C NMR (100 MHz, CDCl 3 ) δ 44.75 (NCH), 50.44 (N(CH 2 ) 2 ), 66.95 (O(CH 2 ) 2 ), 75.87 (CHSH), 127.10, 127.67, 127.94, 128.14, 129.44, 135.10, 141.24 (2Ph)
[0222] Element analysis C 18 H 21 NOS theoretical: C,72.20; H,7.07; N,4.68; O,5.34; S10.71 experimental: C,72.33; H,7.12; N,4.47; O,5.33; S10.75
[0223] High-resolution MS (70 eV) m/e theoretical: 299.4359 experimental: 299.4358
[0224] [Application Mode 1]
[0225] To show effect of the aminothiol of the present invention in addition reactions of organic zinc and aldehyde, diethylzinc (ZnEt 2 ) and benzaldehyde are provided to perform the following reaction:
[0226] Table 2 lists chiral ligands and conditions applied in the addition reaction. In the application, the chiral ligand obtained in the above EXAMPLEs is added into a dried flask at an equivalence concentration (N lig ). The flask is then sealed and vacuumed to remove moisture and then filled with nitrogen. Diethylzinc (ZnEt 2 ) dissolved in toluene or hexane is added in the flask at an equivalence concentration (NZE) and a proper temperature. Next, under a specific temperature (T rxn ), benzaldehyde (0.11 mL, 1.0 mmol) is added into the flask and stirred for a period (t rxn ). To terminate the reaction, 1N aqueous HCl (1 mL) is added into the above solution. The solution is then extracted with acetyl acetate (20 mL), wherein the organic layer is collected and dehydrated with anhydrous MgSO 4 , and then the mixture is filtered. The filtrate is concentrated by reducing pressure through an air pump to obtain crude product. The crude product is purified by column chromatography (Silica gel, eluent is n-Hexane: EtOAc=10: 1).
[0227] HPLC (high-pressure liquid chromatography) with Daicel Chiralcel OD Column is provided for determining enantiomeric excess (e.e.) of the product, wherein the eluent is n-hexane:i-propanol=98.0:2.0, flow rate is 1.5 ml/min. In the above addition reaction of ZnEt 2 and various aldehyde, peaks of products are present at different time, as indicated in Table 3. The enantiomeric excess (e.e.) can be determined according to the following equation:
e . e . ( % ) = S - R S + R × 100 %
[0228] wherein (S+R) in denominator is the product obtained without adding chiral ligands of the present invention;
[0229] S or R in numerator is the product obtained by adding chiral ligands of the present invention.
TABLE 2 N lig N ZE t rxn T rxn e.e. EXAMPLE Ligand (meq) S/C (meq) Solvent (h) (° C.) (%) 1 6b4c 0.05 20 1.2 Toluene 12 −20 96.5 R 2 2f4c 0.05 20 1.2 Toluene 12 −20 95.7 R 3 6c4c 0.05 20 1.2 Toluene 12 −20 94.2 R 4 3f4c 0.05 20 1.2 Toluene 12 −20 93.2 R 5 6f4c 0.05 20 1.2 Toluene 12 −20 99.6 R 0.05 20 1.2 Toluene 6 rt 98.5 R 0.05 20 1.2 Toluene 12 0 99.3 R 0.05 20 1.2 Toluene 12 −20 99.6 R 0.05 20 1.2 Hexane 12 −20 99.2 R 0.05 20 1.2 T/THF 12 −20 92.1 R 0.05 20 1.2 T/CH2Cl2 12 −20 99.5 R 0.05 20 1.2 T/C6H6 12 −20 99.6 R 0.05 20 2 Toluene 12 −20 99.6 R 0.05 20 3 Toluene 12 −20 99.5 R 0.05 20 4 Toluene 12 −20 99.5 R 0.05 20 5 Toluene 12 −20 99.5 R 0.05 20 1.2 Toluene 12 −40 99.7 R 0.05 20 1.2 Toluene 24 −78 90.2 R 6f4c 0.5 2 1.2 Toluene 12 −20 99.6 R 0.2 5 1.2 Toluene 12 −20 99.6 R 0.05 20 1.2 Toluene 12 −20 99.6 R 0.001 1000 1.2 Toluene 12 −20 99.2 R 0.0005 2000 1.2 Toluene 12 −20 98.5 R 0.0001 10000 1.2 Toluene 12 −20 96.5 R 6 0.05 20 1.2 Toluene 6 rt 98.3 R 6g4c 0.05 20 1.2 Toluene 12 0 99.3 R 0.05 20 1.2 Toluene 12 −20 99.5 R 0.05 20 1.2 Toluene 12 −40 99.6 R 0.05 20 1.2 Toluene 24 −78 88.2 R 7 6g5c 0.05 20 1.2 Toluene 12 rt 99.0 R 0.05 20 1.2 Toluene 12 0 99.0 R 0.05 20 1.2 Toluene 12 −20 99.6 R 0.01 100 1.2 Toluene 12 −20 99.0 R 0.001 1000 1.2 Toluene 12 −20 98.1 R 0.05 20 1.2 Toluene 12 −40 99.6 R 0.05 20 1.2 Toluene 12 −78 93.7 R 8 7g4c 0.1 10 5 Toluene 12 −20 99.3 R 0.1 10 4 Toluene 12 −20 99.5 R 0.1 10 3.7 Toluene 12 −20 99.5 R 0.1 10 3 Toluene 12 −20 99.4 R 0.1 10 2 Toluene 12 −20 99.3 R 0.1 10 1.2 Toluene 12 −20 99.3 R 0.05 20 1.2 Toluene 6 rt 99.1 R 0.05 20 1.2 Toluene 9 0 99.2 R 0.05 20 1.2 Toluene 12 −20 99.3 R 0.05 20 1.2 Toluene 12 −40 99.5 R 0.05 20 1.2 Toluene 24 −78 94.2 R 0.0002 5000 3.7 Toluene 12 −20 99.0 R 0.0005 2000 3.7 Toluene 12 −20 99.1 R 0.001 1000 3.7 Toluene 12 −20 99.2 R 8 7g4c 0.003 333 3.7 Toluene 12 −20 99.3 R 0.006 167 3.7 Toluene 12 −20 99.3 R 0.01 100 3.7 Toluene 12 −20 99.3 R 0.02 50 3.7 Toluene 12 −20 99.4 R 0.05 20 3.7 Toluene 12 −20 99.4 R 0.1 10 3.7 Toluene 12 −20 99.5 R 0.2 5 3.7 Toluene 12 −20 99.5 R 0.4 3 3.7 Toluene 12 −20 98.8 R 9 7g5c 0.1 10 3.7 Toluene 12 −20 99.7 R 0.05 20 2 Toluene 12 0 99.7 R 10 7g6c 0.1 10 3.7 Toluene 12 −20 99.5 R
[0230] In Table 2, S/C is an equivalence ratio of benzaldehyde (substrate, 1.0 mmol) to the chiral ligand. As shown in Table 2, the chiral ligands of the present invention exhibit superior enantioselectivity in the asymmetric of benzaldehyde and diethyl zinc, even as S/C are very high. For example, when compounds (6f4c), (6g5c) and (7g4c) obtained from EXAMPLEs 5, 7 and 8 are applied at S/C as high as 1,000, enantiomeric excess are more than 98%. Therefore, aminothiol compounds in the present invention are indeed very economic for applying the above asymmetric reactions to industries.
[0231] Table 3 list more aminothiol compounds with various ligands and application results thereof in varied reaction conditions. These aminothiol compounds can be produced through similar procedures of above EXAMPLEs by supplying proper reactants having respective ligands. Therefore, detailed description is omitted in the specification.
[0232] In Table 3, Compound (5g3c) has the following formula.
[0233] The related analysis of Compound (5g3c) include:
[0234] [0234] 1 H NMR (400 MHz, CDCl 3 ) δ 3.04-3.22(m, 2H, PhCH 2 ), 3.503.60 (m, 1H, CNH), 3.60 (s, 4H, PhCH 2 N), 4.37 (t, J=4.0 Hz, 1H, PhCHS), 6.81-7.41 (m, 20H, ArH)
[0235] [0235] 13 C NMR (100 MHz, CDCl 3 ) δ 24.68, 26.53, 46.06, 51.41, 72.86, 125.83, 126.81, 127.94, 128.10, 128.14, 129.31, 140.85, 143.663.
[0236] Element analysis C 29 H 29 NS
TABLE 3 N lig N ZE t rxn T rxn e.e. Ligand (meq) S/C (meq) Solvent (h) (° C.) (%) 2g5c 0.05 20 2 Hexane 12 0 100.0 R 0.05 20 1.2 Toluene 12 rt 91.0 R 0.05 20 1.2 Toluene 12 0 97.9 R 4g5c 0.0005 2000 1.2 Toluene 12 −20 97.7 R 0.0001 10000 1.2 Toluene 12 −20 98.1 R 0.005 200 1.2 Toluene 12 −20 98.1 R 0.001 1000 1.2 Toluene 12 −20 98.1 R 0.05 20 1.2 Toluene 12 −20 98.9 R 0.1 10 1.2 Toluene 12 −20 98.9 R 0.2 5 1.2 Toluene 12 −20 98.8 R 0.05 20 1.2 Toluene 12 −40 99.3 R 5g2c 0.05 20 1.2 Toluene 12 rt 96.9 R 5g3c 0.05 20 1.2 Toluene 12 0 93.5 R 5g4c 0.05 20 1.2 Toluene 12 0 98.9 R 5g5c 0.05 20 5 Toluene 12 0 99.1 R 0.05 20 4 Toluene 12 0 99.4 R 0.05 20 3 Toluene 12 0 99.4 R 0.05 20 2 Toluene 12 0 99.3 R 0.05 20 1.2 Toluene 12 0 99.3 R 0.05 20 1.1 Toluene 12 0 99.3 R 0.05 20 1.2 Hexane 12 0 99.1 R 0.05 20 1.2 T/CH2Cl2 12 0 99.1 R 0.05 20 1.2 T/THF 12 0 72.0 R 0.0001 10000 1.2 Toluene 12 0 98.1 R 0.0002 5000 1.2 Toluene 12 0 98.9 R 5g5c 0.0005 2000 1.2 Toluene 12 0 99.0 R 0.001 1000 1.2 Toluene 12 0 99.1 R 0.002 500 1.2 Toluene 12 0 99.1 R 0.005 200 1.2 Toluene 12 0 99.2 R 0.01 100 1.2 Toluene 12 0 99.3 R 0.02 50 1.2 Toluene 12 0 99.3 R 0.05 20 1.2 Toluene 12 0 99.3 R 0.1 10 1.2 Toluene 12 0 99.4 R 0.2 5 1.2 Toluene 12 0 99.4 R 0.5 2 1.2 Toluene 12 0 99.4 R 1 1 1.2 Toluene 12 0 99.0 R 0.05 20 1.2 Toluene 3 rt 98.1 R 0.05 20 1.2 Toluene 12 0 99.3 R 0.05 20 1.2 Toluene 18 −20 99.4 R 0.05 20 1.2 Toluene 24 −40 99.4 R 0.05 20 1.2 Toluene 48 −78 87.9 R 0.05 20 1.2 Toluene 0.5 rt 97.8 R 0.05 20 1.2 Toluene 1 rt 98.1 R 0.05 20 1.2 Toluene 1.5 rt 98.1 R 5g5c 0.05 20 1.2 Toluene 3 rt 98.1 R 0.05 20 1.2 Toluene 6 rt 98.1 R 5g6c 0.05 20 1.2 Toluene 12 0 98.2 R 6g1c 0.05 20 1.2 Toluene 12 −20 97.7 R 6g2c 0.05 20 1.2 Toluene 12 −20 99.4 R 6g6c 0.05 20 1.2 Toluene 12 0 99.1 R 0.05 20 1.2 Toluene 12 −20 99.4 R
[0237] As shown in Table 3, the aminothiol compounds of the present invention indeed perform excellent catalysts to obtain high enantiomeric excess in the asymmetric addition reaction of benzaldehyde and diethyl zinc.
[0238] Similarly, the aminothiol compounds of the present invention can be provided as chiral ligands to react with other organic metals, for example, Cu, to form organometal complexes. These complexes can also react with carbonyl such as aldehyde, to produce alcohol in the asymmetric addition reactions.
[0239] [Application Mode 2]
[0240] The aminothiol compounds of the present invention also show superior effect in catalizing an addition reaction as follows:
[0241] In this reaction, butyl acetylene (or hexyl acetylene), diethylzinc (ZnEt 2 ) and aldehyde are reacted to produce allyl alcohol in existence of chiral ligands of the present invention. Table 4 lists conditions and results of the reaction catalized with different ligands including Compound (6g5c) obtained in Example 7, Compound (7g5c) obtained in Example 9, Compound (7g6c) obtained in Example 10 and Compound (6f5c).
TABLE 4 Conver- Mole % T rxn N ZE t rxn sion Yield e.e Ligand Ar R′ of ligand (° C.) (eq) (h) (%) (%) (%) Ph C 4 H 9 5(T) −10 2 15 100 89 91.3(R) Ph C 4 H 9 5(T) −20 2 15 100 94 99.0(R) Ph C 4 H 9 5(T) −20 2 15 100 94 98.3(R) 6f5c Ph C 4 H 9 1(T) −30 2 15 100 90 94.3(R) Ph C 4 H 9 2(T) −30 2 15 100 92 94.5(R) Ph C 4 H 9 5(T) −30 2 15 100 94 98.2(R) Ph C 6 H 13 2(T) −30 2 15 100 65 99.0(R) 4—OMe—Ph C 6 H 13 2(T) −30 2 15 100 90 98.1(R) 2—Cl—Ph C 6 H 13 2(T) −30 2 15 100 86 92.6(R) Ph C 6 H 13 2(H) −30 2 15 100 80 99.0(R) Ph C 4 H 9 5(T) −30 2 15 100 94 98.2(R) 2—Cl—Ph C 4 H 9 5(T) −30 2 15 100 — 98.1(R) Ph C 6 H 13 5(T) −30 2 15 100 — 99.4(R) Ph C 4 H 9 5(T) −40 2 15 100 94 98.3(R) Ph C 4 H 9 15(T) −30 2 15 100 — 99.5(R) 6g5c Ph C 4 H 9 5(T) −30 2 15 100 92 96.1(R) Ph C 6 H 13 2(T) −30 2 15 100 92 98.6(R) 7g5c Ph C 4 H 9 5(T) −30 2 15 100 91 95.6(S) Ph C 4 H 9 5(T) −30 2 15 100 93 97.0(R) Ph C 6 H 13 2(T) −30 2 15 100 93 98.4(R) Ph C 6 H 13 5(T) −30 2 15 100 68 98.3(R) 7g6c Ph C 4 H 9 5(T) −30 2 15 100 95 97.3(R)
[0242] In Application Mode 2, ZnEt 2 and aldehyde are respectively added by syringe pump over 20 minutes. T and H in the column (mole % of ligand) are the solvents toluene and hexane. Detailed procedures may be referred to Wolfgang Oppolzer et al. (J. Org. Chem. 2001, 66, 4766-4770) and Brase S. et al. (Org. Lett. 2001, 3, 4119). Enantiometric access is determined with HPLC (Chiralcel OD-H column, flow rate 0.7 ml/min, 3% isopropanol).
[0243] It should be noticed that the above embodiments are only used for explaining the present invention, but not limiting the scope.
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The present invention discloses an aminothiol compound having a general formula I wherein R 1 -R 5 are substitutable ligands. Such compound can perform as a superior catalyst in an asymmetric addition reaction of organic metal compounds and aldehyde. According to the present invention, the aminothiol compound is needed only less than 0.02% based on main reactants to obtain enantioselectivity higher than 98% enantiomeric excess, whereby the asymmetric reactions can become very economic.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present invention relates generally to a solar cell.
[0003] 2. Description of Related Art
[0004] One of the factors limiting the efficiency of a solar cell is the light conversion rate of photoelectric material (e.g., cadmium telluride based and silicon-based photoelectric material). Generally, these photoelectric materials can merely absorb light which has a wavelength in the range from 400 nanometers (nm) to 1100 nanometers and converts it into electric energy. That is, the light out of this wavelength range is wasted.
[0005] Therefore, what is needed is to provide a solar cell which is capable of overcoming the aforementioned problems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Many aspects of the present solar cell can be better understood with references to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0007] FIG. 1 is a schematic view showing a solar cell having a glass layer in accordance with an embodiment.
[0008] FIG. 2 is an ultraviolet visible absorption spectrum of the glass layer in FIG. 1 .
[0009] FIG. 3 is a fluorescence spectrum at 465 nm excitation of glass layer in FIG. 1
DETAILED DESCRIPTION
[0010] Various embodiments of a solar cell will be described in detail with reference to the accompanying drawings.
[0011] Referring to FIG. 1 , a solar cell 10 in accordance with an embodiment includes a photoelectric conversion module 11 provided with a glass layer 12 for modulating wavelength of received light to a higher level and transmitting modulated light to the photoelectric conversion module 11 .
[0012] The photoelectric conversion module 11 includes a front electrode 111 , a back electrode 112 , and a photoelectric layer sandwiched between the front electrode 111 and the back electrode 112 . The photoelectric layer 113 has a light incident surface 101 and a surface 102 opposite to the light incident surface 101 . The front electrode 111 is in contact with the light incident surface 101 , and the back electrode 112 is in contact with the surface 102 . In the present embodiment, the front electrode 111 is a transparent conductive layer. When a light beams is irradiated on the solar cell; it passes through the transparent conductive layer and enters into the photoelectric layer 113 . The photoelectric layer 113 receives the light beam and converts is into electric energy. The front electrode 111 and the back electrode 112 are electronically connected to one or more external loads thereby transmitting electric energy generated in the solar cell 10 to the external loads.
[0013] The transparent conductive layer is comprised of a transparent conductive material (e.g., indium tin oxide). In other embodiments, the transparent conductive layer includes a transparent substrate (e.g., a glass substrate) and a transparent film deposited on the transparent substrate. Examples of the transparent film include films of cadmium oxide (CdO), zinc oxide (ZnO), binary oxides of zinc which have a formula of ZnO:M, wherein M represents aluminum (Al), gallium (Ga), indium (In), and fluorine (F). The back electrode 112 is comprised of a metal (e.g., aluminum, and copper). The photoelectric layer 113 is comprised of a material selected from the group consisting of silicon-based semiconductors, group III-V semiconductors, and group II-VI semiconductors.
[0014] The glass layer 12 contains europium (Eu) or europium-containing compound therein. As shown in FIGS. 2 and 3 , the glass layer 12 is capable of changing the received light of a first wavelength (e.g, 350-470 nm) into light of a second wavelength (e.g, 570-720 nm) greater than the first wavelength and transmitting the light of the second wavelength to the light incident surface 101 . In the present embodiment, the glass layer 12 is comprised of a silicate glass/borate glass doped with Eu or europium-containing compound. The silicate glass/borate glass is comprised of silicon dioxide (SiO 2 ), boron oxide (B 2 O 3 ), and oxides of alkali metals (e.g., sodium oxide (Na 2 O)). A molar percentage of Eu to all compounds in the silicate glass/borate glass (e.g., the sum of SiO 2 , B 2 O 3 , and oxides of alkali metals) is less than 5%. In other embodiments, the molar percentage is less than 2.5%. In this condition, the glass layer 12 can also serve as an anti-reflection film, in other words, the glass layer 12 has a lower reflection rate and is capable of improving the light utilizing efficiency.
[0015] Eu exists in the silicate glass in the form of europium oxide (Eu 2 O 3 ), which is an electrovalent type covalent oxide. Electrovalent type means that Eu in Eu 2 O 3 tends to loose its three outermost electrons and therefore has similar properties to Eu 3+ ions. In other words, Eu also exists in the silicate glass in the form of Eu 3+ ions.
[0016] Process and material for manufacturing the glass layer 12 is selected according to the composition of the silicate glass. For example, metal Eu, or Eu-containing compound (e.g., europium chloride, europium oxide, europium carbonate) is mixed with materials of the silicate glass (e.g., SiO 2 , B 2 O 3 , and Na 2 O) and then heated to above 1300° C. to melt the mixture. The heating process may range from approximately 5 minutes to approximately 10 hours, and then the mixture is cooled to the room temperature (i.e, 25° C.) thereby obtaining the glass layer 12 . It is understood that the heating temperature and heating time may vary according to different materials and devices.
[0017] In one embodiment, the glass layer 12 has a composition represented by the molecular formula 59SiO 2 -33B 2 O 3 -8Na 2 O-xEu 2 O 3 , wherein x=0.5˜2.5. That is, a molar percentage of Eu 2 O 3 to the sum of SiO 2 , B 2 O 3 , and Na 2 O is in the range from 0.5% to 2.5%, and a molar percentage of Eu to the sum of SiO 2 , B 2 O 3 , and Na 2 O is in the range from 1% to 5%. In a process of synthesizing the composition, the mixture of SiO 2 , B 2 O 3 , Na 2 O, and Eu 2 O 3 is placed in a platinum crucible and then heated to increase the temperature of the mixture at a speed of 10° C. per minutes. After the temperature of the mixture reaches to a point in the range from approximately 1400° C. to approximately 1500° C., the temperature is maintained for approximately 30 minutes thereby obtaining a melted mixture. The melted mixture is poured into a mold and fast cooled to obtain the glass layer 12 . An additional annealing process is performed to reduce inner stress in the glass layer 12 .
[0018] To test performance of glass layer 12 containing different contents of Eu 2 O 3 , five glass layer samples (a)-(e), as listed in table 1, are prepared and then tested. Properties of glass layer samples (a)-(e) are listed in table 2, which shows that glass transition temperature and density of glass layer samples increases along with the molar percentage of Eu 2 O 3 added therein.
[0000]
TABLE 1
composition of the glass layer
Composition
(molar percentage)
glass layer samples
SiO 2
B 2 O 3
Na 2 O
Eu 2 O 3
(a)
56.05
35.79
8.16
0.27
(b)
56.18
35.61
8.21
0.85
(c)
56.84
35.00
8.16
1.00
(d)
57.02
34.87
8.11
1.11
(e)
56.68
35.12
8.2
2.47
[0000]
TABLE 2
properties of the glass layer samples
Coefficient of
Glass layer
thermal expansion
Glass transition
Density
samples
(CTE, 10 −7 /° C.)
temperature (T g , ° C.)
(g/cm 3 )
(a)
50.4
479
2.24
(b)
50.2
491
2.30
(c)
50.0
493
2.35
(d)
50.2
499
2.40
(e)
50.2
503
2.45
[0019] FIG. 2 illustrates ultraviolet visible absorption spectrums of glass layer samples (a)-(e), in which absorption peaks appear at 577 nm, 531 nm, 525 nm, 465 nm, 413 nm, 393 nm, 376 nm, and 361 nm. FIG. 3 illustrates fluorescence spectrums at 465 nm excitation of glass layer samples (a)-(e), in which emission peaks appear at 579 nm, 591 nm, 615 nm, and 700 nm. Similar results are also observed using excitation of other wavelength (for example, 361 nm, 376 nm, 393 nm, 413 nm). These indicate that the glass layer samples is capable of changing the received light of a first wavelength (e.g, 350-470 nm) into light of a second wavelength (e.g., 570-720 nm) greater than the first wavelength, which can be utilized by the photoelectric layer 113 . As such, the light utilizing efficiency of the solar cell is improved.
[0020] While certain embodiments have been described and exemplified above, various other embodiments from the foregoing disclosure will be apparent to those skilled in the art. The present invention is not limited to the particular embodiments described and exemplified but is capable of considerable variation and modification without departure from the scope of the appended claims.
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A solar cell includes a photoelectric conversion module having a light incident surface for receiving light and converting the light into electric energy, and glass layer containing europium therein applied on the light incident surface. The glass layer modulates wavelength of received light to a higher level and transmits modulated light to the light incident surface.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/787,052, filed Mar. 6, 2013, which is a continuation of U.S. application Ser. No. 12/828,629, filed Jul. 1, 2010, which is a continuation of U.S. application Ser. No. 12/428,287 (now U.S. Pat. No. 7,757,692—issued Jul. 20, 2010), filed Apr. 22, 2009, which is a continuation of U.S. application Ser. No. 10/847,554, filed May 17, 2004, which is a divisional of U.S. application Ser. No. 09/951,105, filed Sep. 11, 2001, each of which is hereby incorporated herein by reference in its entirety. Any and all priority claims identified in the Application Data Sheet, or any correction thereto, are hereby incorporated by reference under 37 CFR 1.57.
BACKGROUND OF THE INVENTION
[0002] The present invention is generally directed to a treatment of Chronic Obstructive Pulmonary Disease (COPD). The present invention is more particularly directed to removable air passageway obstruction devices, and systems and methods for removing the devices.
[0003] Chronic Obstructive Pulmonary Disease (COPD) has become a major cause of morbidity and mortality in the United States over the last three decades. COPD is characterized by the presence of airflow obstruction due to chronic bronchitis or emphysema. The airflow obstruction in COPD is due largely to structural abnormalities in the smaller airways. Important causes are inflammation, fibrosis, goblet cell metaplasia, and smooth muscle hypertrophy in terminal bronchioles.
[0004] The incidence, prevalence, and health-related costs of COPD are on the rise. Mortality due to COPD is also on the rise. In 1991 COPD was the fourth leading cause of death in the United States and had increased 33% since 1979.
[0005] COPD affects the patients whole life. It has three main symptoms: cough; breathlessness; and wheeze. At first, breathlessness may be noticed when running for a bus, digging in the garden, or walking up hill. Later, it may be noticed when simply walking in the kitchen. Over time, it may occur with less and less effort until it is present all of the time.
[0006] COPD is a progressive disease and currently has no cure. Current treatments for COPD include the prevention of further respiratory damage, pharmacotherapy, and surgery. Each is discussed below.
[0007] The prevention of further respiratory damage entails the adoption of a healthy lifestyle. Smoking cessation is believed to be the single most important therapeutic intervention. However, regular exercise and weight control are also important. Patients whose symptoms restrict their daily activities or who otherwise have an impaired quality of life may require a pulmonary rehabilitation program including ventilatory muscle training and breathing retraining. Long-term oxygen therapy may also become necessary.
[0008] Pharmacotherapy may include bronchodilator therapy to open up the airways as much as possible or inhaled .beta.-agonists. For those patients who respond poorly to the foregoing or who have persistent symptoms, Ipratropium bromide may be indicated. Further, courses of steroids, such as corticosteroids, may be required. Lastly, antibiotics may be required to prevent infections and influenza and pheumococcal vaccines may be routinely administered. Unfortunately, there is no evidence that early, regular use of pharmacotherapy will alter the progression of COPD.
[0009] About 40 years ago, it was first postulated that the tethering force that tends to keep the intrathoracic airways open was lost in emphysema and that by surgically removing the most affected parts of the lungs, the force could be partially restored. Although the surgery was deemed promising, the procedure was abandoned.
[0010] The lung volume reduction surgery (LVRS) was later revived. In the early 1990's, hundreds of patients underwent the procedure. However, the procedure has fallen out of favor due to the fact that Medicare stopping reimbursing for LVRS. Unfortunately, data is relatively scarce and many factors conspire to make what data exists difficult to interpret. The procedure is currently under review in a controlled clinical trial. What data does exist tends to indicate that patients benefited from the procedure in terms of an increase in forced expiratory volume, a decrease in total lung capacity, and a significant improvement in lung function, dyspnea, and quality of life. However, the surgery is not without potential complications. Lung tissue is very thin and fragile. Hence, it is difficult to suture after sectioning. This gives rise to potential infection and air leaks. In fact, nearly thirty percent (30%) of such surgeries result in air leaks.
[0011] Improvements in pulmonary function after LVRS have been attributed to at least four possible mechanisms. These include enhanced elastic recoil, correction of ventilation/perfusion mismatch, improved efficiency of respiratory muscaulature, and improved right ventricular filling.
[0012] Lastly, lung transplantation is also an option. Today, COPD is the most common diagnosis for which lung transplantation is considered. Unfortunately, this consideration is given for only those with advanced COPD. Given the limited availability of donor organs, lung transplant is far from being available to all patients.
[0013] In view of the need in the art for new and improved therapies for COPD which provide more permanent results than pharmacotherapy while being less invasive and traumatic than LVRS, at least two new therapies have recently been proposed.
[0014] Both of these new therapies provide lung size reduction by permanently collapsing at least a portion of a lung.
[0015] In accordance with a first one of these therapies, and as described in U.S. Pat. No. 6,258,100 assigned to the assignee of the present invention and incorporated herein by reference, a lung may be collapsed by obstructing an air passageway communicating with the lung portion to be collapsed. The air passageway may be obstructed by placing an obstructing member in the air passageway. The obstructing member may be a plug-like device which precludes air flow in both directions or a one-way valve which permits air to be exhaled from the lung portion to be collapsed while precluding air from being inhaled into the lung portion. Once the air passageway is sealed, the residual air within the lung will be absorbed over time to cause the lung portion to collapse.
[0016] As further described in U.S. Pat. No. 6,258,100, the lung portion may be collapsed by inserting a conduit into the air passageway communicating with the lung portion to be collapsed. An obstruction device, such as a one-way valve is then advanced down the conduit into the air passageway. The obstruction device is then deployed in the air passageway for sealing the air passageway and causing the lung portion to be collapsed.
[0017] The second therapy is fully described in copending U.S. application Ser. No. 09/534,244, filed Mar. 23, 2000, for LUNG CONSTRICTION APPARATUS AND METHOD and, is also assigned to the assignee of the present invention. As described therein, a lung constriction device including a sleeve of elastic material is configured to cover at least a portion of a lung. The sleeve has a pair of opened ends to permit the lung portion to be drawn into the sleeve. Once drawn therein, the lung portion is constricted by the sleeve to reduce the size of the lung portion.
[0018] Both therapies hold great promise for treating COPD. Neither therapy requires sectioning and suturing of lung tissue.
[0019] While either therapy alone would be effective in providing lung size reduction and treatment of COPD, it has recently been proposed that the therapies may be combined for more effective treatment. More specifically, it has been proposed that the therapies could be administered in series, with the first mentioned therapy first applied acutely for evaluation of the effectiveness of lung size reduction in a patient and which lung portions should be reduced in size to obtain the best results. The first therapy is ideal for this as it is noninvasive and could be administered in a physician's office. Once the effectiveness of lung size reduction is confirmed and the identity of the lung portions to be collapsed is determined, the more invasive second mentioned therapy may be administered.
[0020] In order to combine these therapies, or simply administer the first therapy for evaluation, it will be necessary for at least some of the deployed air passageway obstruction devices to be removable. Unfortunately, such devices as currently known in the art are not suited for removal. While such devices are expandable for permanent deployment, such devices are not configured or adapted for recollapse after having once been deployed in an air passageway to facilitate removal. Hence, there is a need in the art for air passageway obstruction devices which are removable after having been deployed and systems and methods for removing them.
SUMMARY OF THE INVENTION
[0021] The invention provides device for reducing the size of a lung comprising an obstructing structure dimensioned for insertion into an air passageway communicating with a portion of the lung to be reduced in size, the obstructing structure having an outer dimension which is so dimensioned when deployed in the air passageway to preclude air from flowing into the lung portion to collapse the portion of the lung for reducing the size of the lung, the obstructing structure being collapsible to permit removal of the obstruction device from the air passageway.
[0022] The invention further provides an assembly comprising a device for reducing the size of a lung, the device being dimensioned for insertion into an air passageway communicating with a portion of the lung to be reduced in size, the device having an outer dimension which is so dimensioned when deployed in the air passageway to preclude air from flowing into the lung portion to collapse the portion of the lung for reducing the size of the lung, a catheter having an internal lumen and being configured to be passed down a trachea, into the air passageway, and a retractor dimensioned to be passed down the internal lumen of the catheter, seizing the device, and pulling the obstruction device proximally into the internal lumen to remove the device from the air passageway. The device is collapsible after having been deployed to permit the device to be pulled proximally into the internal lumen of the catheter by the retractor.
[0023] The invention further provides a method of removing a deployed air passageway obstruction device from an air passageway in which the device is deployed. The method includes the steps of passing a catheter, having an internal lumen, down a trachea and into the air passageway, advancing a retractor down the internal lumen of the catheter to the device, seizing the device with the retractor, collapsing the device to free the device from deployment in the air passageway, and pulling the device with the retractor proximally into the internal lumen of the catheter.
[0024] The invention still further provides an air passageway obstruction device comprising a frame structure, and a flexible membrane overlying the frame structure. The frame structure is collapsible upon advancement of the device into the air passageway, expandable into a rigid structure upon deployment in the air passageway whereby the flexible membrane obstructs inhaled air flow into a lung portion communicating with the air passageway, and re-collapsible upon removal from the air passageway.
[0025] The invention still further provides an air passageway obstruction device comprising frame means for forming a support structure, and flexible membrane means overlying the support structure. The frame means is expandable to an expanded state within an air passageway to position the membrane means for obstructing air flow within the air passageway and is collapsible for removal of the device from the air passageway.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by making reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like referenced numerals identify identical elements, and wherein:
[0027] FIG. 1 is a simplified sectional view of a thorax illustrating a healthy respiratory system;
[0028] FIG. 2 is a sectional view similar to FIG. 1 but illustrating a respiratory system suffering from COPD and the execution of a first step in treating the COPD condition in accordance with the present invention;
[0029] FIG. 3 is a perspective view, illustrating the frame structure of a removable air passageway obstruction device embodying the present invention;
[0030] FIG. 4 is a perspective view of the complete air passageway obstruction device of FIG. 3 ;
[0031] FIG. 5 is an end view of the device of FIG. 3 illustrating its operation for obstructing inhaled air flow;
[0032] FIG. 6 is another end view of the device of FIG. 3 illustrating its operation for permitting exhaled air flow;
[0033] FIG. 7 is a perspective view of the device of FIG. 3 , illustrating its operation for permitting partial exhaled air flow;
[0034] FIG. 8 is a side view illustrating a first step in removing the device of FIG. 3 in accordance with one embodiment of the present invention;
[0035] FIG. 9 is another side view illustrating the collapse of the device of FIG. 3 as it is removed from an air passageway;
[0036] FIG. 10 is a side view illustrating an initial step in the removal of the device of FIG. 3 in accordance with another embodiment of the present invention;
[0037] FIG. 11 is a side view illustrating engagement of the frame structure of the device with a catheter during removal of the device;
[0038] FIG. 12 is a side view illustrating the collapse of the device by the catheter during removal of the device;
[0039] FIG. 13 is a side view of another air passageway obstruction device embodying the present invention during an initial step in its removal from an air passageway;
[0040] FIG. 14 is another side view of the device of FIG. 13 illustrating its collapse during removal from the air passageway;
[0041] FIG. 15 is a perspective view of the frame structure of another removable air passageway obstruction device embodying the present invention;
[0042] FIG. 16 is a cross-sectional side view of the device of FIG. 15 shown in a deployed state;
[0043] FIG. 17 is a perspective side view of the device of FIG. 15 shown in a deployed state;
[0044] FIG. 18 is a side view illustrating an initial step in removing the device of FIG. 15 from an air passageway;
[0045] FIG. 19 is a side view illustrating an intermediate step in the removal of the device of FIG. 15 ; and
[0046] FIG. 20 is a side view illustrating the collapse of the device of FIG. 15 during its removal from an air passageway.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] Referring now to FIG. 1 , it is a sectional view of a healthy respiratory system. The respiratory system 20 resides within the thorax 22 which occupies a space defined by the chest wall 24 and the diaphragm 26 .
[0048] The respiratory system 20 includes the trachea 28 , the left mainstem bronchus 30 , the right mainstem bronchus 32 , the bronchial branches 34 , 36 , 38 , 40 , and 42 and sub-branches 44 , 46 , 48 , and 50 . The respiratory system 20 further includes left lung lobes 52 and 54 and right lung lobes 56 , 58 , and 60 . Each bronchial branch and sub-branch communicates with a respective different portion of a lung lobe, either the entire lung lobe or a portion thereof. As used herein, the term “air passageway” is meant to denote either a bronchial branch or sub-branch which communicates with a corresponding individual lung lobe or lung lobe portion to provide inhaled air thereto or conduct exhaled air therefrom.
[0049] Characteristic of a healthy respiratory system is the arched or inwardly arcuate diaphragm 26 . As the individual inhales, the diaphragm 26 straightens to increase the volume of the thorax 22 . This causes a negative pressure within the thorax. The negative pressure within the thorax in turn causes the lung lobes to fill with air. When the individual exhales, the diaphragm returns to its original arched condition to decrease the volume of the thorax. The decreased volume of the thorax causes a positive pressure within the thorax which in turn causes exhalation of the lung lobes.
[0050] In contrast to the healthy respiratory system of FIG. 1 , FIG. 2 illustrates a respiratory system suffering from COPD. Here it may be seen that the lung lobes 52 , 54 , 56 , 58 , and 60 are enlarged and that the diaphragm 26 is not arched but substantially straight. Hence, this individual is incapable of breathing normally by moving the diaphragm 28 . Instead, in order to create the negative pressure in the thorax 22 required for breathing, this individual must move the chest wall outwardly to increase the volume of the thorax. This results in inefficient breathing causing these individuals to breathe rapidly with shallow breaths. It has been found that the apex portion 62 and 66 of the upper lung lobes 52 and 56 , respectively, are most affected by COPD.
[0051] In accordance with this embodiment of the present invention, COPD treatment or evaluation is initiated by feeding a conduit or catheter 70 down the trachea 28 , into a mainstream bronchus such as the right mainstem bronchus 32 , and into an air passageway such as the bronchial branch 42 or the bronchial sub-branch 50 . An air passageway obstruction device embodying the present invention is then advanced down an internal lumen 71 of the catheter 70 for deployment in the air passageway. Once deployed, the obstruction device precludes inhaled air from entering the lung portion to be collapsed. In accordance with the present invention, it is preferable that the obstruction device take the form of a one-way valve. In addition to precluding inhaled air from entering the lung portion, the device further allows air within the lung portion to be exhaled. This results in more rapid collapse of the lung portion. However, obstruction devices which preclude both inhaled and exhaled air flow are contemplated as falling within the scope of the invention.
[0052] The catheter 70 is preferably formed of flexible material such as polyethylene. Also, the catheter 70 is preferably preformed with a bend 72 to assist the feeding of the catheter from the right mainstem bronchus 32 into the bronchial branch 42 .
[0053] FIGS. 3 and 4 show an air passageway obstruction device 80 embodying the present invention. The device 80 includes a proximal end 82 and a distal end 84 . The device 80 further includes a frame structure 86 including frame supports 88 , 90 , and 92 .
[0054] Each of the frame supports has a shape to define a generally cylindrical center portion 94 and a pair of oppositely extending inwardly arcuate conical end portions 96 and 98 . The frame structure further includes a plurality of fixation members 100 , 102 , and 104 which extend distally from the proximal end 82 . The fixation members have the generally conical shape and terminate in fixation projections or anchors 106 , 108 , and 110 which extend radially outwardly.
[0055] Overlying and partially enclosing the frame structure 86 is a flexible membrane 112 . The flexible membrane extends over the generally cylindrical and conical portions 94 and 98 defined by the frame structure. Hence, the flexible membrane is opened in the proximal direction.
[0056] The flexible membrane may be formed of silicone or polyurethane, for example. It may be secured to the frame structure in a manner known in the art such as by crimping, riveting, or adhesion.
[0057] The frame structure 86 and the device 80 are illustrated in FIGS. 3 and 4 as the device would appear when fully deployed in an air passageway. The frame structure supports and frame structure fixation members are preferably formed of stainless steel or Nitinol or other suitable material which has memory of an original shape. The frame structure permits the device to be collapsed for advancement down the internal lumen 71 of the catheter 70 into the air passageway where the device is to be deployed. Once the point of deployment is reached, the device is expelled from the catheter to assume its original shape in the air passageway. In doing so, the generally cylindrical portion 94 contacts the inner wall of the air passageway and the fixation projections 106 , 108 , and 110 pierce the wall of the air passageway for fixing or anchoring the device 80 within the air passageway.
[0058] When the device 80 is deployed, the frame structure 86 and flexible membrane 112 form an obstructing structure or one-way valve. FIGS. 5 and 6 show the valve action of the device 80 when deployed in an air passageway, such as the bronchial branch 42 .
[0059] As shown in FIG. 5 , during inhalation, the flexible membrane is filled with air and expands outwardly to obstruct the air passageway 42 . This precludes air from entering the lung portion being collapsed. However, as shown in FIG. 6 , during expiration, the flexible membrane 112 deflects inwardly to only partially obstruct the air passageway 42 . This enables air, which may be in the lung portion being collapsed, to be exhaled for more rapid collapse of the lung portion. FIG. 7 is another view showing the device 80 during expiration with a portion 114 of the membrane 112 deflected inwardly.
[0060] FIGS. 8 and 9 illustrate a manner in which the device 80 may be removed from the air passageway 42 in accordance with one embodiment of the present invention. As previously mentioned, it may be desired to remove the device 80 if it is only used for evaluating the effectiveness of collapsing a lung portion or if it is found the more effective treatment may be had with the collapse of other lung portions.
[0061] The device 80 is shown in FIG. 8 in a fully deployed state. The catheter 70 having the internal lumen 71 is advanced to the proximal end of the device 80 . In FIG. 8 it may be noted that the fixation members 102 and 104 define a larger conical radius than the frame supports 88 and 90 . Hence, when the proximal end of the device is engaged by a retractor and the catheter 70 is moved distally as shown in FIG. 9 , the internal lumen of the catheter engages the fixation members 102 and 104 before it engages the frame supports 88 and 90 . This causes the fixation projections to first disengage the inner wall of the air passageway 42 . With the device now free of the air passageway side wall, the retractor may be used to pull the device into the internal lumen 71 of the catheter 70 causing the support structure and thus the device to collapse. The collapsed device may now fully enter the internal lumen of the catheter for removal.
[0062] FIGS. 10-12 show another embodiment of the present invention for removing the device 80 from the air passageway 42 . Here, the catheter 70 is fed down a bronchoscope 118 to the device 80 . The retractor takes the form of a forceps 120 .
[0063] In FIG. 10 it may be seen that the forceps has just engaged the proximal end 82 of the device 80 . In FIG. 11 the forceps 120 is held stationary while the catheter 70 is advanced distally so that the internal lumen 71 of the catheter 70 engages the fixation members 102 and 104 . Further advancement of the catheter 70 as seen in FIG. 12 deflects the fixation projections 110 and 108 inwardly away from the inner wall of the air passageway 42 . Now, the forceps may be used to pull the device 80 into the internal lumen 71 of the catheter 70 for removal of the device 80 from the air passageway 42 .
[0064] FIGS. 13 and 14 show another removable air passageway obstruction device 130 and a method of removing it from an air passageway in accordance with the present invention. The device 130 is shown in FIG. 13 deployed in the air passageway 42 and the catheter 70 is in ready position to remove the device 130 from the air passageway 42 .
[0065] The device 130 is of similar configuration to the device 80 previously described. Here however, the fixation members 136 and 138 are extensions of the frame supports 132 and 134 , respectively. To that end, it will be noted in FIG. 13 that the frame supports 132 and 134 cross at a pivot point 140 at the distal end 142 of the device 130 . They extend distally and then are turned back at an acute angle to terminate at fixation or anchor ends 146 and 148 . When the device is deployed as shown in FIG. 13 , the cylindrical portions of the support frame engage the inner wall of the air passageway 42 and the fixation points 146 and 148 project into the inner wall of the air passageway 42 to maintain the device in a fixed position. The flexible membrane 150 extends from the dashed line 152 to the pivot or crossing point 140 of the frame supports 132 and 134 to form a one-way valve.
[0066] When the device is to be removed, the frame structure of the device 130 is held stationary by a retractor within the catheter 70 and the catheter is advanced distally. When the catheter 70 engages the frame supports 132 and 134 , the frame supports are deflected inwardly from their dashed line positions to their solid line positions. This also causes the fixation members 136 and 138 to be deflected inwardly from their dashed line positions to their solid line positions in the direction of arrows 154 . These actions disengage the device 130 from the inner wall of the air passageway 42 . Now, the retractor may pull the device into the internal lumen 71 of the catheter 70 for removal of the device 130 from the air passageway 42 .
[0067] FIGS. 15-17 show a still further removable air passageway obstruction device 160 embodying the present invention. As shown in the initial collapsed state in FIG. 15 , the device 160 includes a plurality of frame supports 162 , 164 , 166 , and 168 . The frame supports extend between a proximal ring 170 and a distal ring 172 . The device 160 is preferably laser cut from a sheet of Nitinol.
[0068] Since each of the frame supports are identical, only frame support 164 will be described herein. As will be noted, the support 164 includes a bend point 174 with a relatively long section 176 extending distally from the bend point 174 and a relatively short section 178 extending proximally from the bend point 174 . The short section 178 includes a fixation projection or anchor 180 extending slightly distally from the bend point 174 .
[0069] FIGS. 16 and 17 show the device 160 in its deployed configuration. When the device is deployed, it is advanced down a catheter to its deployment site in its collapsed state as shown in FIG. 15 . When the deployment site is reached, the device 160 is held outside of the catheter and the rings 170 and 172 are pulled toward each other. This causes the device to bend at the bend points of the frame supports. This forms fixation projections 180 , 182 , and 184 extending into the inner wall of the air passageway to fix the device in position.
[0070] The relatively long sections of the frame supports are covered with a flexible membrane 186 as shown in FIGS. 16 and 17 to form a one-way valve. The valve functions as previously described to obstruct inhaled air flow but to permit exhaled air flow.
[0071] FIGS. 18-20 illustrate a manner of removing the device 160 from an air passageway. Once again a catheter 70 is advanced down a bronchoscope 118 to the device 160 . Next, a retractor including a forceps 120 and pin 190 are advanced to the device. The pin 190 , carrying a larger diameter disk 192 , extends into the device as the forceps 120 grasps the proximal ring 170 of the device 160 . The pin 190 continues to advance until the disk 192 engages the distal ring 172 of the device 160 as shown in FIG. 19 . Then, while the forceps 120 holds the proximal ring 170 , the pin 190 and disk 192 are advanced distally carrying the distal ring 172 distally. This causes the device 160 to straighten and collapse as shown in FIG. 20 . Now, the forceps 120 , pin 190 , and the device 160 may be pulled into the internal lumen 71 of the catheter 70 for removal of the device. As will be appreciated by those skilled in the art, the foregoing steps may be reversed for deploying the device 160 .
[0072] While particular embodiments of the present invention have been shown and described, modifications may be made, and it is therefore intended in the appended claims to cover all such changes and modifications which fall within the true spirit and scope of the invention.
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An air passageway obstruction device includes a frame structure and a flexible membrane overlying the frame structure. The frame structure is collapsible upon advancement of the device into the air passageway, expandable into a rigid structure upon deploying in the air passageway and recollapsible upon removal from the air passageway. The flexible membrane obstructs inhaled air flow into a lung portion communicating with the air passageway. The device may be removed after deployment in an air passageway by recollapsing the device and pulling the device proximally through a catheter.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates to a driving unit used to reduce rotation speed of a hydraulic motor and output the reduced rotation speed, which is used as a driving device for a traveling apparatus.
2. Description of the Prior Art
A driving unit is used as a driving device of a construction machine traveled by a crawler as typified particularly by a driving device of a hydraulic shovel among construction machines. In the driving unit, a hydraulic motor is disposed in an interior of a fixed casing fixed to a vehicle body, so that the rotation as output is transmitted to a rotating casing concentrically fitted to the fixed casing to freely rotate through a planetary gear mechanism, so as to drive the crawler by means of a sprocket disposed around a periphery of the rotating casing. Because of the constraint that the driving unit is located in the interior of the crawler, there is a restriction on the entire inner configuration space, for the reason of which the driving unit is required to have small size and high power.
The driving units of this type are known by publications such as Japanese Laid-open (Unexamined) Patent Publications No. Hei 4-140538, No. Hei 6-249297, Hei 8-247223 and No. Hei 9-240525.
However, the driving units of this conventional type are all being demanded to be further downsized.
It is the object of the present invention to provide a driving unit structurally optimized for every principal part, to provide downsizing and improved durability.
SUMMARY OF THE INVENTION
In accordance with a 1st aspect of the invention, there is provided a driving unit comprising a fixed casing having a hydraulic motor therein; a rotating casing rotatably supported around a periphery of the fixed casing via a bearing inserted from one end portion of the fixed casing and having an internal gear around an inside thereof; a sun gear mounted on an output shaft projected from the hydraulic motor toward the one end portion of the fixed casing; a planetary gear train disposed between the sun gear and the internal gear to reduce speed in two or more stages; a trunnion boss, integrally projected from the one end portion of the fixed casing, for rotatably supporting the planetary gear train of a final stage engaging with the internal gear; a holder in which a front end portion of the trunnion boss is inserted; support pillars projecting from the holder toward the fixed casing; and fastening means for fixing the support pillars and the fixed casing.
Known as a conventional driving unit is the one disclosed by Japanese Laid-open (Unexamined) Patent Publication No. Hei 4(1992)-140538, for example. A typical conventional driving unit 101 is shown in FIG. 25 . The driving unit 101 has a cylindrical fixed casing 102 in which a hydraulic motor 103 is disposed. An output shaft 104 a of the hydraulic motor 103 is coupled with an input shaft 104 b via a spline coupling 117 , and a sun gear 105 is mounted on a front end portion of the input shaft 104 b. A rotating casing 107 is rotatably supported around a periphery of the fixed casing 102 via a bearing 106 , and an internal gear 108 is formed around an inside of the rotating casing 107 . The rotation of the sun gear 105 is transmitted to the internal gear 108 through a planetary gear 109 , a second sun gear 111 engaged with a planetary gear frame 110 of the planetary gear 109 , and a second planetary gear 113 supported on a trunnion boss 112 projected from the front end portion of the fixed casing 102 , to rotate the rotating casing 107 at a reduced speed. A flange 114 of the fixed casing 102 is bolted to the body (not shown), and a flange 115 of the rotating casing 107 is bolted to a crawler sprocket (not shown).
The driving torque of the hydraulic motor 103 fixedly mounted in the fixed casing 102 is reduced via a planetary gear train of the first stage comprising the sun gear 105 and the planetary gears 109 and a planetary gear train of the second stage comprising a second sun gear 111 and second planetary gears 113 and is transmitted to the rotation of the rotating casing 107 .
However, since the trunnion boss 112 for rotatably supporting the second planetary gears 113 is projected from the end of the fixed casing 102 in a cantilever fashion, a bending stress is generated at the basal end of the trunnion boss 112 when a load is applied thereto through the second planetary gears 113 . For this reason, the trunnion boss 112 is required to have a large thickness. As a result of this, the bearing 106 and the floating seal 116 inserted from the trunnion boss 116 side of the fixed casing 102 are increased in size, which causes the rotating casing 107 to increase in size and in turn causes the entire driving unit 101 to increase in radial dimension.
According to the construction of the 1st aspect of the invention, the trunnion boss is allowed to be supported at opposite ends thereof by the holder fixed to the fixed casing through the support pillars. This enables the load applied to the trunnion boss to be dispersed to the holder and the fixed casing, and as such can allow the trannion boss to be reduced in diameter or can allow the fixed casing to be reduced in circumferential dimension. This produces the result that the rotating casing supported around the periphery of the fixed casing by the bearing inserted thereon is also reduced in outer diameter. Also, the support pillars projected from the holder have thickness such that even when the holder body is small in thickness, the fastening means to be fixed to the fixed casing applies a sufficient fastening force at the support pillars. This enables the support of the planetary gear train for rotation, without any axial elongation and with good durability. Thus, the downsizing of the driving unit can be achieved and improved durability can also be provided.
In accordance with a 2nd aspect of the invention, there is provided a driving unit according to 1st aspect of the invention, wherein the support pillars are in abutment with support pillars projected from the fixed casing at their abutment surfaces, which are located within a width of the planetary gear of the final stage.
This construction enables the abutment surfaces to be away from the basal ends of the support pillars to which a maximum bending moment is applied, by projecting the support pillars from the fixed casing side as well.
In accordance with a 3rd aspect of the invention, there is provided a driving unit according to 1st aspect of the invention, wherein the trunnion boss is projected along a periphery of the fixed casing and a rounded portion is formed at a basal end of the trunnion boss except an area close to the periphery of the fixed casing.
According to this construction, since the direction of the load acting on the trunnion boss is a tangent direction to the fixed casing, the fixed casing can be reduced in circumferential diameter by forming no rounded portion for relaxing the bending stress at the basal end of the trunnion boss located around the periphery of the fixed casing.
In accordance with a 4th aspect of the invention, there is provided a driving unit according to 1st aspect of the invention, wherein the abutment surfaces are located at an approximately widthwise center portion of the planetary gear of the final stage.
This construction can allow the abutment surfaces to be located at an approximately axial center of the support pillar at which a bending moment is minimized. Also, this construction can ensure a dimension from underhead of the bolt used as the fastening means to the abutment surfaces.
In accordance with a 5th aspect of the invention, there is provided a driving unit comprising a fixed casing having a hydraulic motor therein; a rotating casing rotatably supported around a periphery of the fixed casing via a bearing inserted from one end portion of the fixed casing and having an internal gear around an inside thereof; a sun gear mounted on an output shaft projected from the hydraulic motor toward the one end portion of the fixed casing; a planetary gear train disposed between the sun gear and the internal gear to reduce speed in two or more stages; a trunnion boss, supported at the one end portion of the fixed casing, for rotatably supporting the planetary gear train of a final stage engaging with the internal gear; a holder in which a front end portion of the trunnion boss is inserted; support pillars projecting from the holder toward the fixed casing; and fastening means for fastening the support pillars and the fixed casing, wherein the support pillars are in abutment with support pillars projected from the fixed casing at their abutment surfaces, which are located within a width of the planetary gear of the final stage.
According to this construction, the trunnion boss is allowed to be supported at opposite ends thereof by the fixed casing and the holder fixed to the fixed casing through the support pillars. This enables the load applied to the trunnion boss to be dispersed to the holder and the fixed casing, and as such can allow the trannion boss to be reduced in diameter or can allow the fixed casing to be reduced in circumferential dimension. This produces the result that the rotating casing supported around the periphery of the fixed casing by the bearing inserted thereon is also reduced in outer diameter. Also, since the abutment surfaces at which the support pillars projected from the holder and the support pillars projected from the fixed casing are in abutment are within the width of the planetary gear of the final stage, the support pillars projected from the holder have thickness such that even when the holder body is small in thickness, the fastening means to be fixed to the fixed casing applies a sufficient fastening force at the support pillars. This enables the support of the planetary gear train for rotation, without any axial elongation and with good durability. Also, by projecting the support pillars from the fixed casing side as well, the abutment surfaces can be allowed to be away from the basal ends of the support pillars to which a maximum bending moment is applied. Thus, the downsizing and improved durability of the driving unit can be achieved.
In accordance with a 6th aspect of the invention, there is provided a driving unit according to 5th aspect of the invention, wherein the abutment surfaces are located at an approximately widthwise center portion of the planetary gear of the final stage.
This construction can allow the abutment surfaces to be located at an approximately axial center of the support pillar at which a bending stress is minimized. Also, this construction can ensure a dimension from underhead of the bolt used as the fastening means to the abutment surfaces.
In accordance with a 7th aspect of the invention, there is provided a driving unit comprising a hydraulic motor and a planetary gear type of reducer to reduce an output of the hydraulic motor and transmit the reduced output to a driving portion, wherein an output shaft portion of the hydraulic motor and an input shaft portion of the reducer are integrally formed in the form of a single rotating shaft; wherein a sun gear of the reducer is put in spline engagement with a front end portion of the rotating shaft; and wherein the spline is so formed that a clearance therebetween can gradually broaden toward the end thereof
With the conventional type of driving unit 101 , since the output shaft 104 a and the input shaft 104 b are coupled with the coupling 117 using the spline engagement, the driving unit is increased in radial dimension as well as in axial length at that coupling part.
In contrast to this, with the construction of the 7th aspect of the invention, since the rotating shaft can be used both as the input shaft and as the output shaft by projecting the output shaft of the hydraulic motor beyond the center of the reducer, no intermediate coupling is required, thus enabling the radial thickness of the rotating shaft to be optimized. The rotating shaft is journaled by two bearings in the hydraulic motor at two lengthwise locations thereof. When pressure is introduced into the cylinder block, the rotating shaft is subject to a bending load at its portion between the two bearings, so that the front end portion of the rotating shaft is inclined. However, since the spline cogs of the rotating shaft are formed in a crowning fashion or a like fashion so that it can gradually narrow toward the front end to produce a clearance gradually broadened toward the front end, so as to ensure the clearance corresponding to the inclination of the rotating shaft. This can allow the rotating shaft to surface-contact with the sun gear to transmit the running torque of the rotating shaft to the sun gear smoothly.
In accordance with a 8th aspect of the invention, there is provided a driving unit according to 7th aspect of the invention, wherein spline grooves are formed around an inside of the sun gear so that they are each located at an approximately circumferential center between adjacent spaces between cogs formed around a periphery of the sun gear.
According to this construction, since the spaces between the cogs of the sun gear and the spline grooves at the fitting portions between the sun gear and the rotating shaft are out of position from each other with respect to the circumferential direction, even when the sun gear is reduced in diameter, the wall thickness of the sun gear can be ensured.
In accordance with a 9th aspect of the invention, there is provided a driving unit comprising a hydraulic motor and a planetary gear type of reducer to reduce an output of the hydraulic motor and transmit the reduced output to a driving portion, wherein an output shaft portion of the hydraulic motor and an input shaft portion of the reducer are integrally formed in the form of a single rotating shaft; wherein a sun gear of the reducer is mounted on a front end portion of the rotating shaft; and wherein at least one of a planetary gear engaging with the sun gear and the sun gear have cogs which are so formed that a clearance therebetween can gradually broaden toward the end thereof.
According to this construction, since the rotating shaft can be used both as the input shaft and as the output shaft by projecting the output shaft of the hydraulic motor beyond the center of the reducer, no intermediate coupling is required, thus enabling the radial thickness of the rotating shaft to be optimized. Also, the sun gear and/or the planetary gears allow for the clearance corresponding to the inclination of the rotating shaft, so that the surface-contact between these gears is ensured.
In accordance with a 10th aspect of the invention, there is provided a driving unit according to 8th aspect of the invention, wherein a distance between P and a tangent line touching one tooth flank of the sun gear at a point and extending perpendicularly to an axis of the sun gear is set at a value of not less than and asymptotic to 2 ι sin θ when the reducer is in an unloaded state:
where δ is a maximum radial variation of the sun gear caused by inclination of the rotating shaft; θ is an angle formed by the tangent line and a moving direction of the sun gear in such a positional relationship that when the rotation shaft is inclined, the one tooth flank of the sun gear which is on the opposite side to the other tooth flank of the sun gear which is put into engagement with the planetary gear comes nearest to a confronting tooth flake of the planetary gear; and P is a point on the tooth flank of the planetary gear closest to the sun gear.
According to this construction, even when the rotating shaft is inclined, the sun gear and the planetary gears can be prevented from colliding with each other at a tooth flake on the opposite side to a tooth flake at which they are engaged with each other.
In accordance with a 11th aspect of the invention, there is provided a driving unit comprising a hydraulic motor and a planetary gear type of reducer to reduce an output of the hydraulic motor and transmit the reduced output to a driving portion, the driving unit comprising a sun gear coupled with an output shaft portion of the hydraulic motor, planetary gears engaging with the sun gear, and an internal gear engaging with the planetary gears and formed around an inside of a rotating casing of the reducer, wherein a length of pass of contact of the internal gear is shortened so that an engaging area between the planetary gears and the sun gear can be equal in durable period to that between the internal gear and the sun gear.
This construction can allow the internal gear to reduce in length, and as such can allow the rotating casing to be reduced in size. Thus, the internal gear and the casing can be reduced in weight and further the costs for hardening treatment of the internal gear can be cut.
In accordance with a 12th aspect of the invention, there is provided a driving unit comprising a fixed casing having a hydraulic motor therein; a rotating casing rotatably supported around a periphery of the fixed casing via a bearing inserted from one end portion of the fixed casing and having an internal gear around an inside thereof; a sun gear mounted on an output shaft projected from the hydraulic motor toward the one end portion of the fixed casing; and a planetary gear train disposed between the sun gear and the internal gear to reduce speed, wherein at least one stage of the planetary gear train has two planetary gears symmetrically disposed about the output shaft and a planetary gear frame for rotatably supporting the two planetary gears at both axial ends thereof in sandwich relation, the planetary gear frame having a pair of flat plate portions for supporting the two planetary gears in sandwich relation and support pillars for connecting between the pair of flat plate portions, the support pillars being partially extended along a periphery of the flat plate portions and disposed near the planetary gears.
In general, the driving unit having three planetary gears arranged in regular triangle, as disclosed by Japanese Laid-open (Unexamined) Patent Publication No. Hei 8(1996)-247223, for example, is in wise use, in term of the stable support configuration. At present, it can be said that it has reached a critical limit for the structure having the three planetary gears to further reduce parts count and downsizing of the components.
The construction according to the 12th aspect of the invention can produce the driving unit with two planetary gears having a structural stability. Hence, as compared with the conventional type of driving unit having three planetary gears, parts count can be reduced to a large extent and also the structure can be simplified. Hence, the driving unit having an advantage in cost can be produced.
In accordance with a 13th aspect of the invention, there is provided a driving unit according to 12th aspect of the invention, wherein the flat plate portions are formed into a generally ellipse-like shape.
This construction enables the components of the driving unit comprising the two planetary gears to be further reduced in size and weight by forming the planetary gear frame into an ellipse-like shape.
In accordance with a 14th aspect of the invention, there is provided a driving unit comprising a fixed casing having a hydraulic motor therein; a rotating casing rotatably supported around a periphery of the fixed casing via a bearing inserted from one end portion of the fixed casing and having an internal gear around an inside thereof; a sun gear mounted on an output shaft projected from the hydraulic motor toward the one end portion of the fixed casing; a planetary gear train disposed between the sun gear and the internal gear to reduce speed in two or more stages; a trunnion boss, disposed at the one end portion of the fixed casing, for rotatably supporting the planetary gear train of a final stage engaging with the internal gear; a holder in which a front end portion of the trunnion boss is inserted and which is mounted on the fixed casing; a nut threadedly engaged with the periphery of the fixed casing to position the bearing with respect to an axial direction of the fixed casing; and a key plate for locking the nut against rotation, wherein the key plate is fixed at a position corresponding to an end face of the fixed casing from which the trunnion boss is projected.
In the driving unit, the bearing for rotatably supporting the rotating casing around the periphery of the fixed casing is generally positioned by the nut, to which a lock means is given. Known as this type of conventional driving unit is the one disclosed by Japanese Laid-open (Unexamined) Patent Publication No. Hei 6(1994)-249297, which is shown in FIG. 26 . The driving unit 118 has a cylindrical fixed casing 119 in which a hydraulic motor 120 is disposed. A first sun gear 122 is mounted on a front end portion of an output shaft 121 of the hydraulic motor 120 . A rotating casing 124 is rotatably supported around a periphery of the fixed casing 119 via a bearing 123 , and an internal gear 125 is formed around an inside of the rotating casing 124 . The rotation of the first sun gear 122 is transmitted to the internal gear 125 through a first planetary gear 126 , a second sun gear 128 engaged with a planetary gear frame 127 of the first planetary gear 126 , a third sun gear 130 engaged with the planetary gear flame 129 of the second planetary gear 128 , and a third planetary gear 132 rotatably supported on a carrier 131 threadedly engaged with the fixed casing 119 , to rotate the rotating casing 124 at a reduced speed. A flange 133 of the fixed casing 119 is bolted to the body (not shown), and a flange 134 of the rotating casing 124 is bolted to a crawler sprocket 135 .
The rotating casing 124 is rotatably supported to the fixed casing 119 via the bearing 123 , for which a conical roller bearing is used, and a preload is applied to the bearing 123 by screwing the nut 136 with an adequate torque. In order to keep the bearing 123 in the state in which the preload is applied thereto, the nut 136 must be locked against rotation. For this reason, the structure shown in FIGS. 27 ( a ), 27 ( b ) is adopted, wherein a key plate 137 having a key 137 a to be fitted in a key slot 119 a of the fixed casing 119 and the nut 136 are fixed by bolts 138 . A number of threaded holes 136 a are formed in the side of the nut 136 at regular intervals so that the bolts 138 can be screwed in the related threaded holes 136 a by only a slight turning of the nut 136 which is in an adequate fastened state.
However, due to the structure that the key slot 119 a is formed in the fixed casing 119 and, in addition to the nut 136 , the key plate 137 and bolt heads 138 are interposed between the bearing 123 and the carrier 131 , a distance d between the nut 136 and the end portion of the fixed casing 119 is disadvantageously elongated.
With the construction according to the 14th aspect of the invention, since the planetary gear of the final stage and the key plate are so disposed as to be partially overlapped, the driving unit can be reduced in axial dimension to the extent corresponding to the overlapped portion.
In accordance with a 15th aspect of the invention, there is provided a driving unit according to 14th aspect of the invention, wherein support pillars projected from the fixed casing and support pillars projected from the holder are fixed in abutment with each other, and the key plate is fixed to the end face of the fixed casing in the state of being partially engaged in a cutout portion of the support pillar on the fixed casing side.
According to this construction, since the key plate is disposed in place by means of the cutout portions provided in the support pillars between the holder for supporting the front end portion of the trunnion boss and the fixed casing, it can be prevented from interfering with the planetary gears.
In accordance with a 16th aspect of the invention, there is provided a driving unit according to 14th aspect of the invention, wherein the trunnion bosses are disposed along the periphery of the fixed casing.
This construction enables the fixed casing to be reduced in circumferential dimension by extending the fixed casing along a circumscribed circle of the trunnion bosses. This enables the driving unit to be reduced in radial dimension as well as in axial dimension.
In accordance with a 17th aspect of the invention, there is provided a driving unit comprising a fixed casing having a hydraulic motor therein; a rotating casing rotatably supported around a periphery of the fixed casing via a bearing inserted from one end portion of the fixed casing and having an internal gear around an inside thereof; a sun gear mounted on an output shaft projected from the hydraulic motor toward the one end portion of the fixed casing; a planetary gear train disposed between the sun gear and the internal gear to reduce speed in two or more stages; a trunnion boss, disposed at the one end portion of the fixed casing, for rotatably supporting the planetary gear train of a final stage engaging with the internal gear; a holder in which a front end portion of the trunnion boss is inserted and which is mounted on the fixed casing; and a nut threadedly engaged with the periphery of the fixed casing to position the bearing with respect to an axial direction of the fixed casing; and a pin, disposed between the nut and the holder, for locking the nut against rotation.
According to this construction, since the nut and the holder are connected by the pin without any use of the key plate, the nut can be locked against rotation without any elongation of the axial dimension of the fixed casing.
In accordance with a 18th aspect of the invention, there is provided a driving unit according to 17th aspect of the invention, wherein support pillars projected from the fixed casing and support pillars projected from the holder are fixed in abutment with each other, a projection projecting from the holder along a periphery of the support pillar, and the pin is disposed between the projection and the nut.
According to this construction, at the same time when the holder is inserted toward the fixed casing so that the end faces of the support pillars at the front ends thereof are put into abutment with each other, the nut is locked against rotation by means of the pin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a driving unit of a first embodiment of the present invention;
FIG. 2 is a schematic diagram of a holder supporting structure to an end face of a fixed casing of the first embodiment of the present invention;
FIG. 3 is a front view of one end surface of the fixed casing of the first embodiment of the present invention;
FIG. 4 is a sectional view taken along line A—A of FIG. 3;
FIG. 5 is a front view of the holder of the first embodiment of the present invention;
FIG. 6 is a sectional view taken along line B—B of FIG. 5;
FIG. 7 is a diagram showing stress distribution of the holder supporting structure to the end face of the fixed casing of the first embodiment of the present invention;
FIG. 8 is a front view of the fixed casing to which a nut is screwed in and a key plate is mounted in the first embodiment of the present invention;
FIG. 9 is a sectional view taken along line C—C of FIG. 8;
FIG. 10 is a side view showing a supporting structure of a rotating haft of the first embodiment of the present invention;
FIG. 11 illustrates a structure of a first sun gear of the first embodiment of the present invention, FIG. 11 ( a ) is a side view of the same and FIG. 11 ( b ) is a vertically sectioned view of the same;
FIG. 12 illustrates a configuration example of spline cogs at an end portion of an input shaft portion of the rotating shaft of the first embodiment of the present invention, FIG. 12 ( a ) is a front view of the input shaft portion; FIG. 12 ( b ) is a sectional view of the input shaft portion; and FIG. 12 ( c ) is a top view of one of the spline cogs;
FIG. 13 illustrates another configuration example of the spline cogs at the end of the input shaft portion of the rotating shaft of the first embodiment of the present invention, FIG. 13 ( a ) is a front view of the input shaft portion; FIG. 13 ( b ) is a sectional view of the input shaft portion; and FIG. 13 ( c ) is a top view of one of the spline cogs;
FIG. 14 is a sectional view of a driving unit of a second embodiment of the present invention;
FIG. 15 illustrates a structure of the first sun gear of the second embodiment of the present invention, FIG. 15 ( a ) is a side view of the same and FIG. 15 ( b ) is a vertically sectioned view of the same; and 15 ( c ) is a top view of one of the engaging cogs of the first sun gear;
FIG. 16 is a sectional view of a planetary gear frame as viewed from line D—D of FIG. 14;
FIG. 17 is a sectional view taken along the arrowed line E—E of FIG. 16, and developed with the hydraulic motor side up;
FIG. 18 is a view of the planetary gear frame of the second embodiment of the present invention, as viewed from the opposite side to the hydraulic motor side;
FIG. 19 is a view showing engagement of a sun gear, planetary gears and a internal gear of the second embodiment of the present invention;
FIG. 20 is an enlarged view of a principal part of FIG. 19;
FIG. 21 is a front view of a holder of the second embodiment of the present invention;
FIG. 22 is a sectional view taken along line G—G of FIG. 21;
FIG. 23 is a front view of one end face of a fixed casing of the second embodiment of the present invention;
FIG. 24 is a sectional view taken along line H—H of FIG. 23;
FIG. 25 is a sectional view of an example of a conventional driving unit;
FIG. 26 is a sectional view of another example of a conventional driving unit; and
FIG. 27 ( a ) is an enlarged sectional view of a principal part showing a structure of a lock nut of FIG. 26 taken along line I—I of FIG. 27 ( b ); and
FIG. 27 ( b ) is an enlarged view of a side surface of a key plate of FIG. 26 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, description will be given to the preferred embodiments of the present invention with reference to the accompanying drawings. FIGS. 1-13 are illustrations on the first embodiment of the present invention. FIGS. 14-24 are illustrations on the second embodiments of the present invention.
(An Example of First Embodiment)
First, an example of the first embodiment of the present invention will be described below. FIG. 1 is a sectional view of a driving unit la according to the first embodiment of the present invention. FIG. 2 is a perspective view schematically showing a holder 24 supporting structure to an end face of a fixed casing 11 .
In FIG. 1, the driving unit la comprises a hydraulic motor 3 disposed in an interior of a fixed casing 11 , a rotating casing 12 rotatably fitted to the fixed casing 11 , and a reduction gear mechanism 2 of a two-stage planetary gear train housed in the rotating casing 12 .
The rotating casing 12 is mounted on the outer of the fixed casing 11 , so as to be freely rotatable and be axially immovable via bearings 13 . The rotating casing 12 and the hydraulic motor 3 are combined with each other, with partially overlapping in the axial direction, at an approximately axial center of which a flange 14 for mounting a sprocket thereon, not shown, is provided. The bearing 13 and a floating seal 32 are fitted to the fixed casing 11 from one end portion thereof at the opposite side to the hydraulic motor 3 . For avoidance of increase of outer diameters of the bearing 13 and floating seal 32 , it is necessary to reduce an outer diameter of the fixed casing 11 on the reduction gear mechanism 2 side.
The reduction gear mechanism 2 having a two-stage planetary gear train for a large reduction gear ratio with a smallest possible number of gears is disposed in the interior of the rotating casing 12 at the one end portion of the fixed casing 11 . An internal gear 15 is formed around the inner periphery of the rotating casing 12 . A first sun gear 17 is fitted to an end of an output shaft 16 of the hydraulic motor 3 , which serves as an input shaft of the reduction gear mechanism 2 , via a spline 18 . In other words, the hydraulic motor 3 and the first sun gear 17 are coupled with each other via the integrally molded rotating shaft. Three first planetary gears 20 which are rotatably supported on the planetary gear frame 19 are engaged between the first sun gear 17 and the internal gear 15 . An outer periphery of a second sun gear 22 and an inner periphery of the planetary gear frame 19 which operates to transmit a orbital motion of the first planetary gear 20 around the first sun gear 17 are engaged with each other via a spline 21 . The single first sun gear 17 , the three first planetary gears 20 , the internal gear 15 and the planetary gear frame 19 , that functions as the output shaft as well, form a first stage of the planetary gear train.
Three trunnion bosses 25 are integrally projected from one end portion of the fixed casing 11 , and three second planetary gears 26 engaging between a second sun gear 22 and the internal gear 15 are rotatably supported by the trunnion bosses 25 . There is provided a holder 24 having holes 37 in which end portions of the trunnion bosses 25 are fitted. Support pillars 27 extending from the holder 24 and support pillars 28 extending from the fixed casing 11 side are put in abutment with each other at their abutment surfaces 29 and are fixed by bolts 30 and locating pins 31 . The second sun gear 22 , the three second planetary gears 26 , and the internal gear 15 that functions as the output shaft, form a second stage of the planetary gear train.
With the reduction gear mechanism 2 thus structured, when the first sun gear 17 is rotated by the drive of the hydraulic motor 3 , the first planetary gears 20 engaging with both of the first sun gear 17 and the internal gear 15 are rotated together with the planetary gear frame 19 at a reduced speed around the first sun gear 17 . The rotation is transmitted to the second sun gear 22 and, further, through the second planetary gear 26 , the rotating casing 12 having the internal gear 15 is rotated at a reduced speed, so that the sprocket (not shown) mounted on the flange 14 or the driving portion is rotationally driven.
Referring to FIGS. 2-6, the support structure of the second planetary gear 26 of the secondary planetary gear train of the final stage will be described. FIG. 3 is a front view of one end face of the fixed casing 11 and FIG. 4 is a sectional view taken along line A—A of FIG. 3 . The three trunnion bosses 25 are projected at the one end portion of the fixed casing 11 at regular circumferential intervals of 120°. The trunnion bosses 25 are rounded to have rounded portions 34 at their basal ends. However, a diameter of a circumscribed circle 35 of the three trunnion bosses 25 is substantially the same as a diameter of the periphery 36 of the fixed casing 11 onto which the bearing 13 (FIG. 1) is fitted. Thus, the rounded portions 34 are not provided at portions thereof at which they interfere with the circumscribed circle 35 .
Three support pillars 28 , each having a generally triangular shape, are provided between the adjacent trunnion bosses 25 at the one end portion of the fixed casing 11 so as to integrally project therefrom. The support pillars 28 are positioned at a height H substantially the same as an approximately widthwise center of the second planetary gears 26 supported by the trunnion bosses 25 (See FIG. 1 ).
FIG. 5 is a front view of the holder 24 and FIG. 6 is a sectional view taken along line B—B of FIG. 5 . The holder 24 having a disk-like shape has three generally triangular support pillars 27 integrally projected toward the one end of the fixed casing 11 . Three holes 37 in which the end portions of the trunnion bosses 25 (FIG. 4) are fitted are provided between the adjacent support pillars 27 .
The second planetary gears 26 (FIG. 1) are fitted onto the trunnion bosses 25 of FIG. 4 so as to be freely rotate via needle bearings and the like. In this state, the pins 31 (FIG. 1) are fitted in holes 38 between the support pillars 27 , 28 and, further, the bolts 30 (FIG. 1) are screwed in bolt holes 39 of the support pillars 27 and threaded holes 40 of the support pillars 28 , so that the support pillars 27 , 28 are fixed in abutment with each other at their abutment surfaces 29 . The bolts 30 and the pins 31 form fastening means of the support pillars 27 , 28 .
Shown in FIG. 2 is the state of the holder 24 fixed at the one end portion of the fixed casing 11 by the fastening means. Portions of the trunnion bosses 25 extending along the circumscribed circle 35 (See FIG. 3) are substantially tangent to the periphery 36 of the fixed casing 11 , and the trunnion bosses 25 are rounded at the basal ends to have the rounded portions 34 thereat. This projected structure of the trunnion bosses 25 can provide reduction in stress concentration to the basal ends, as well as in diameter of the periphery 36 of the portion of the fixed casing 11 onto which the bearing 13 (FIG. 1) is fitted. Also, the support pillars 28 integrally projected from the fixed casing 11 and the support pillars 27 integrally projected from the holder 24 are put in abutment with each other at their abutment surfaces 29 and are fixed together by the bolts 30 through the pins 31 . Thus, the ends of the trunnion bosses 25 are fitted into the holes 37 of the holder 24 and, as a result of this, the trunnion bosses are brought into the state of being supported at both ends.
Shown in FIG. 7 is a diagram showing stress distribution provided when a bending force acts on the one end portion of the fixed casing 11 of FIG. 2 . When a clockwise bending stress acts on an approximately center portion of a trunnion boss 25 , a maximum bending stress (22 kgf/mm 2 ) in the counterclockwise direction is generated at the basal end of the trunnion boss 25 . In addition to this, a large stress (14 kgf/mm 2 ) is also generated in at a counterclockwise corner of the support pillar 28 at the fixed casing 11 side. It is found from these facts that the bending stress caused by the bending force acting on the trunnion boss 25 is dispersed and burdened by the support pillar 28 on the fixed casing 11 side through the support pillar 27 of the holder 24 . It is also found that the bending stress is not substantially generated around the abutment surfaces 29 of the support pillars 27 , 28 , from which it is found that the abutment surfaces 29 should preferably be located within the limits of an effective length of each trunnion boss 25 , or at an approximately center portion of the same, in particular.
This specific constitution of the support pillars 27 , 28 as shown in FIG. 2 enables the bending stress on the basal end of the trunnion bosses 25 to be reduced and also enables the trunnion bosses 25 to be reduced in size. Also, since the circumscribed circle 35 of the trunnion bosses 25 and the periphery 36 of the fixed casing 11 are made substantially equal to each other, the bearing 13 and the floating seal 32 (FIG. 1) which are inserted from the one end portion of the fixed casing 11 can be reduced in outer diameter, and as such can allow the rotating casing 12 to reduce in outer diameter and in turn can allow the radial dimension of the driving unit 1 a to be minimized.
In FIG. 1, a tapered roller bearing is used as the bearing 13 to rotatably support the rotating casing 12 to the fixed casing 11 . The bearing 13 is held in place, with an adequate tightening force kept constant, by a nut 61 screwably engaged with a threaded portion 11 b of the fixed casing 11 formed from an end face 41 toward the bearing 13 .
Referring to FIGS. 8 and 9, a lock mechanism of the nut 61 will be described. FIG. 8 is a front view of the fixed casing 11 to which the nut 61 is screwed and a key plate 62 is mounted. FIG. 9 is a sectional view taken along line C—C of FIG. 8 .
As shown in FIG. 8, a number of pin holes 6 la are formed on the side of the nut 61 at regular intervals. As shown in FIGS. 8 and 9, the fixed casing 11 is cut out in arc at the periphery of the support pillar 28 to form a cutout portion 65 extending laterally from the end face 41 . The key plate 62 is fixed to a side surface 65 a of the cutout portion 65 by two bolts 64 , with its side surface being in abutment with the side surface 65 a. The two bolts 64 are disposed at different lateral distances from a center line 11 c therebetween. Also, the key plate 62 has two pin holes 62 a corresponding in position to the pin holes 61 a of the nut 61 which are formed symmetrically at equal distances from the center line 11 c. By screwing the nut 61 slightly, either of the two pin holes 62 a can be aligned with any one of the pin holes 61 a of the nut 61 .
As shown in FIG. 9, a pin 63 is fitted in the aligned pin holes 61 a, 62 a, so that the nut 61 is locked against rotation by the key plate 62 .
Although the circular-curved cutout portion 65 is provided at the approximately circumferential center of the one support pillar 28 on the fixed casing 11 side, since a little stress is distributed over the entire support pillar 28 , except the ends of the support pillar 28 at the circumferential side thereof, as shown in FIG. 7, the provision of the cutout 65 does not impair the stress relief function of the support pillar 28 . In addition, since the key plate 62 is disposed outside of the side surface 41 at one end portion of the fixed casing 11 , the fixed casing 11 is prevented from being elongated axially by the key plate 62 .
In FIG. 1, the fixed casing 11 has an inner cavity 52 which has a bottom 50 at one end portion thereof at the inside and is closed by a lid 51 at the other end portion thereof. The rotating shaft 16 is disposed along an axis of the inner cavity 52 . The rotating shaft 16 is journaled for free rotation by a bearing 53 fitted in the lid 51 at one end of the shaft 16 and by a bearing 54 fitted in the bottom 50 at a mid portion of the other end side of the shaft 16 . A cylinder block 56 in which a plurality of pistons 55 are slidably inserted is splined to the output shaft 16 for non-rotatable and sidable movement. A swash plate 58 swingably supported by means of a steel ball 57 is mounted on the bottom 50 side, and a cylinder 59 for slanting the swash plate 58 is disposed at one end of the swash plate 58 . Front ends of the pistons 55 are in abutment with the swash plate 58 for freely sliding movement. Compressed oil is fed to and discharged from the cylinder block 56 via a counterbalance valve (not shown) provided in the lid 51 .
As clearly shown in FIG. 10, the rotating shaft 16 journaled by the two bearings 53 , 54 located on the hydraulic motor 3 side is cantilevered beyond a center of the reduction gear mechanism 2 , passing through it. The rotating shaft 16 is formed by an output shaft portion 16 a on the hydraulic motor 3 side and an input shaft portion 16 b on the reduction gear mechanism 2 side being formed into one piece. The first sun gear 17 is fitted to the end of the input shaft portion 16 b by means of the spline 18 . The spline 18 comprises spline cogs 18 a on the outer periphery side of the input shaft 16 b and spline grooves 18 b on the inner periphery side of the first sun gear 17 .
Shown in FIG. 11 is the structure of the first sun gear 17 . FIG. 11 ( a ) is a side view of the first sun gear and FIG. 11 ( b ) is a vertically sectioned view of the same. In FIG. 11 ( b ), the first sun gear 17 has engaging cogs 17 a engageable with the first planetary gear 20 , not shown, formed around the periphery of the first sun gear 17 , and the spline grooves 18 b engageable with the spline cogs 18 a of the input shaft 16 b, not shown, formed around the inside of the first sun gear 17 . In FIG. 11 ( a ), the engaging cogs 17 a formed around the periphery of the first sun gear 17 are equal in number to the spline grooves 18 b formed around the inside thereof. The spline cogs 18 a are arranged so that the spline grooves 18 b can be positioned between spaces 17 b between the engaging cogs 17 a. This arrangement can prevent the spaces 17 b between the engaging cogs 17 a and the spline cogs 18 a from being overlapped with each other to ensure the wall thickness t of the first sun gear 17 , and as such can allow the first sun gear 17 to have a reduced outer diameter.
Shown in FIG. 12 is the structure of the spline cogs 18 a at the end of the input shaft portion 16 b of the rotating shaft 16 . FIG. 12 ( a ) is a front view of the input shaft 16 b; FIG. 12 ( b ) is a sectional view of the input shaft portion 16 b; and FIG. 12 ( c ) is a top view of a single spline cog. The spline cogs 18 a extend in an axial direction of the input shaft portion 16 b, as shown in FIGS. 12 ( a ) and 12 ( b ). A groove 16 c is used for fitting therein a lock ring for locking the first sun gear 17 to the input shaft portion 16 b. Opposite slanted surfaces of each spline cog 18 a have a curved surface extending along an arcuate line of a radium R, such that the each spline cog 18 a has a crown shape, protruding at an axial center thereof and gradually narrowing toward the opposite ends. The angle of inclination at the both ends of the spline cog 18 a is α.
Turning to FIG. 10, a reaction force to a force of the piston 55 to press the swash plate 58 acts on the rotating shaft 16 , and the load F is applied thereto. The input shaft portion 16 b is rotated, with its front end inclined at an angle of α by the load F. The angle of inclination α at the front end of the rotating shaft 16 and the angle of inclinations α at the opposite ends of the spline cog 18 a are generally identical with each other. As shown in FIG. 12, the spline cog 18 a at the front end of the rotating shaft 16 has a widthwise crowned portion, so that even when inclination is caused at the end of the rotating shaft 16 , the spline cog 18 a is brought into abutment with the spline groove 18 b (FIG. 11) at an approximately lengthwise center thereof.
Shown in FIG. 13 is the structure of another spline cog 181 a at the front end of the input shaft portion 16 b of the rotating shaft 16 . FIG. 13 ( a ) is a front view of the input shaft portion 16 b, FIG. 13 ( b ) is a sectional view of the input shaft portion 16 b, and FIG. 13 ( c ) is a top view of a single spline cog. As shown in FIG. 13 ( c ), the spline cog 181 a has a tapered shape to be gradually narrowed toward the front end. The degree to which the spline cog is narrowed corresponds to the degree to which the angle of inclination of the side surfaces becomes α. Other respects are the same as those of FIG. 12 .
As shown in FIGS. 12 and 13, the spline cog is preferably crowned or inclined to be gradually narrowed toward the end thereof, in terms of machinability and function. Alternatively, the spline groove 18 b on the first sun gear 17 side may be crowned so that an axial center of the spline groove 18 b is gradually narrowed in width or may be inclined so that the spline groove 18 b is gradually widened toward the axial front end thereof. Further, both of the spline cog 18 a and the spline groove 18 b may be provided with a crowned portion or an inclined portion corresponding to clearance.
As mentioned above, the front end portion of the rotating shaft 16 is inclined by the application of the reaction force of the hydraulic motor 3 . To allow for this inclination, either or both of the spline cog and the spline groove of the spline 18 are provided with the crowned portion or inclined portion so that the clearance therebetween can be gradually widened toward the front end of the spline 18 . This clearance can prevent generation of collision between the spline cog and the spline groove even when the front end portion of the rotating shaft 16 is bent. Thus, in contrast to the prior art shown in FIG. 25 which is so constituted that the inclination of the rotating shaft is absorbed by a coupling 117 for connecting between an output shaft 104 a of the motor and an input shaft 104 b of the reduction gear, the embodiment of the present invention is so constituted that the inclination can be absorbed by the first sun gear 17 . Hence, the subsequent gears are prevented from being adversely affected by the inclination of the rotating shaft 16 .
Also, as shown in FIG. 1, the output shaft portion 16 a and the input shaft portion 16 b of the rotating shaft 16 are formed in one piece without any coupling provided therebetween, so that the rotating shaft 16 involves no large diameter portion at any location throughout the rotating shaft 16 . This enables the second sun gear 22 disposed around the input shaft portion 16 b of the rotating shaft 16 to be reduced in diameter, thus enabling the number of teeth of the second sun gear 22 to be reduced. As a result of this, if the reduction gear ratio is kept unchanged, the number of teeth of the internal gear 15 can also be reduced, and as such can reduce the diameter or size of the rotating casing 12 . In addition, the distance between a center of the second sun gear 22 and a center of the second planetary gear 26 is shortened and, as a result of this, outward protrusion of the second sun gear 26 can be reduced. Therefore, the radial dimension or size of the driving unit la can be minimized.
Further, as shown in FIG. 11, the spaces 17 b between the engaging cogs 17 a and the spline cogs 18 a are prevented from being overlapped with each other so that the first sun gear 17 can be allowed to have a reduced outer diameter. This enables the number of teeth of the first sun gear 17 to be reduced. As a result of this, if the reduction gear ratio is kept unchanged, the number of teeth of the internal gear 15 can also be reduced, and as such can reduce the diameter or size of the rotating casing 12 . Consequently, outward protrusion of the first planetary gear 20 can be reduced. Therefore, the first planetary gear train and the second planetary gear train can both be reduced in size.
The example of the first embodiment of the invention as described above may be modified as follows, for practical use of the invention.
(1) While the reduction gear mechanism 2 having the two-stage planetary gear train was illustrated, the supporting structure of the embodiment of the present invention can be applied to a three-stage planetary gear train as well by the application to the final stage planetary gear train.
(2) The planetary gears revolving around the sun gear of the planetary gear train is not limited in number to three. For example, for four planetary gears, the supporting structure of the embodiment of the present invention can be applied thereto by increasing the trunnion bosses and the support pillars in number to four.
(3) In FIGS. 12 and 13, the spline 18 is not limited to the straight spline extending in parallel to the axis of the rotating shaft. The spline formed to extend obliquely with respect to the axial direction may be used.
(An Example of Second Embodiment)
Then, an example of the second embodiment of the present invention will be described below. To avoid repetition of description of corresponding construction to that of the example of the first embodiment, like numerals are labeled to corresponding parts throughout the drawings. FIG. 14 is a sectional view of the driving unit 1 b according to an example of the second embodiment. The driving unit 1 b of the example of the second embodiment is different from the driving unit 1 a of the example of the first embodiment shown in FIG. 1 in the following points.
{circle around (1)} Rather than being integrally projected from the bottom 50 of the fixed casing 11 , a trunnion boss 75 is formed as a single part and journaled at its opposite ends between the bottom 50 of the fixed casing 11 and the holder 24 ;
{circle around (2)} The crowned portion is formed in the engaging cog 17 c of the first. sun gear 17 , rather than being formed in the spline cog 18 a of the rotating shaft 16 as in the example of the first embodiment;
{circle around (3)} While in the example of the first embodiment, the first-stage planetary gear train comprises three first planetary gears 20 , the first planetary gears 20 in the example of the second embodiment are reduced in number to two;
{circle around (4)} The internal gear 15 is formed to have a reduced length, as compared with the example of the first embodiment; and
{circle around (5)} While in the example of the first embodiment, the nut 61 for supporting the bearing 13 is locked against rotation by the key plate 62 , the nut is locked against rotation by a pin, instead of the key plate.
In the following, description on the different points mentioned above will be given. First, reference is given to the first difference that the trunnion boss 75 is formed as a single part and journaled at its opposite ends.
In FIG. 14, the trunnion boss 75 is formed as a single part, comprising a large diameter body 75 a and two small diameter shafts 75 b projecting from the opposite ends of the large diameter body 75 a. A hole 76 is formed in the bottom 50 of the fixed casing 11 , and a hole 37 is formed in the holder 24 in such a manner as to confront the hole 76 . The one shaft 75 b of the trunnion boss 75 is fitted in the hole 76 and the other shaft 75 b of the same is fitted in the hole 37 , whereby the trunnion boss 75 is journaled at its opposite ends between the bottom 50 of the fixed casing 11 and the holder 24 . Three trunnion bosses 75 are arranged circumferentially and three second planetary gears 26 engageable between the second sun gear 22 and the internal gear 15 are rotationally supported on the bodies 75 a of the three trunnion bosses 75 , respectively.
Three support pillars 27 are integrally projected from a portion of the holder 24 between the trunnion bosses 75 , and three support pillars 28 are integrally projected from a portion of the fixed casing 11 between the trunnion bosses 75 . The support pillars 27 on the holder 24 side and the support pillars 28 on the fixed casing 11 side are put in abutment with each other at their abutment surfaces 29 and are fixed by bolts 30 and locating pins 31 . The abutment surfaces 29 are preferably within the width of the second planetary gear 26 , or preferably at an approximately center thereof.
By virtue of this supporting structure wherein the trunnion bosses 75 are journaled at the opposite ends between the fixed casing 11 and the holder 24 , the trunnion bosses 75 are replaceable with new ones and are supported with little bending. Also, since the abutment surfaces 29 of the support pillars 27 of the holder 24 and those of the support pillars 28 of the fixed casing 11 are located within the width of the second planetary gear 26 and are located at an approximately center thereof, the support pillars 27 , 28 can be tightened firmly by the bolts 30 . In addition, since the basal ends of the support pillars 27 , 28 are integral with the holder 24 or the fixed casing 11 , the support pillars can withstand a stress concentration. By virtue of these specific designs, the radial and axial dimension of the fixed casing 11 can be reduced, thus providing a reduced size and weight of the device.
Second, reference is given to the second difference that the crowned portion is formed in the engaging cog 17 c of the first sun gear 17 , rather than being formed in the spline cog 18 a of the rotating shaft 16 . FIG. 15 ( a ) is a side view of the first sun gear 17 , FIG. 15 ( b ) is a vertically sectioned view, and FIG. 15 ( c ) is a top view showing one of the engaging cogs of the first sun gear. In FIG. 15 ( c ), the opposite slanted surfaces of each engaging cog 17 c have a curved surface extending along an arcuate line of a radium R, such that the each engaging cog 17 c has a crown shape, protruding at an axial center thereof and gradually narrowing toward the opposite ends. The angle of inclination at the both ends of the engaging cog 17 c is α. As is the case with the example of the first embodiment of FIG. 10, the rotating shaft is rotated in the state in which the input shaft portion 16 b of the rotating shaft 16 is inclined at an angle a at the front end portion thereof by the load F. This inclination of the rotating shaft 16 causes the first sun gear 17 to be inclined. But, since the engaging cogs 17 c of the first sun gear 17 are provided with the widthwise crowned portions, the engaging cogs 17 c come into abutment with the first planetary gears 20 at their approximately lengthwise center portions thereof.
Thus, all the spline cogs of the rotating shaft 16 are brought into abutment with the first sun gear 17 at the splined connection therebetween. This can prevent a running torque of the rotating shaft from being transmitted by only some spline cogs, and as such can provide improved durability of the rotating shaft 16 and the first sun gear 17 . It is to be noted that the cogs of the first sun gear 17 may be tapered as is the case with the front end portion of the rotating shaft 16 of FIG. 13 .
Third, reference is given to the third difference that the first planetary gears 20 are reduced in number to two. As shown in FIG. 14, the two first planetary gears 20 are rotatably supported on the planetary gear frame 19 and are engaged between the first sun gear 17 and the internal gear 15 .
Shown in FIGS. 16-18 is the constitution of the planetary gear frame 19 . FIG. 16 is a sectional view of the planetary gear frame 19 as viewed from line D—D of FIG. 14 . FIG. 17 is a sectional view taken along the arrowed line E—E of FIG. 16 and developed with the hydraulic motor 3 side up. FIG. 18 is a view of the planetary gear frame 19 as viewed from the opposite side to the hydraulic motor 3 side. As best shown in these. diagrams, the planetary gear frame 19 has a pair of generally ellipse-like flat plate portions 19 a, 19 b. As best shown in FIG. 16, the flat plate portion 19 a has an insertion hole 19 c for inserting the rotating shaft 16 therein. As best shown in FIG. 18, the flat plate portion 19 b has an opening 19 d from which the first sun gear 17 can be fitted onto the rotating shaft 16 . The insertion hole 19 c has, around its inside, grooves engageable with the periphery of the second sun gear 22 which form the spline 21 (See FIG. 17, not shown in FIG. 16 ). The opening 19 d is closed by a lid 23 after the first sun gear 17 is fitted onto the rotating shaft 16 , as shown in FIG. 14 .
As best shown in FIGS. 16 and 18, the flat plate portions 19 a, 19 b have two supporting hole 19 e for the two first planetary gears 20 to be supported in such a manner as to be symmetrically disposed about the rotating shaft 16 . As shown in FIG. 14, the first planetary gears 20 are mounted on shaft members fitted into the supporting holes 19 e. In other words, the two first planetary gears 20 are rotatably supported at the axially opposite ends thereof in sandwich relation between the two flat plate portions 19 a, 19 b.
When the two first planetary gears 20 are rotated around the first sun gear 17 , the reaction forces are applied to the first sun gear 17 from the two first planetary gears 20 , respectively. Since the two first planetary gears 20 are symmetrically disposed about the rotating shaft 16 , the reaction forces are balanced each other out, and as such can prevent the first sun gear 17 from being moved in the radial direction by the reaction forces. Thus, an undesired partial abutment between the first planetary gears 20 and the first sun gear 17 can be restricted, and as such can provide improved durability of these gears.
The planetary gear frame 19 has paired support pillars 19 f for the pair of flat plate portions 19 a, 19 b to be fixedly held at positions symmetrical with respect to the rotating shaft 16 . The two pairs of support pillars 19 f extend partially along a generally ellipse-like circumference of the flat plate portions 19 a, 19 b and are disposed at positions in the vicinity of the first planetary gears 20 . The positions of the support pillars 19 f enable the support pillars, to which the reaction forces generated when the first planetary gears 20 are driven are applied, to be slenderized. This can produce the driving unit comprising the two first planetary gears combining structural stability with weight reduction.
Thus, the driving unit thus constructed can be reduced in size to a large extent, as compared with the conventional driving unit having three first planetary gears. Further, parts count can also be reduced to a large extent and also the structure can be simplified. Thus, the driving unit thus produced is also excellent in cost. Also, the ellipse-like shape of the planetary gear frame 19 contributes to the downsizing and lightweight of the driving unit.
In addition, the output shaft of the motor is doubled as the input shaft by forming the rotating shaft in one piece and projecting it to extend through a center portion of the reduction gear. This enables the radial movement of the rotating shaft to be reduced, as compared with the rotating shaft comprising the output shaft and the input shaft coupled with each other through an intermediate coupling. As a result of this, undesired partial abutment between the planetary gears and the sun gear can be restricted, and as such can maintain the durability of the sun gear and the rotating shaft.
Further, since the spaces between the cogs of the sun gear and the spline grooves at the fitting portions of the sun gear and the rotating shaft are out of position from each other with respect to the circumferential direction, even when the sun gear is reduced in diameter, the wall thickness of the sun gear can be ensured. As a result of this, deformation of the sun gear produced when it transmits the output can be reduced, so that the noise emitted when the sun gear and the planetary gears are engaged can be suppressed.
Further, as is the case with the example of the first embodiment, the first sun gear can be reduced in radial dimension without the distances between the spline grooves and the spaces between the cogs of the first sun gear being shortened and, as a result, the second sun gear can also be reduced in diameter to such an extent that when the rotating shaft is inclined, the second gear does not interfere with it. This enables the reduction gear ratio of the reduction gear to be increased. As a result of this, a compact, low-torque, high-revolution, hydraulic motor can be applied to the driving unit, then enabling the driving unit to be reduced in size.
Here, detailed description will be given on the engagement structure between the first sun gear 17 and the first planetary gears 20 of the driving unit 1 b of the example of the second embodiment. FIG. 19 is a view showing the engaging state of the sun gear 17 , the first planetary gears 20 and the internal gear 79 having internal cogs 15 . FIG. 20 is an enlarged view of a principal part F surrounded by a dotted line of FIG. 19 . In FIG. 20, P is a point on a tooth flank 20 b of the first planetary gear 20 which is in the opposite side to a tooth flank 20 a where the first sun gear 17 and the first planetary gear 20 are put in engagement with each other and which comes nearest the first sun gear 17 when the rotation shaft 16 is inclined, and Q is a point on a tooth flank 17 d of the confronting first sun gear 17 . A straight line connecting between P and Q is parallel to a connecting line between the axes of the two first planetary gears 20 . θ is an angle formed by a tangent line j extending perpendicularly to the axis of the first sun gear 17 and a moving direction R of the first sun gear 17 (the direction of the connecting line P-Q). δ is a distance of the first sun gear 17 in the moving direction R. A distance between the point P and the tangent line, in other words, a clearance 1 between the tooth flank 20 b and the tooth flank 17 d which is a length of a perpendicular dropped from the point P to the tangent line j is set to 2 δ sin θ.
This can produce the result that even when the rotating shaft 16 is inclined, the tooth flank 17 d of the first sun gear 17 and the tooth flank 20 b of the first planetary gear 20 are prevented from colliding with each other, thus providing improved durability. Also, since the inclination of the rotating shaft 16 is absorbed between the first sun gear 17 and the first planetary gears 20 , inclination of the first planetary gears 20 or second planetary gears 26 , partial abutment between the respective gears, and the like adverse effect can be prevented. Further, since a value of the clearance 1 (2 δ sin θ) is a minimum value to prevent the collision between the tooth flake 17 d and the tooth flake 20 b, the backlash of the first planetary gears 20 resulting from the clearance 1 can be minimized. Thus, undesirable movement of a construction machine using the driving unit of the example of this embodiment resulting from the clearance can be suppressed, so that the construction machine can be prevented from swinging back or slipping down a sloping road.
Fourth, reference is given to the fourth difference that the internal gear 15 is formed to have a reduced length. In FIG. 14, a length of pass of contact n between the first sun gear 17 and the first planetary gears 20 is set to a bending stress calculated to obtain a desired durable period. The bending stress is small in the engaging area between the internal gear 15 and the first planetary gears 20 , because tooth thickness of dedendum of the internal gear 15 is formed to be larger than that of dedendum of the first sun gear 17 , as shown in FIG. 19 . Further, the number of times the internal gear 15 engages with the first planetary gears 20 is smaller than the number of times the first sun gear 17 engages with the first planetary gear 20 . Thus, a length of pass of contact m between the internal gear 15 and the first planetary gears 20 can be formed to be smaller than the length of pass of contact n between the first sun gear 17 and the first planetary gears 20 . Preferably, the length of pass of contact m should be determined so that the engaging area between the first sun gear 17 and the first planetary gears 20 are equal in durable period to that between the internal gear 15 and the first planetary gear 20 .
This can allow the internal gear 15 to be shortened by making the engaging area between the first sun gear 17 and the first planetary gears 20 equal in durable period to that between the internal gear 15 and the first planetary gears 20 . Further, the casing can be reduced in size. Thus, the internal gear and the casing can be reduced in weight and, as a result of this, the hardening treatment of the internal gear can be cut.
Finally, reference is given to the fifth difference that the nut 61 for supporting the bearing 13 is locked against rotation by use of a pin 78 , instead of the key plate. In FIG. 14, a projection 77 projecting toward the periphery of the support pillars 28 of the fixed casing 11 is disposed at an end face of the support pillar 27 of the holder 24 at the periphery side thereof, and a lock pin 78 is disposed between the projection 77 and the nut 61 pressing the bearing 13 .
As shown in FIGS. 21 and 22, the projection 77 projected from the holder 24 is integrally projected toward the periphery of the support pillar 27 of the holder 24 . The projection 77 has a hole 77 a for the pin 78 to be axially inserted. Fitted in the hole 77 a is a spring 78 a to prevent the pin 78 from falling out. As shown in FIG. 23, pin holes 61 a for fitting the pins 78 therein are formed in the side wall of the nut 61 , with higher density than those in the example of the first embodiment of FIG. 8 .
As shown in FIG. 24, the nut 61 is screwed into the threaded portion 11 b of the fixed casing 11 to press the bearing 13 to a predetermined position. The nut 61 is stopped screwing with the pin hole 61 a up, as shown in FIG. 23 . Then, the holder 24 is pressed in on the basis of the locating pin 31 . At that time, when the pin 78 is previously fitted in either of the holes 77 a and 61 a, the pin 78 is put into the fitted state shown in the diagram to lock the nut 61 against rotation.
Since no cutout is provided for the support pillar 28 on the fixed casing 11 side, the strength of the support pillar 28 is maintained. In addition, since the key plate 62 is not used in the driving unit of the second embodiment, differently from the driving unit 1 a of the example of the first embodiment, the parts count is further reduced and also the axial dimension of the fixed casing 11 is not increased to that extent.
The example of the second embodiment of the invention as described above may be modified as follows, for practical use of the invention.
(1) While in this embodiment, it is only the first planetary gear that comprises two planetary gears, the second planetary gear may also comprise the two planetary gears;
(2) The reduction gear mechanisms that may be used include the one comprising at least a two-stage planetary gear train (e.g. a three-stage or more planetary gear train). Also, the third stage or subsequent stage of planetary gear train that may be used include the one comprising two. or three planetary gears.
(3) The second planetary gears revolving around the second sun gear is not limited in number to three. For example, for four planetary gears, the supporting structure of the embodiment of the present invention can be applied thereto by increasing the trunnion bosses and the support pillars in number to four.
(4) The arrangement of the support pillars for supporting the planetary gear frame is not necessarily limited to the illustrated arrangement wherein two pairs of support pillars are arranged to partially extend along the circumferential direction of the generally ellipse-shaped flat plate portion. For example, a pair of or three pairs of support pillars may be used. Also, the support pillars may be formed into a wall-like configuration arranged to partially along the circumferential direction.
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The present invention relates to a driving unit comprising a multiple-stage planetary gear type reducer used to reduce rotation speed of a hydraulic motor and output the reduced rotation speed, which is used as a driving device for a traveling apparatus. The driving unit of the present invention is so structured that a trunnion boss for rotatably supporting a planetary gear train of a final state is supported at opposite ends thereof. This structure enables the load applied to the trunnion boss to be dispersed to the both ends, and as such can allow the trannion boss to be reduced in diameter or can allow the fixed casing to be reduced in circumferential dimension. This can produce a downsized driving unit. The present invention has additional features, such as the feature that an output shaft of the hydraulic motor and an input shaft of the reducer are formed in the form of a single rotating shaft. This can provide a driving unit structurally optimized for every principal part, to provide downsizing and improved durability.
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FIELD OF THE INVENTION
[0001] The present invention relates to paper supports that are used in neonatal screening and is particularly concerned with paper supports which can be used in the storage, recovery and further processing of biological materials such as biopharmaceutical drugs.
BACKGROUND TO THE INVENTION
[0002] The use of solid supports such as filter paper for the collection and analysis of human blood dates back to the early 1960s, when Dr. Robert Guthrie used dried blood spot (DBS) specimens to measure phenylalanine in newborns for the detection of phenylketonuria (Mei, J., et al., 2001; Journal of Nutrition, 131:1631S-1636S). This novel application for collecting blood led to the population screening of newborns for the detection of treatable, inherited metabolic diseases. DBS have now been used for over 40 years to screen for a large range of neonatal metabolic disorders.
[0003] DBS specimens are collected by spotting whole blood onto a solid support, such as a membrane, glass fiber or paper, either from venous blood or directly from a finger or heel prick, making this method particularly suitable for the shipment of specimens from peripheral clinics to central laboratories. Furthermore, DBS packed in zip-lock plastic bags with desiccant can be stored and shipped at ambient temperature, thus avoiding the need for i) cold chain storage and ii) fast specialized transportation. DBS collected by applying a drop of blood onto an absorbent material such as Whatman 903 Neonatal STD paper are not subject to the IATA Dangerous Goods Regulations (Addendum II, March 2005).
[0004] Additional solid paper supports that are used for collecting, transportation and storing DBS and other bodily fluids for newborn and neonatal screening purposes include
[0005] 1. Ahlstrom 226
[0006] 2. Munktell TFN (CE marked)
[0007] 3. Toyo Roshi grade 545 Advantec Toyo, Tokyo (see Elvers L et al 2007; J. Inherit Medtab Dis 30, 4, 609).
[0008] All of these papers like the Whatman 903 Neonatal STD paper consist of cotton linters. The Whatman 903 Neonatal STD and Ahlstrom 226 papers are classified as Class II Medical devices. Solid paper supports that have the potential to be developed into devices for newborn and neonatal screening purposes include those manufactured by Macherey Nagel (e.g. MN818), Reeve Angel (e.g. Double ring) and Hahnemuhle Grade 2292.
[0009] The consumable costs for DBS are less than US$1 per test, and transport costs are markedly reduced compared with plasma, which requires a liquid format and specialized transportation conditions (Johannessen, A., et al., 2009; J Antimicrobial Chemotherapy, 64, 1126-1129). Although the actual assay costs remain unchanged, and the extraction of analytes from DBS involves some extra hands-on time at a centralised laboratory, the use of DBS and specifically solid paper supports is increasingly used in the storage and/or analysis of biological materials such as nucleic acids, proteins etc. In addition, DBS have also been utilised during the drug discovery process in which candidate low molecular weight drug compounds have been introduced into test animals and concentration levels in the blood monitored.
[0010] In recent years, biotechnologically-derived recombinant proteins, peptides and antibody-based drugs, as well as antisense oligonucleotides and DNA for gene therapy, have developed into mainstream therapeutic agents and now constitute a substantial portion of the compounds under clinical development. These agents are commonly termed “biotech-drugs” or “biopharmaceutical drugs” to differentiate them from low molecular weight drug compounds.
[0011] Drug Metabolism and Pharmacokinetic (DMPK) analysis of Biotech-drugs and low molecular weight drug compounds is important as DMPK analysis is vital to drug discovery as it provides insight into how drug candidates may be absorbed, metabolised and excreted by the body. Analyses are routinely performed at the drug discovery stage and involve dosing animals with the compound of interest, and measuring the drug (or metabolite) concentration in biological fluids as a function of time. This generates valuable information such as drug clearance, bioavailability etc, but demands a significant amount of time and resource (Beaudette, P., et al., 2004; J. of Chromatography B 809, 153-158).
[0012] Major problems associated with the DMPK analysis, typically conducted in drug screening programmes, are the apparent lack of a suitable storage media for maintaining stability and integrity in blood samples prior to analysis. Current methodologies use plasma or whole blood collected from the dosed animals at designated times. However, this method has a number of drawbacks including the involvement of time-consuming procedures which create a bottleneck in the analysis process. In addition, the multiple bleeding of individual animals for time-course experiments is restrictive. This puts a limitation on throughput and increases the use of animals, which has the result that fewer lead compounds can be advanced.
[0013] The small blood volume needed for DBS enables serial blood sampling from one animal rather than composite bleeds from several animals which significantly improves the quality of DMPK and toxicokinetic data and assessments. The ethical benefits of the reduced blood volume (typically 15-20 μl per spot) needed for DBS with regard to the “3Rs” (reduction, refinement, and replacement) are obvious in preclinical drug development. The numbers of test animals can be significantly reduced. In addition, non-terminal blood sampling is possible in juvenile toxicity studies which are increasingly required by authorities as part of the safety evaluation of drugs for paediatric use. Another advantage for regulatory animal toxicology studies is the increase in data quality.
[0014] Therefore due to the growing need for rapid analysis of large quantities of blood samples in pharmacokinetic research, DBS have become an attractive option. For paper to perform as a solid support for DBS it is desirable that the paper combines satisfactory mechanical properties with an ability to hold the biological material of interest in a stable condition in such a way that it can be subjected to further processing and/or analysis post-storage. Examples of such papers used for DMPK analyses are those known as 903 Neonatal specimen collection papers and also papers known as FTA and FTA Elute described, for example, in U.S. Pat. Nos. 5,75,126 and 5,939,259.
[0015] For effective downstream processing and analysis, the analyte of interest (such as endogenous proteins or Biotech drugs) must be easy to extract from the solid paper support using relatively simple techniques that are amenable to high throughput.
[0016] The combination of DBS and the detection of endogenous protein has been described in the scientific literature. For example, the biomarker for cystic fibrosis (CF) immunoreactive trypsin (IT), the first reported use of endogenous IT from DBS for CF screening was published by Ryley et al., in 1981 (J. Clin. Pathol. 34, 906-910). Since then, IT has been routinely used as an indicator of CF using DBS from neonates. A number of commercial organisations supply FDA approved immunoassay kits for this application. Many simply use a “paper-in” approach, in which a paper punch containing the DBS is applied directly in to the immunoassay and the analyte of interest is extracted in situ. Recently (Lindau-Shepard & Pass, 2010, Clinical Chem. 56, 445-450) demonstrated that IT exists in two different isoforms. These authors reported the development of a suspension (or paper-in) array-based immunoassay for the diagnosis of CF using the two different isoforms of IT. All these protein-based studies were carried out on uncoated Guthrie cards (Whatman 903 paper).
[0017] Since the inception of anonymous human immuno-deficiency (HIV) screening, over 1.2 million DBS tests have been carried out for the serological detection of endogenous anti-HIV antibodies in the blood from expectant mothers.
[0018] These studies have proved that i) concerns about long-term storage of blood and any associated proteins of interest have proved unfounded and ii) the presence of haem in the DBS does not interfere with assay performance.
[0019] It is therefore desirable to produce paper supports which provide a simple, stable storage medium for biological materials, including i) endogenous moieties and ii) biopharmaceutical or biotech drugs, which give a high yield or recovery of the biological material on further processing. The present invention addresses these needs and provides methods that enhance the recovery levels of biological materials such as biopharmaceutical drugs from biological samples stored as DBS on solid paper supports.
Definitions
[0020] The term “biological material” as used herein shall mean any “biomolecule”, “synthetically-derived biomolecule”, “biopharmaceutical drug” or “cellular component” as defined below:
[0021] i) A biomolecule is any organic molecule that is produced by a living organism, including large polymeric molecules such as proteins, polysaccharides, and nucleic acids as well as small low molecular weight molecules such as primary metabolites, secondary metabolites, and natural products.
[0022] ii) A synthetically-derived biomolecule, is a “biomolecule” as defined in i) above that is generated using recombinant DNA technologies or chemically synthesised by other non-living in-vitro methods.
[0023] iii) A biopharmaceutical drug (or “biotech drug”) is a biotechnologically-derived recombinant protein, peptide or antibody-based drug, or an antisense oligonucleotide, protein nucleic acid (PNA) or deoxy ribonucleic acid (DNA) for gene therapy.
[0024] iv) A cellular component is a unique, highly organized substance or substances of which cells, and thus living organisms, are composed. Examples include membranes, organelles, proteins, and nucleic acids. Whilst the majority of cellular components are located within the cell itself, some may exist in extracellular areas of an organism.
SUMMARY OF THE INVENTION
[0025] According to a first aspect of the present invention, there is provided a paper support for neonatal screening having at least one surface coated with a chemical that enhances the recovery of a biological material from said surface, wherein the chemical is selected from the group consisting of polyvinyl alcohol (PVA), non-ionic detergent and disaccharide.
[0026] In one aspect, the chemical is polyvinyl alcohol (PVA).
[0027] In another aspect, the non-ionic detergent is Tween 20.
[0028] In a further aspect, the disaccharide is α-β-trehalose.
[0029] In one aspect, the paper support is a 903 Neonatal STD paper.
[0030] According to a second aspect of the present invention, there is provided a method of recovering a biological material from a paper support comprising the steps of
i) contacting a surface of a paper support as hereinbefore described with a sample containing a biological material; ii) drying the sample on the surface of the paper support; iii) storing the paper support; and iv) extracting the biological material from the surface.
[0035] In one aspect, step iii) comprises storing the paper support a temperature in the range of 15 to 40° C. Preferably, the temperature is in the range of 20 to 30° C. In another aspect, the paper support is stored at a lower temperature depending on the thermal stability of the biological material.
[0036] The nature of the sample will depend upon the source of the biological material. For example, the source may be from a range of biological organisms including, but not limited to, virus, bacterium, plant and animal. Preferably, the source will be a mammalian or a human subject. For mammalian and human sources, the sample may be selected from the group consisting of tissue, cell, blood, plasma, saliva and urine.
[0037] In another aspect, the biological material is selected from the group consisting of biomolecule, synthetically-derived biomolecule, cellular component and biopharmaceutical drug.
[0038] In a further aspect, the biological material is a biopharmaceutical drug.
[0039] According to a third aspect of the present invention, there is provided a method of making a paper support as hereinbefore described, comprising coating at least one surface of a paper support with a solution of a chemical that enhances the recovery of a biological material from said surface, wherein the chemical is selected from the group consisting of polyvinyl alcohol (PVA), non-ionic detergent and disaccharide.
[0040] In one aspect, the chemical is selected from the group consisting of polyvinyl alcohol (PVA), Tween 20 and α-β-trehalose.
[0041] According to a fourth aspect of the present invention, there is provided a use of a paper support as hereinbefore described for enhancing the recovery of a biological material therefrom.
[0042] In one aspect, the biological material is a biopharmaceutical drug.
BRIEF DESCRIPTION OF THE FIGURES
[0043] FIG. 1 presents the recovery of exogenously-added IL-2 from dried blood spots applied to various paper matrices.
[0044] FIG. 2 presents the recovery of exogenously-added IL-2 from dried blood spots applied to 903 Neonatal STD papers coated with various chemicals.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Recombinant IL-2±carrier (R & D Systems; Cat. 202-IL-CF-10 μg; lot AE4309112 and Cat. 202-IL-10 μg; lot AE4309081 respectively) was dissolved in either Dulbecco's PBS without calcium and magnesium (PAA; Cat. H15-002, lot H00208-0673), EDTA-anti-coagulated human, rabbit or horse blood (TCS Biosciences) at 50 pg or 100 pg/μl.
[0046] Aliquots (1 μl containing 0, 50 or 100 pg of IL-2) were applied to the following GE
[0047] Healthcare filter papers; 903 Neonatal STD card, Cat. 10538069, lot 6833909 W082; DMPK-A card, Cat. WB129241, lot FT6847509; DMPK-B card, Cat. WB129242, Lot FE6847609 and DMPK-C card, Cat. WB129243, Lot FE6847009. Samples were allowed to dry overnight at ambient temperature and humidity.
[0048] Punches (3 mm diameter) were extracted from each paper type using the appropriately sized Harris Uni-core punch (Sigma, Cat. Z708860-25ea, lot 3110). Single punches were placed into individual wells of the IL-2 microplate derived from the Human IL-2 Quantikine ELISA (R & D Systems, Cat. D0250, lot 273275). These plates are coated with a mouse monoclonal antibody against IL-2. The IL-2 protein was eluted from the paper punch using the assay buffer (100 μl) supplied with the Quantikine kit. All subsequent steps were performed according to the instructions supplied with the Quantikine kit using a “paper in” method (paper punches are placed directly into the assay buffer and the analyte eluted directly in situ). On completion of the assay the optical density of the microplate was monitored at 450 nm using a Thermo Electron Corporation, Multiskan Ascent. The recovery of IL-2 was determined by comparing values to a standard curve of known IL-2 concentrations. A fresh IL-2 standard curve was prepared for each individual experiment.
[0049] Additional experiments involved the addition of IL-2-spiked blood to 903 Neonatal STD cards after the cards had been saturation dipped in several chemical solutions (as described below).
[0050] Chemicals Used
[0051] A list of the chemicals and their sources is given below.
[0052] Poly-vinyl-alcohol (Sigma; Cat. P8136, lot 039k0147).
[0053] Poly-ethyl-enemine, 50% in water (Fluka; Cat. P3143, lot 29k1492).
[0054] Inulin, 1% in water (Sigma; Cat. 12255-100 g, lot 079F7110).
[0055] Tween 20, 1% in water (Sigma, Cat. P7949-100 ml, lot. 109k01021).
[0056] α-β-Trehalose, 10 mg/ml (Sigma, Cat. T0299-50 mg, lot 128k1337).
[0057] Poly-ethylene glycol 1000, 1% in water (Biochemika, Cat. 81189, lot 1198969).
[0058] Poly-ethylene glycol 200, 1% in water (Fluka, Cat. 81150, lot 1384550).
[0059] Experimental Results
[0060] When IL-2 was dissolved in EDTA-anti-coagulated blood, the 903 and DMPK-C cards facilitated the recovery of 45-55% of the cytokine, while only 2-3% was recovered from the DMPK-A and B cards (see Table 1 and FIG. 1 ). The 903 and DMPK-C cards are the basic base papers and have not been dipped or coated with any chemical, whilst the DMPK-A and B cards are coated with a proprietary mixture of chemicals that facilitate the denaturation and inactivation of proteins, micro-organisms and cells respectively. These cards have been designed to facilitate the transportation and prolonged storage of nucleic acids. Therefore the low IL-2 recovery levels observed when using the DMPK-A and B cards may actually be a reflection of the presence of these denaturing reagents and the ELISA-based antibody detection system used. The ELISA detection system requires the eluted IL-2 to exhibit an intact native structure.
[0000]
TABLE 1
The Recovery of exogenously-added IL-2 from dried blood spots
applied to various paper types. The p-value compares ±
carrier for each paper type. The presence of the carrier had
no significant effect on the recovery of IL-2 (p-value > 0.05).
Paper type
IL-2 recovery (%)
p-value
903; minus carrier
46.9 ± 13.3
>0.05
903; plus carrier
50.7 ± 5.8
DMPK A; minus carrier
2.0 ± 0.0
>0.05
DMPK A; plus carrier
2.0 ± 0.0
DMPK B; minus carrier
2.0 ± 0.0
>0.05
DMPK B; plus carrier
2.0 ± 0.0
DMPK C; minus carrier
53.9 ± 4.8
>0.05
DMPK C; plus carrier
45.2 ± 5.4
[0061] No IL-2 recovery was observed when the cytokine was dissolved in PBS irrespective of the paper type used (data not shown). The IL-2 recovery levels observed in the absence of added IL-2 were essentially equivalent to background levels indicating that the EDTA-anti-coagulated blood contain negligible amounts of endogenous IL-2 (data not shown).
[0062] Several chemicals were used to saturation dip the 903 Neonatal STD cards, some of which appeared to facilitate the recovery of elevated IL-2 levels compared to non-dipped papers (p-value<0.05). For the 903 Neonatal STD cards (Table 2 and FIG. 2 ), chemicals such as poly-vinyl-alcohol (PVA), Tween 20 and α-β-trehalose facilitated an increased IL-2 recovery mean >55 compared to ˜45% observed for the corresponding un-dipped paper. Coating the 903 neonatal STD paper with the following chemicals had a negligible effect on IL-2 recovery levels; Poly-ethyl-enemine (PEI), Inulin, Poly-ethylene glycol-1000 (PEG 1000) and Poly-ethylene glycol 200 (PEG 200).
[0000]
TABLE 2
The Recovery of exogenously-added IL-2 from dried blood spots
applied to 903 Neonatal STD papers coated with various chemicals.
The table is derived from 2 independent experiments (n =
6). The p-value compares the values derived from the dipped
papers to those derived from the Un-dipped 903 paper.
Chemical
IL-2 recovery (%)
p-value
Un-dipped
44.9 ± 6.5
n/a
Poly-vinyl-alcohol (PVA)
62.6 ± 11.2
<0.05
Poly-ethyl-enemine (PEI)
41.8 ± 6.0
>0.05
Inulin
50.4 ± 7.6
>0.05
Tween 20
67.1 ± 9.0
<0.05
α-β-Trehalose
54.8 ± 8.6
<0.05
Poly-ethylene glycol 1000 (PEG 1000)
42.5 ± 9.1
>0.05
Poly-ethylene glycol 200 (PEG 200)
43.3 ± 11.0
>0.05
[0063] While preferred illustrative embodiments of the present invention are described, one skilled in the art will appreciate that the present invention can be practised by other than the described embodiments, which are presented for the purposes of illustration only and not by way of limitation. The present invention is limited only by the claims that follow.
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The present invention relates to paper supports for neonatal screening that are used for the storage and further processing of biological materials. The invention is particularly concerned with paper supports which have at least one surface coated with a chemical that enhances the recovery of the biological material from the support. Methods of preparing and using the paper supports are also described.
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The Government has rights in this invention pursuant to Contract No. DE-AC19-80BC10175.
BACKGROUND OF THE DISCLOSURE
Many apparatuses for use in guiding the drilling of a petroleum well in a non-vertical intentionally angular direction are available. In most of these, a lower portion of the apparatus is permanently and fixedly at an angle to the vertical upper portion of the apparatus and in some apparatuses the lower apparatus portion is adjustably or controllably angular. U.S. Pat. Nos. 3,457,999, 3,561,549, 3,563,323, 3,637,356, 3,667,556, 3,713,500, 3,811,519, 3,841,420, 3,903,974, 3,993,127, 4,077,657, and Russian Pat. Nos. 275,917, and 543,730 disclose various forms of directional drilling apparatuses. The above listed patents show various forms of apparatuses which have fixed deviation guide portions so that the drill string on passing therethrough is deviated at its lower end to cause angular drilling. The following patents show lateral deflectors for rotating drill pipe: U.S. Pat. Nos. 2,891,769, 3,023,821, 3,298,449, 3,326,305, 3,370,657, 3,424,256, 3,460,639, 3,565,189, 3,572,450, 2,593,810, 3,595,326, 3,599,733, 3,637,032, 3,650,338, 3,743,034, 3,746,108, 3,799,279, 3,825,081, 3,961,674, 3,974,886, 4,015,673, 4,076,084, 4,108,265, and Russian Pat. No. 616,395. Many of the tools described in these patents include means for monitoring the angular direction of the lower end of the drill string, same being necessary in order that a proper angular direction may be achieved. None of these patents mentioned provides a variable tool which is completely operable from the surface without tools run downhole to deviate the drill string in a desired direction, with need still to monitor, as deviation depends on rock dip, weight on bit, and the like. This invention seeks to provide an apparatus controllable completely from the surface, which will deviate the drill string at a desired angular direction and with complete control and certainty as to the direction at which the drill string will be deviated.
SUMMARY OF THE INVENTION
This invention provides a directional drilling tool which achieves angularity of its lower end portion through end-to-end engagement of angular surfaces, and which is controlled through a series of angles from vertical by operation of a barrel cam which rotates a lower end portion of the tool with respect to an upper portion to produce the angular deviation, and in which the angular deviations achieved are predetermined and accurate, the tool also providing rotational correction so that the angularly deviated tool portion is guided in the proper direction. Operation of the apparatus is achieved entirely by altering the fluid pressure within the drill string, controlled from the surface, and no auxiliary operating tools are used at all. No apparatus must be run or pumped down the drill string in order to achieve the desired results. The apparatus provided according to the invention provides accurate angular deviation in a drill string in a preselected direction with no downhole monitoring of the angular tool position (Azimuth) being necessary due to bend angle change.
A principal object of the invention is to provide improved directional drilling apparatus which is entirely controllable from the surface. Another object of the invention is to provide such apparatus which is simple, efficient, and dependable. Yet another object of the invention is to provide such an apparatus through use of which the drill string is deviated stepwise to the selected deviated direction, and in which the deviation is reversible. Yet another object of the invention is to provide such an apparatus which is actuated by pressures introduced into the well from the surface to cause actuation of barrel cam devices to provide tool sub angularity and to provide azimuthal correction. A still further object of the invention is to provide such an apparatus which is economical in manufacture and use. A still further object of the invention is to provide an apparatus which gives surface-detectable indication of actuation.
Other objects and advantages of the invention will appear from the following detailed description of a preferred embodiment, reference being made to the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIGS. 1-7 are axial quarter sections showing successive longitudinal portions of the complete apparatus, from top to bottom.
FIGS. 8-9 are drawings showing the upper and lower barrel cam configurations, respectively, used in connection with the apparatus of FIGS. 1-7.
FIGS. 10-11 schematic drawings explaining the functions of the barrel cam grooves of FIGS. 8-9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, and first to FIGS. 1-7, the apparatus includes three main body sections, upper elongate tubular body member 10, middle elongate tubular body member 11, and lower elongate tubular body member 12, these being joined at joints 13 and 14. At joint 13, fitting 15 has threaded pin 16 which is screwed into threaded socket 17 of middle body 11. Fitting 15 has pin 18 having axially spaced semi-circular peripheral grooves 19, 20 therearound, socket 21 of body member 10 having corresponding semi-circular interior grooves 22, 23 therearound. Grooves 19 and 22, together form a circular passage of uniform circular cross section and grooves 20, 23 together form a circular groove of uniform circular cross section. These grooves of circular cross section are filled by bearing balls 26, introduced into grooves 19, 22 through port 27, and into grooves 20, 23 through port 28. A pin 29 having a semi-circular groove across its end is held in place by screwed in plug 30 rotationally fixed by pin 31 inserted into a drilled opening formed at the intersection of pin 29 with the wall of port 27. Bearing balls 26 are introduced into grooves 20, 23 through port 28 which is filled by a pin 32 held in place by plug 33 which is rotationally fixed in position by pin 34 inserted into a drilled opening at the intersection of pin 32 and port 28. The bearing balls 26 in the two circular cross sectional passageways prevent withdrawal of pin 18 from socket 21 and provide for rotation between adapter 15 and body member 10. The rotatable joint 13 is sealed by seal element 115A.
At joint 14, pin 36 of lower body member 12 is connected into socket 37 of middle body member 11 in the same manner that pin 18 is connected into socket 21. The bearing balls 26 introduced through ports 27a and 28a hold pin 36 within socket 37 yet permit rotation between body member 11 and 12. It should be noted however that lower end 11a of body member 11 and upper end 12a of body member 12 are not perpendicular to the axes of these members but are at a slight angle (1.25 degrees) such that when member 12 is rotated about its axis relative to body member 11, body member 12 will become angular with respect to body member 11. The angularity between members 11 and 12 depends on the degree of relative rotational movement therebetween, the angle being zero when the members are in their positions as shown and being maximum when member 12 is rotated 180° from the position shown in the drawings. Joint 14 is sealed externally by seal 115. Body member 10 has an axial passage 40 therethrough which is enlarged at its lower portion 41, below shoulder 42. A clutching sleeve 43 lines the lower end of passage portion 41.
The upper portion of passages 40, 41 is lined by sleeve-like valve ball housing 44, which has an outer annular shoulder 45 engaged with shoulder 42. A ring shaped valve seat member 46 has spherically shaped seat 47 having a seal 48 in a groove therearound, member 46 being disposed within valve ball housing 44 against shoulder 49. At the opposite side of valve ball 50 there is disposed another valve seat member 51 having spherical seat 52 around which is disposed a circular seal ring 53 in a suitable groove around the seat. Seat members 46, 51 are joined at opposite sides by unitary longitudinal plates (not shown) which support two opposite pins 79 in opposite ball slots 80. Opposite pins 77 are formed on valve ball 50. Slots 78 are formed in the longitudinal plates. The seats 46 and 51 are sealed inwardly and outwardly against adjacent members by O-rings 54, 55, 56, 57. A tubular piston member 58 is outwardly enlarged at 59 to fit flushly against the interior of valve ball housing 44. Between the thin walled lower portion 60 of piston 58 and valve ball housing 44 there is provided an accumulator chamber 62 which is controlled by check valve element 63 the passage to which is closed by plug 64 when not in use. Nitrogen gas under pressure, or the like, is introduced through check valve 63, with plug 64 removed, through passage 61 into accumulator space 62, before the apparatus is run into the well hole, and the pressure within accumulator 62 biases piston 58 in an upward direction to against a shoulder 65 at the interior of housing 44. An O-ring 66 is provided about housing portion 59, to seal between the piston and the housing 44. Pressure-balanced ball pusher 58A has therearound, below seat member 51, an outwardly protruding flange or collar 67 which rests against ball 50 when the piston 58 is in its upward position. A compression spring 68 is disposed between collar 67 and shoulder 69 at the interior of tube 44a, which is the upper portion of mandrel 84, to be further described later. Mandrel 84 is connected to housing 44 at threaded connection 70. A helical compression spring 71 is disposed between the lower end of housing 44 and the upper end of clutching sleeve 43. When pressured fluid is introduced into interior passage 73 through a drill string screwed into threaded socket 74 at the upper end of upper body member 10 and the pressure becomes higher than that in accumulator 62, then piston 58 is forced downwardly to compress spring 68, ball 50 being closed. Ball 50 is closed by rotation to move ball passage 76 to a transverse position by sliding of pins 77 in slots 78 while stationary pins 79 act in grooves 80 to cause ball rotation. Upon full downward movement of piston 58, the ball is rotated by 90° to move flow passage 76 to a position perpendicular to that shown in the drawing, thereby closing the ball valve against the lower seat member 51. Upon release of pressure within passage 73, the piston 58, ball 50, and ball pusher 58a are returned upwardly by spring 68, this causing opening of ball valve 50. Thus, when sufficiently pressured fluid is introduced into passage 73, piston 58 is moved downwardly to close ball valve 50, and when the pressure is relieved to a level only slightly above accumulator 62 pressure, the piston 58 moves upwardly and the ball valve 50 opens.
Briefly, the apparatus operates as follows: Middle body member 11 is rotatable with respect to upper body member 10. Lower body member 12 is rotatable with respect to middle body member 11. The engaged ends between body members 11 and 12 are angular, not perpendicular to the tool axis, so that the angle of the axis of body member 12 with respect to the axis of body member 11 (the tool axis) changes as body member 12 rotates with respect to body member 11. However, as the angle of the axis of body member 12 changes with respect to the axis of body member 11, the axis of body member 12 rotates about the tool axis. In order that this rotation of body member 12 will not occur in a fixed reference system, body member 11 is compensatingly rotated with respect to body member 10 so that as body member 12 rotates with respect to body member 11, the deviation angle of body member 12 remains in a single plane.
The relative rotation of body member 10 and 11 and of body members 11 and 12 are controlled by two barrel cams located internally in the tool at locations 81 and 82. The "rolled-out" or flattened projection of barrel cam 81 is shown in FIG. 8 and the "rolled-out" or flattened projection of barrel cam 82 is shown in FIG. 9.
A camming assembly is disposed within the bores of the body members 10-12. The camming assembly includes upper tube 84, linking tube 85, and lower tube 86. Upper tube 84 is joined to linking tube 85 at universal or U-joint 87 and linking tube 85 is joined to lower tube 86 at universal or U-joint connection 88. Tubes 84, 85, 86 are reciprocatingly movable upwardly and downwardly within body members 10-12. Lower tube 86 is constrained against rotation with respect to middle body section 11 by pin 88 which is slidably disposed in straight slot 89 at the upper end of lower tube 86. The bore 91 of upper body member 10 is coaxial with the body member, the upper bore 92 of middle body member 11 is coaxial with the body member and is enlarged in order to allow movements of the middle or linking tube 85 at universal joints 87, 88, and the lower bore 93A of middle body 11 and the bore 93 of lower body member 12 are angular or askew, as shown.
Oil injected through ports 94, 95, closeable by threaded plugs 96, 97, respectively, lubricates between camming assembly tube elements 84, 85, 86 and elements exterior thereof, and lubricates the balls 26 at the couplings between elements 10, 11 and 11, 12. Elastomeric sleeve 98 fixed around U-joints 87, 88 by band clamps 110, 111, prevents drilling mud from contaminating the lubricating oil around the camming assembly and when oil outside the camming assembly is depleted, expands to maintain the lubricating oil pressured. Guide cylinder 99 held by guide holder 100 and retained by a plug 101 screwed into body threads slides in single straight slot 102 in the exterior of clutching sleeve 43, to prevent rotation of the clutching sleeve with respect to upper body member 10. Detent ball 103 seated in recess formation 104 of plug 105 is normally engaged in opening 106 in clutching sleeve 43. When clutching sleeve 43 moves downwardly, with slide cylinder 99 sliding in groove 102, sink 107 is moved to the position of ball 103 and ball 103 enters the sink to become disengaged from detent holder 105. This action declutches sleeve 43 from body member 10 so that sleeve 43 carrying upper barrel cam pin 108 is freely movable longitudinally with respect to body member 10. Pin 108, screwed through a tapped opening through the wall of camming assembly sleeve 43, is engaged in the groove of upper barrel cam 81, the contour of which is shown in rolled out or flattened form in FIG. 8 of the drawings. The declutching of sleeve 43 from body member 10 prevents pin 108 from bottoming out in the short grooves of the upper barrel cam 81. Since camming assembly sleeve 43 cannot rotate within body member 10 because of slide cylinder 99 in slot 102, the camming action of barrel cam 81 causes rotation of upper camming assembly tube 84 within upper body member 10 and within connector adapter 15.
Elastomeric sleeve 98, previously mentioned, is held in place by band clamps 111, 110 which respectively clamp the upper end of the elastomeric sleeve to upper camming assembly tube 84 and the lower end thereof to lower camming assembly tube 86.
O-ring seals 116, and rod wiper seal 117 are provided around the lower end of camming assembly tube 86, as shown, to provide seals thereof with body member 12. Pin 118 carried by plug 119 screwed into a tapped opening through body member 12 engages a camming slot 120 in camming assembly tube 86 to control rotation of tube 86 with respect to lower body member 12. Helical compression spring 121 engages between the lower end of camming assembly tube 86 and a ported lower stop ring 122, and serves to return the camming assembly upward within body members 10-12 when fluid pressure above ball valve 50 is relieved. Lower body member 12 has at its lower end a threaded pin 123 for connection thereof to lower portions of the drill string.
When sufficiently pressured drilling fluid is introduced into passage 73 the increased pressure acts on the larger upper end of piston 58 to push the piston downwardly when the accumulator pressure is exceeded to close ball valve 50, as has already been explained. When ball valve 50 is closed, the increased pressure in passage 73 acting on the top of the closed ball valve pushes ball housing 44 downwardly, this also moving tubes 84-86 downwardly against the compression of springs 71 and 121, but does not initially move sleeve 43 downwardly. Camming assembly tubes 84-86 are moved downwardly because of the threaded connection of tube 84 to valve housing 44 at threaded connection 70. When sink 107 reaches ball detent 103, sleeve 43 is declutched from body member 10 and also moves downwardly, the pin 108 moving in the groove of upper barrel cam 81, the upper barrel cam 81 being formed on the exterior of camming assembly tube 84. The action of pin 108 in the groove of the upper barrel cam causes stepwise rotation of camming assembly tube 84 when the tube 84 is moved back up after pressure is relieved. At the same time, the lower barrel cam 82, the configuration of which is shown in FIG. 9, acts to rotate the lower camming assembly tube 86, and forces the lower body member 12 in rotation to change its angle at surfaces 11a, 12a. The incremental rotations of camming assembly tubes 84 and 86 are completed on the tube upstrokes, that is, when pressure above ball 50 is relieved and the ball opens and the springs 71 and 121 move the camming assembly tubes upwardly, as can be seen by study of the cam configurations in FIGS. 8 and 9. Thus, when pressure is increased above ball valve 50 to move the camming assembly tubes downwardly and then released so that they move upwardly, rotations of camming assembly tubes 84 and 86 occur. The lower barrel cam causes rotation of lower body member 12 to cause angular and rotational deviation thereof, and the opposite rotational deviation caused by the upper barrel cam maintains the angular deviation of tube 12 in a single fixed plane. Thus, the angular deviation of lower body member 12 can be taken through the steps corresponding to the parallel grooves of the lower barrel cam 82 from 0 degrees initially, to 5/8 degrees, 13/8 degrees, 2 degrees, and finally to 21/2 degrees and then back to zero by reverse sequence. This is done by the sole steps of increasing the drill string pressure and then reducing it. This procedure may be repeated as often as desired and in a rapid, efficient manner without running any tool down the drill string.
Restriction of the movement of fluid around the enlarged diameter of ball housing 44 damps the motion of the upper camming tube 84. The lower extension of lower camming tube 86 inside spring 121, encounters a reduced bore section when it moves through the bore of lower spring stop 122 prior to completing a full stroke. A flow restriction thus results for the fluid entering the space between the lower extension of part 86 and the lower spring stop 122, thus damping the motion of the lower tube 86. These damping features prevent impact of the camming pins within the upper and lower barrel cam grooves, and eliminate shock to the apparatus.
The bore 93 of lower body member 12 is preferably at an angle of 1.25 degrees to the tool axis (the axis of members 10-11). The angularities of the engaged ends 11a, 12a of members 11-12 are also preferably 1.25 degrees. When members 11, 12 are rotated such that their end angularities are opposed to cancel one another, then the axes of members 11-12 coincide. When members 11-12 are rotated so that their full end angularities are additive, then since the axis of rotation of member 12 is at 1.25 degrees with respect to the axis of member 11 (the tool axis), member 12 is in a rotative position such that the angularity of its bore 93 with respect to the tool axis is 2.5 degrees (1.25° bore angle +1.25° member 12 angle).
As has been mentioned, member 12 is rotated stepwise with respect to tube 86 as pin 118 moves along the course of upper barrel cam 82 (see FIG. 9). The cam grooves, acting through pin 118, force member 12 to rotate around tube 86, the cam being in tube 86 and pin 118 being carried by body member 12. Movements of pin 118 in longitudinal (parallel to the cam 86 axis) courses a-n of cam 82 do not rotate member 12, but movements of pin 118 in angular courses at the lower and upper ends of the cam groove cause member 12 rotations. The arrows in FIG. 9 show pin movements along the cam groove, and it should be understood that a relative upward pin 118 movement corresponds to an actual downward movement of tube 86, and vice versa.
Referring to FIG. 8, pin 108 moves along the course of upper barrel cam groove 81 in a similar manner, causing rotation of tube 84 (and rotatably coupled tubes 85, 86 therebelow) as the pin moves along the angular portions of the cam groove.
It should be noted that groove 81 has eight angular slot portions which correspond with the eight stages of groove 82, so that the action of cam groove 81 cancels rotation of the angular position of bore 93 for each full increment stage of its rotation by cam groove 82, so that the angular position of bore 93 remains in a fixed plane, and angular boring tendencies of the non-rotating drill string remain in a fixed plane. The drill string does not rotate during drilling, the drill bit being motor driven at the lower end of the drill string. The cam groove patterns 81, 82 can be altered to give different numbers of steps or different step sizes for increasing versus decreasing bends.
Referring to FIGS. 10-11, to explain further the functions of cam grooves 81 and 82, when lower mandrel body 86 rotates to rotate lower body member 12, the axis of lower body member 12 rotates in a circle away from and then back to the tool axis. Body member 12, FIG. 11, has the arcuate movements A-B, B-C, C-D, D-E, E-F, F-G, G-H, and H-A, totaling a full circle. The lengths of the arcs correspond to the groove spacings of the lower cam groove 82, FIG. 9. Note that point B is at a greater angle with diameter A-E (the plane of the bend of body member 12), than is point C. Points D, E have successively smaller angles with diameter A-E. Therefore, when lower body member 12 rotates from A to B, the counter rotation by upper barrel cam 81 must move body 12 back to plane A-E, through angle φ 1 . Then when body member 12 rotates to point C, the counter rotation by cam 81 is to a smaller angle with plane A-E, so that the second step of cam 81 (angle φ 2 ) is in the opposite direction to the first step of groove 81. Study of FIGS. 10-11 will explain the complete shape of cam groove 81 (FIG. 8).
For each full movement of pins 108, 118 along their respective cam grooves, tube 84 makes a partial rotational orbit within member 10 and member 12 makes a full rotation about tube 86, so that the bore 92 moves from 0° angularity through angular steps to maximum 2.5° angularity, and then stepwise back to 0° angularity. Drilling may be done with bore 92 at any selected stepwise angularity corresponding to available barrel cam positions.
The two dashed lines in FIG. 9 indicate the same position of barrel cam 82, which is cylindrically disposed about tube 86.
The described apparatus is operated in a simple manner, by simply increasing the pressure within the drill string and then reducing it, repeatedly for repeated deviations for the lower body section 12. The operation of the apparatus is entirely controlled and virtually fool proof, so that field use is accomplished without complications or breakdowns. Thus, an improved apparatus is provided which performs in an entirely suitable manner to permit angularly deviated well boring operations as and when desired.
While a preferred embodiment of apparatus according to the invention has been described and shown in the drawings, many modifications thereof may be made by a person skilled in the art, without departing from the spirit of the invention, and it is intended to protect by Letters Patent all forms of the invention falling within the scope of the following claims.
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Directional drilling apparatus for incorporation in a drill string, wherein a lower apparatus section is angularly deviated from vertical by cam action and wherein rotational displacement of the angularly deviated apparatus section is overcome by additional cam action, the apparatus being operated by successive increases and decreases of internal drill string pressure.
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The invention disclosed and claimed herein deals with a device which attaches to the exhaust of a motor ski vehicle and diverts water such that a water spray is created in the form of the well-known "rooster tail".
This device allows the diversion of a certain amount of the water passing through the exhaust of the motor ski vehicle to create a water spout behind the vehicle while at the same time allowing the motor ski vehicle to maintain the normal speeds and maneuvering that it was designed to do.
BACKGROUND OF THE INVENTION
Applicant is not aware of any patents or other publications which describe such devices as are claimed herein. Motor ski vehicles are very popular and are used by the millions as recreational vehicles on lakes and streams.
Part of the recreation is the ability to throw a long spout of water behind the vehicle as it is maneuvering across a body of water. This water spout, commonly known as a "rooster tail" has not been produced by any production models of motor ski vehicles. Some vehicles are equipped with a built-in water diverter which produces a 3/4 inch water spout, but is not commonly thought of as a "rooster tail". This equipment is utilized for safety reasons, in that, the water spout produced by this equipment is a solid water flow having a diameter of about 3/4 inches and generally rising about ten feet above the vehicle and trailing the vehicle by about eight feet, so that other watercraft can see the vehicle producing such spouts.
The device of the instant invention allows for the production of a significant rooster tail, on the order of up to about thirty feet high and about thirty feet long, yet this device does not detract from the normal speed of the vehicle, nor does it cut down on the ability of the vehicle to turn or otherwise maneuver.
THE INVENTION
The invention herein deals with a water diverting device which is detachedly attachable to the exhaust of a motor ski vehicle such that it provides a water spray or "rooster tail" from such device when the motor ski vehicle is used on the water.
Thus, the invention is a water diverting apparatus the apparatus comprising a bell housing having an outside surface, a flat front end, an angled back end, and a top surface. The bell housing has a hole through its top surface near the angled back end. The hole is surmounted by a hub, the hub having an interior surface and the hub containing an attaching means on the its inside surface.
There is a diverter assembly, which can be comprised of a unitary construction comprising three essential segments: (i) a hollow center segment which is adapted to be attached to the hub; (ii) a lower segment which is a first hollow tube having a fluid communication with and projecting downwardly from the center segment, the first hollow tube having an outside surface. The first hollow tube is essentially open through the outside surface facing the front of the bell housing. There is a third segment, (iii) which is an upper segment. The upper segment is comprised of a second hollow tube having an upper end and a lower end, the second hollow tube being surmounted on the center segment by the lower end thereof. It has a fluid communication with the hollow center segment. The upper end of the second hollow tube has an opening having essentially an elongated configuration such that a portion of any water moving through the front of the bell housing is moved into the open outside surface of the lower segment, enters and passes through the interior of the center segment, and exits the diverter assembly through the elongated opening.
In addition, the inventors contemplate within the scope of this invention the modification of the device as set forth in FIGS. 5, 6, and 7 comprising a semi-circular housing rather than a full bell housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a full side view of a device of this invention.
FIG. 2 is a cross sectional view of FIG. 1 through the line A--A.
FIG. 3 is a full front view of the device of FIG. 1.
FIG. 4 is a full back view of the device of FIG. 1.
FIG. 5 is a full side view of a device of this invention that has been modified.
FIG. 6 is a full front view of the device of FIG. 5.
FIG. 7 is a full back view of the device of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, there is shown a water diverting apparatus 1 of this invention wherein there is shown a bell housing 2 having an outside surface 3, a flat front end 4, an angled back end 5, and a top surface 6. The bell housing 2 has a large hole 7 through its top surface 6 (see FIG. 2), near the angled back end 5. The large hole 7 is surmounted by a large hub 8 and the hub 8 has an interior surface 9 (see FIG. 2), and the hub 8 contains an attaching means 10 on the interior surface 9 which is used to attached a hollow center segment 12 of the diverter assembly 13, which is described in detail infra.
The diverter assembly 13 is generally shown in FIG. 2 which is comprised generally of a unitary construction, but it is contemplated within the scope of this invention that the diverter assembly 13 can be comprised of one or more segments by the use of Luer lock® connections, or threaded parts, or the like. Preferred is a unitary construction. The diverter assembly 13 can be removed and replaced with a solid plug so as to have a true water flow through the exhaust when the user wishes to prevent a rooster tail.
The diverter assembly 13 has three general elements or segments.
The first segment is a hollow center segment 12 which is adapted to be attached to the hub 8 by the attaching means 10 as described above.
The second, or lower segment 14 comprises a first hollow tube 15 having a fluid communication with the hollow center segment 12. This segment 15 projects downwardly from the center segment 12 and opens into the bell housing 2. The hollow tube 15 has an opening 16 (FIG. 3), the opening 16 facing the flat front end 4 of the bell housing 2.
The third, or upper segment 17 comprises a second hollow tube 18 (FIG. 2) having an upper end 19 and a lower end 20. The second hollow tube 18 is surmounted on the center segment 12 at the lower end 20 and aligned therewith such that their respective hollow centers are essentially commensurate with each other. The second hollow tube 18 has a fluid communication with the hollow center segment 12. The upper end 19 of the second hollow tube 18 has an opening 21 having essentially an elongated configuration (see FIG. 4) such that a portion of any water moving through the flat front end 4 of the bell housing 2 can move into the open lower segment 14, enter and pass through the interior of the center segment 12, and exit the diverter assembly 13 through the elongated opening 21. When the water exits, it is under extreme pressure which causes the water to be ejected upwardly and creating the rooster tail effect. The major portion of the water, and any exhaust from the engine of the motor ski vehicle moves past the lower segment 14 and out through the angled back end 5 of the bell housing 2 to create the propulsion for the motor ski vehicle.
Turning now to the device as illustrated in FIG. 5, it can be observed that the device is essentially the same device as is found in FIG. 1, except that the bottom half of the bell housing 2 is removed to leave a semicircular housing 24. As is shown in FIGS. 6 and 7, the semi-circular housing 24 leaves the bottom of the bell housing 2 open.
By diverting a small portion of the exiting water by this means, the motor ski vehicle loses only a very small amount of the speed it was designed to accommodate. Furthermore, the maneuverability of the motor ski vehicle is not affected by the use of this device.
The devices of this invention can be attached to the motor ski vehicle at the manufacturer's site such as by welding in the case of metal, gluing such as in the case of plastic, threading or bolting, such as in the case of metal or plastic, or they can be configured such that they are portable and attachable to any motor ski vehicle. Thus, this invention also contemplates in addition, a means of affixing a device of this invention to a motor ski vehicle. With reference to FIG. 1, there is therefore shown holes 22 and 22', 22 shown in FIG. 1 and holes 22 and 22' shown in phantom in FIG. 3. Furthermore, contemplated within the scope of this invention is a means of adapting the bell housing 2 to the exhaust of a motor ski vehicle, which is shown in FIG. 3, as adapters 23 and 23' which are shown as a portion of a ring configuration, although the inventor herein contemplates that the adapters 23 and 23' can be one continuous ring around the inside surface of the bell housing 2.
As implied above, the devices of this invention can be fabricated from plastic or metal, especially reinforced plastics or crosslinked plastics, such as fiber reinforced nylons or urethanes, or crosslinked polyethylenes.
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A water diverting apparatus for adaptation to a recreational motor ski vehicle. The apparatus provides a water rooster tail during the operation of the motor ski vehicle without degrading the nominal speed of the motor ski vehicle or preventing agile maneuvering of the motor ski vehicle.
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TECHNICAL FIELD
This invention relates generally to a method for controlling emissions and, more specifically, to a method for controlling emissions by controlling cold start intake manifold pressure in a parallel hybrid motor vehicle.
BACKGROUND OF THE INVENTION
When an internal combustion engine (ICE) in a motor vehicle is initially started (especially in a cold climate), the interior surfaces of the engine are cold. In addition, because the engine is initially turning at a very low RPM, the intake manifold absolute pressure (MAP) is near atmospheric pressure. Because liquid fuel does not combust as easily or cleanly as gaseous fuel, it is desirable that the fuel sprayed into and mixed with the air jet traveling into the combustion cylinders of the engine be vaporized in order to reduce emissions from the ICE. Unfortunately, both the relatively high MAP and the cold condition of the engine make it difficult to vaporize the fuel injected into the combustion cylinders. Therefore, in order to produce the desired amount of power at start-up and during high-torque initial accelerations shortly after start-up when the engine is still cold, additional (i.e., excess) amounts of fuel must be pumped into the intake manifold to obtain a sufficient amount of vaporized fuel. All of the additional fuel is not completely vaporized and the incompletely vaporized fuel is not completely combusted. The consequence of the poor fuel vaporization at startup and during initial high-torque accelerations is increased emissions. The excess fuel that is not completely combusted at start-up and the period shortly after start-up creates an exhaust mixture that is too fuel-rich to be stoichiometric at the catalytic converter, thus leading to increased hydrocarbon and carbon monoxide emissions.
Under most operating conditions, once the intake valves have heated up adequately (usually within about 60 seconds after engine start-up), the excess fuel is no longer necessary, as the intake valves are hot enough to properly vaporize the injected fuel. At this time, the engine RPM is also high enough to provide a low MAP, assisting with the fuel vaporization. Even in high torque-demand situations, such as during acceleration, which causes the MAP to increase, the hot intake valves are able to vaporize the fuel so that it combusts thoroughly.
High emissions, however, can also result from rapid changes in MAP even with the engine heated, as well as from the high MAP at startup. When there is a rapid drop in torque demand, such as at the end of a rapid acceleration, the throttle closes and the MAP will quickly drop from the high MAP consistent with the rapid acceleration to a low MAP consistent with the lower torque demand. Any liquid fuel left in the intake manifold after the throttle closes rapidly flashes to a gaseous state because of the low MAP and the hot engine components. There is usually too little of this gaseous fuel to fully combust; the fuel-air mixture is too lean (has too much air present) to properly and completely ignite in the cylinder combustion chamber. The unburned fuel-air mixture is exhausted and passes to the catalytic converter. This unburned fuel-air mixture again leads to increases in the hydrocarbon and carbon monoxide emissions.
Air injection reaction (AIR) systems have been employed as one means to reduce the emissions resulting from start-up and from the driving immediately thereafter by pumping air into the exhaust manifold. The injected air helps provide the catalytic converter with a stoichiometric mixture of unburned fuel and air. Additionally, advanced engine controls and advanced fuel-swirling devices have been used to provide a more easily ignited air/fuel mixture for injection into the cylinders. Problems exist, however, with both of these approaches. The AIR system is only used for about 20 seconds at the initial start-up of the motor vehicle and has no function thereafter in the operation of the motor vehicle. The AIR system adds weight and complexity (and thus cost) to the motor vehicle and yet is only functionally necessary for a short period of time at cold start-up. The advanced engine controls and fuel-swirling techniques also add complexity and cost to the motor vehicle. Both of these methods help primarily with reducing start-up and initial emissions and are largely unable to reduce emissions in other driving situations such as conditions resulting in rapid changes in MAP.
Presently available methods for controlling emissions during cold start-up and in situations of rapid changes in MAP are costly and/or ineffective. Accordingly, a need exists for an improved emissions control method that will provide cold start intake manifold pressure control and that can provide a reliable method of limiting both the range of the intake manifold absolute pressure and the rate of change of intake manifold absolute pressure in the interests of lowered emissions throughout the operation of the motor vehicle.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the invention, a method is provided for controlling emissions in a parallel hybrid motor vehicle that includes an electric propulsion system in parallel with a combustion propulsion system. Manifold absolute pressure (MAP) is monitored in the intake manifold of the combustion propulsion system. The electric propulsion system is engaged to reduce the MAP measured in the intake manifold to a predetermined pressure, and then fueling and combustion of the combustion propulsion system are initiated only after the MAP is reduced to a pressure less than the predetermined pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The emissions control method in accordance with the invention will be understood after review of the following description considered together with the drawings in which:
FIG. 1 illustrates in graphical form the effect of intake manifold pressure on cold start fuel vaporization;
FIG. 2 schematically illustrates a parallel hybrid cold start intake manifold pressure emission control method in accordance with one embodiment of the invention; and
FIG. 3 illustrates in graphical form the cold start and drive-away MAP limiting for fuel vaporization in accordance with an embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The cold start intake manifold pressure control method in accordance with the invention is applicable to parallel hybrid powertrain motor vehicles. The parallel hybrid drive train motor vehicle includes a battery-pack operated electric propulsion system (such as an electric motor) coupled in parallel with a combustion propulsion system (such as an internal combustion engine). For ease of description, but without limitation, the electric propulsion system and the combustion propulsion system will hereafter be referred to as an electric motor and an internal combustion engine, respectively. In accordance with the invention, during start-up and any high-torque demand situations within a short but predetermined time period after start-up of the internal combustion engine (ICE), an electric motor supplements the torque that the internal combustion engine is called upon to provide so that the manifold absolute pressure (MAP), as measured in the intake manifold of the ICE, remains in a predetermined MAP range. The electric motor and internal combustion engine together provide enough combined torque to meet driving condition. The lowered MAP provides for adequate vaporization of fuel injected into the combustion chambers of the internal combustion engine even under cold engine conditions so that the cold start engine emissions are controlled. After this predetermined amount of time has elapsed, the intake valves of the internal combustion engine are hot enough to properly vaporize the liquid fuel regardless of the MAP. During and after this time period, in accordance with a further embodiment of the invention, a control unit also regulates throttle opening and torque from the electric motor in order to avoid rapid MAP changes that may result in high emissions.
FIG. 1 illustrates graphically the effect of manifold absolute pressure (MAP) as measured in the intake manifold on cold start fuel vaporization. Fuel vapor fraction is plotted on vertical axis 80 and injected liquid fuel pulse width (the amount of time the fuel injector sprays fuel) is illustrated on horizontal axis 82 . Lines 84 , 86 , 88 , and 90 illustrate the resulting fuel vapor fraction as a function of injected fuel pulse widths with intake manifold absolute pressure [measured in kilopascals (kPa) as a parameter]. Fuel path 92 appearing below the graph illustrates the effect of injected fuel pulse width on resulting vaporization. For low emission operation of the motor vehicle, it is desirable to have an injected fuel pulse width that provides the vapor fraction necessary to meet the demanded torque load, while being short enough to insure that the injected fuel remains in a spray or surface vaporization state. If the pulse width is too long, the injected fuel does not vaporize adequately and instead is present as surface droplets. In the extreme case, if excessive fuel is injected (long pulse width), liquid fuel collects and becomes a fuel puddle. Neither surface droplets nor fuel puddles combust well and are therefore detrimental to emissions. Line 94 in FIG. 1 indicates the vapor fuel fraction necessary to meet the load conditions. Thus, it can be seen that a MAP of about 70 kPa or less is desirable as it allows an injected fuel pulse width short enough to insure that the fuel path remains as spray and surface vaporization, and not as surface droplets or fuel puddles. For example, as line 90 illustrates, the injected fuel pulse width required to meet the torque demand load at a MAP of 80 kPa is too long and falls into the fuel puddle range of the fuel path. FIG. 1 also illustrates the need to control the rate of MAP change from a higher load to a lower load. As illustrated by line 90 , to meet the load requirement at a higher MAP, such as at 80 kPa, some fraction of the injected fuel is not vaporized. When the throttle plate is released, there is a sudden drop in air mass, and the MAP falls to a lower value such as 40 kPa, as line 86 illustrates. The resulting excess fuel vapor fraction that is generated at the lower pressure creates an uncontrolled fuel-rich mixture that passes uncombusted through the combustion chamber and into the catalytic converter, where it cannot be completely oxidized.
FIG. 2 illustrates schematically, in accordance with an embodiment of the invention, a parallel hybrid cold start intake manifold pressure emission control method. Intake manifold 12 conveys air to each cylinder of an internal combustion engine (ICE) 10 . In accordance with the illustrated embodiment, ICE 10 is a six cylinder engine, although the method is applicable to an ICE with a greater or lesser number of cylinders. Six fuel injectors 11 reside inside the ends of intake manifold 12 , each fuel injector proximate the intake port of one of the six cylinders. Fuel pump 15 delivers fuel to fuel injectors 11 . A pressure sensor 14 is located inside intake manifold 12 to provide measurements of the manifold absolute pressure (MAP) in the manifold. Throttle flap 28 controls the amount of air allowed to pass through intake manifold 12 to each individual cylinder in ICE 10 . The throttle flap rotates through a ninety degree arc within the intake manifold, from a “closed” position perpendicular to the air stream flow that completely blocks air flow, to an “open” position parallel to the air stream flow that allows an unrestricted air flow. ICE 10 delivers power to transmission 26 which, in turn, is coupled to the drive wheels (not illustrated) of the vehicle. Electric motor 16 draws power from battery pack 18 and is connected to ICE 10 by coupling 20 . Coupling 20 may be, for example, a system of gears, a belt drive, or the like. Coupling 20 allows the electric motor to act as a starter motor for ICE 10 as well as to provide power to transmission 26 either in parallel with ICE 10 or in opposition to it. Accelerator pedal sensor 24 measures torque demand based on the position of the accelerator pedal (not illustrated) and relays signals to control unit 22 regarding this torque demand. Control unit 22 is configured to receive communicatory signals from pressure sensor 14 and accelerator pedal sensor 24 , to send communicatory signals to fuel injectors 11 , and to send and receive communicatory signals to and from ICE 10 , throttle flap 28 , and electric motor 16 . Through these signals control unit 22 is configured to control the frequency and length of the injected fuel pulse width of the fuel injectors as well as the degree to which throttle flap 28 is open. The control unit is programmed to calculate the volume of air passing through intake manifold 12 based on the degree to which the throttle flap is open. Control unit 22 also is able to continuously adjust the frequency and pulse width of the fuel injectors to match the volume of incoming air from the intake manifold in order to create a fuel/air mixture that meets engine demand and is also highly efficient and low in emissions. The control unit also controls the amount of power electric motor 16 sends ICE 10 through coupling 20 . Control unit 22 may be, for example, a stand alone processor unit, a portion of the engine control unit, or the like.
FIG. 3 illustrates in graphical form a cold start and drive-away MAP limiting method for fuel vaporization to control vehicle emissions in accordance with an embodiment of the invention. ICE rotations in revolutions per minute (RPM) divided by twenty and MAP measured in kPa are plotted on vertical axis 30 , with time in seconds plotted on horizontal axis 32 . Dotted-line 34 represents ICE RPM, solid line 36 represents intake manifold absolute pressure, and dashed-line 38 represents fuel pulse width. Again with reference to FIG. 2, for the first start of ICE 10 at time T0, control unit 22 monitors the intake manifold absolute pressure (MAP) using pressure sensor 14 while electric motor 16 begins powering ICE 10 (with throttle flap 28 closed and without fuel being delivered to the ICE) to a high RPM, low MAP engine rotational speed such as about 500-600 RPM. Once the control unit senses, at time T1, through pressure sensor 14 , that the MAP has dropped below a predetermined upper pressure limit (for example, 70 kPa, represented on FIG. 3 by horizontal line 40 ), the control unit causes throttle flap 28 to open partially and causes the fuel pump to begin pumping fuel to the fuel injectors 11 , which then begin spraying fuel into the cylinders of ICE 10 . Control unit 22 then initiates combustion. As soon as ICE 10 begins combusting fuel and powering itself, electric motor 16 stops powering the ICE. Control unit 22 monitors torque demand based on signals from accelerator pedal sensor 24 and adjusts both the throttle flap opening and the fuel injectors' pulse width. At time T2, transmission 26 is shifted into a gear and the MAP increases slightly as the throttle flap is opened further. Time T3 represents the time at which the controller initiates a moderate acceleration or “crowd,” such as when the motor vehicle is backed out of a garage or accelerates into traffic. As more torque is demanded from the engine, control unit 22 increases throttle flap opening (to increase air flow to the ICE cylinders) and increases the injected fuel pulse width, in order to provide the cylinders with more fuel, while monitoring MAP through pressure sensor 14 . If the MAP reaches the predetermined pressure limit (line 40 ) before the ICE can meet torque demand, as illustrated at time T4 in FIG. 3, control unit 22 maintains the opening setting of throttle flap 28 and the fuel injector pulse width at their existing values (in order to keep MAP below the predetermined upper pressure limit) and, at the same time, causes electric motor 16 to provide transmission 26 (through coupling 20 ) with any additional torque necessary to meet demand. The electric motor continues supplementing the torque from the ICE until the intake manifold MAP drops below the upper pressure limit (line 40 ). In FIG. 3 shaded areas 29 and 31 represent the times electric motor 16 is supplementing the torque demand and indicate the times MAP would exceed the predetermined upper pressure limit if it were not for the use of the electric motor. Similarly, cross-hatched area 33 indicates the high pulse width fuel injection (with its attendant high liquid fraction) that is avoided by the use of the electric motor. The foregoing method, in accordance with the invention, of preventing the MAP from exceeding a predetermined upper pressure limit by controlling throttle flap opening and injector fuel pulse width and using the electric motor to provide supplemental torque necessary to meet demand continues for a predetermined amount of time (for example, 60 seconds). Once this time period has elapsed, the intake valves of the ICE should be hot enough to properly vaporize the liquid fuel, regardless of MAP. The control unit then no longer limits the fuel pump opening based on the upper MAP limit.
In accordance with a further embodiment of the invention, control unit 22 is also programmed to implement a second emission control method in response to sudden drops in torque. High emissions can result from sudden, negative changes in MAP (rapid changes from a high MAP to a low MAP that follow a drop in torque demand, such as after an acceleration) when the throttle flap is abruptly closed and liquid fuel in the intake manifold, due to the rapid pressure gradient, flashes to a gaseous state. The remaining fuel mixture, being too lean to burn properly in the cylinders, temporarily raises emissions. When control unit 22 senses, based on signals from accelerator pedal sensor 24 , a sudden drop in torque demand, control unit 22 partially closes throttle flap 28 but does not fully close it. Instead, the control unit commands electric motor 16 to provide, through coupling 20 to transmission 26 , a torque that works counter to the torque of the internal combustion engine. The electric motor thus creates a resistive torque in partial opposition to the torque from ICE 10 , so that the resultant torque, the combined torque from the electric motor and the ICE, is the amount demanded by accelerator pedal sensor 24 . Because the throttle flap is still partially open, the rapid negative change in MAP and the high emissions that result from such a change are avoided. This method of maintaining a throttle flap opening and using the electric motor to provide a resistive torque may be applied anytime during the operation of the motor vehicle when a sudden high to low MAP change might otherwise occur, whether it is during the predetermined startup time period or after this time period.
Thus, it is apparent that there has been provided, in accordance with the invention, a method for controlling emissions in a parallel hybrid motor vehicle that fully meets the needs set forth above. The device is reliable and provides low emissions throughout the operation of the vehicle, not just after a cold first engine start. Although the invention has been described and illustrated with reference to specific embodiments thereof, it is not intended that the invention be limited to such illustrative embodiments. For example, the predetermined time period after startup during which the first method of reducing emissions operates can be tailored to suit different climates or condition. Additionally, the MAP pressure range in which the internal combustion engine is to operate during the predetermined time limit can be adjusted to suit climate, fuel combustion range, and conditions for optimum engine performance. Those of skill in the art will recognize that many variations and modifications of such embodiments are possible without departing from the spirit of the invention. Accordingly, it is intended to encompass within the invention all such modifications and variations as fall within the scope of the appended claims.
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A method is provided for controlling emissions in a parallel hybrid motor vehicle that includes an electric propulsion system in parallel with a combustion propulsion system. In accordance with one embodiment of the invention, manifold absolute pressure (MAP) is monitored in the intake manifold of the combustion propulsion system. The electric propulsion system is engaged to reduce the MAP to a predetermined pressure, and then fueling and combustion of the combustion propulsion system are initiated only after the MAP is reduced to a pressure less than the predetermined pressure.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a system and method for controlling a clutch, particularly a power take-off (PTO) shaft clutch.
[0002] Various systems and methods are known for controlling a torque transmitting clutch, such as a PTO clutch for transmitting power to an attached implement. There are, for example, control systems which use sensed rotational speed to determine operating conditions of a PTO shaft clutch. Published patent DE-A-40 01 398 describes a power take-off shaft clutch which is controlled by an electronic evaluation unit and thereby can react to critical operating conditions. In particular, slip of the power take-off shaft clutch is to be avoided in order to prevent increased wear or destruction of the clutch. Sensors sense engine specific data, such as rotational speed and torque, so that the evaluation unit can react to certain limit values. If a certain engine limit rotational speed value is not reached, the power take-off shaft clutch is disengaged and the load on the driveline is removed.
[0003] The system of DE-A-40 01 398 also senses the rotational speed values at the inlet and the outlet of the power take-off shaft clutch, and monitors the clutch slip by comparison of these values. When pre-determined values of slip are exceeded, the electronic evaluation unit disengages the power take-off shaft clutch by means of a control valve. However, disengaging the clutch when the slip limit values are exceeded leads to an interruption of the operating process that can only be resumed after a renewed clutch engagement process. A similar condition occurs when an engine rotational speed limit is not reached and the PTO shaft clutch is disengaged, in order to reduce the load on the engine driveline. In this case, the clutch can be re-engaged only under restricted operating conditions.
[0004] It would be desirable to provide a method and a system for controlling a PTO clutch and which overcomes the aforementioned problems. In particular, it would be desirable to monitor the load on the clutch during the operation of attached implements, so that overload conditions on the driveline as well as on the attached implement and the components connected to it can be avoided.
SUMMARY
[0005] Accordingly, an object of this invention is to provide a PTO clutch control system which maintains a constant slip in the clutch.
[0006] This and other objects are achieved by the present invention, wherein a pressure operated PTO clutch of an agricultural vehicle connects an input driveline to an output driveline for coupling to an attached implement. A method and system for controlling the PTO clutch includes sensors for sensing rotational speeds on both sides of the clutch. Clutch slip is determined from the sensed speeds. A controller receives an actual slip signal and a desired slip signal and controls pressure in the clutch to maintain a constant desired clutch slip in order to avoid overload conditions on the input driveline or the output driveline of agricultural machines and their attached implements. A signal representing the torque transmitted by the clutch is displayed to an operator. The torque transmitted by the clutch is determined as a function of the slip in the clutch and the clutch pressure.
[0007] A controller maintains the slip at a constant value independent of the torque transmitted, by actively controlling the clutch pressure. Since the torque transmitted by the clutch has an approximately linear relationship with the clutch pressure and the valve current, these parameters can be utilized to determine the torque transmitted by the clutch. The higher the valve current, and therewith the pressure level at which the clutch can be operated at the desired slip, the higher is the torque transmitted by the clutch. The load or torque transmitted by the clutch is determined as a function of the constant slip value and the clutch pressure.
[0008] Detecting load by electronically controlling slip has been shown to be useful in PTO shaft drives. The control can react to changes in the load so rapidly that a stable operation with relatively constant slip is possible. During testing on a PTO clutch brake with a defined load it could be shown that the clutch pressure and therewith the valve control electrical current are representative of the torque in the PTO shaft and that it is possible to determine load during operation. A further advantage of the slip control is the protective function against overload. Shock loads and related torque peaks in the PTO shaft driveline during operation are intercepted and damped by short term peaks in the slip of the PTO shaft clutch.
[0009] The clutch slip is preferably maintained at a predetermined standard slip value, such as between 0.1% to 2.0%. The most appropriate value has been found to be a standard slip value of approximately 0.5%.
[0010] Slip is maintained constant by varying the clutch pressure with a valve, preferably a proportional pressure control valve. Valve electrical current is utilized as control magnitude for the control of the slip. Preferably, the control magnitude is limited by an input of a maximum control magnitude so that a maximum torque cannot be exceeded in the PTO shaft, thus protecting the vehicle driveline, the PTO shaft gearbox and the drive for the attached implement.
[0011] The maximum control magnitude can be inputted manually or automatically by an identification system on the attached implement which can be plugged into a CAN, ISO, LBS or a similar interface in a “Plug-and-Play” manner.
[0012] The PTO shaft clutch control system includes sensors and an evaluation system. The sensors detect a rotational speed on each side of the clutch. The evaluation system, which is part of an electronic control system, determines the slip in the clutch considering the gear ratio of the clutch system. The control system continuously senses clutch pressure. Clutch pressure is controlled to maintain clutch slip at a constant value. The torque transmitted by the clutch is determined from the constant value of the slip and the clutch pressure. Preferably, the electronic control is an integrated controller and is configured corresponding to DIN 19226.
[0013] The invention determines the torque transmitted by the clutch using simple sensors, and displays this information continuously to the operator. With this invention the torque transmitted by the clutch can be limited to protect the driveline and the attached implement against overloads. In addition, sudden changes in the torque are prevented by short-term increases in the clutch slip. The invention is extremely economical because no significant increase in sensor capability is required.
[0014] This control system may be applied to agricultural machines which have a PTO shaft connected to an attached implement. The PTO shaft clutch is preferably a wet multi-disk clutch such as used on John Deere series 6010 to 6910 agricultural tractors. Such clutches have a very high durability, even when subjected to slipping operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a schematic diagram of a control system for controlling the slip of a PTO shaft clutch.
[0016] [0016]FIG. 2 is a control system diagram of the present invention.
DETAILED DESCRIPTION
[0017] Referring to FIG. 1, an internal combustion engine 10 drives a drive shaft 12 . A rotation speed sensing gear 14 is coupled to drive shaft 12 . A hydraulic PTO shaft clutch 16 connects the drive shaft 12 with a two-stage PTO shaft gearbox 18 that transmits torque to a PTO shaft 20 . An implement 54 can be connected to the PTO shaft 20 or the PTO stub shaft. As is well known, the engine 10 drives the vehicle drive wheels (not shown) through a vehicle gearbox (not shown).
[0018] The input stage 22 of the PTO shaft drive gearbox 18 is connected to a hydraulic brake 24 which can brake and stop the entire PTO shaft output driveline. A gear 26 is mounted on the PTO shaft 20 for sensing the output shaft rotational speed. Rotational speed sensors 28 and 30 sense the rotational speeds of the drive shaft 12 and the PTO shaft 20 and supply speed signal n 1 and n 2 to an evaluation unit 34 which is integrated into a control unit 32 . The evaluation unit 34 determines the slip X of the clutch 16 from speeds n 1 and n 2 and receives a gear ratio signal of the PTO shaft gearbox 18 , from an appropriate sensor (not shown).
[0019] The clutch 16 and the brake 24 are controlled by a electrohydraulic proportional valve 42 , which in a first position, as shown, connects the clutch 16 with a hydraulic pump 44 and connects the brake 24 with an unpressurized reservoir 46 . In a second position the proportional valve 42 connects the brake 24 with the hydraulic pump 44 and connects the clutch 16 with the reservoir 46 . Proportional valve 42 controls the pressure in clutch 16 and maintains the pressure in clutch 16 proportional to the magnitude of the electrical current applied to the solenoid of valve 42 .
[0020] A pressure sensor 36 transmits a clutch pressure signal P to the evaluation unit 34 . Unit 34 determines the torque transmitted by the clutch 16 as a function of the clutch slip and the clutch pressure, and supplies a torque signal to display 48 . A target slip value input unit 38 provides a target slip value Xs to the control unit 32 so that the controlled value of the slip can be adjusted. Evaluation unit 34 receives the target slip value Xs, compares it to the actual slip X, and provides a differential slip value Xd as an input to controller 40 . Controller 40 operates as shown FIGS. 2 and 3 and provides a solenoid control electrical current to the solenoid of proportional valve 42 to maintain the slip in clutch 16 at the desired target slip.
[0021] A manual input unit 50 , such as a rotary potentiometer placed in the vehicle cab (not shown), can be used to set a limit value for the valve current and thereby the pressure in the clutch or the maximum torque that can be transmitted by the clutch 16 . The control unit 32 uses this limit value to avoid overload conditions on the input driveline as well as the output driveline.
[0022] An implement connected to the PTO shaft 20 can be identified to the control unit 32 by an interface 52 , such as a CAN, ISO, LBS or similar interface, to which can be coupled a connector (not shown) in a “Plug and Play” manner. For each type of attached implement a maximum torque value can be stored in the control unit 32 , so that torque can be limited to a maximum value specific to the particular attached implement.
[0023] Referring now to FIG. 2, the engine 10 rotates at a rotational speed of n 1 and delivers torque M 1 , which is transmitted by the clutch 16 and gearbox 18 to a PTO shaft 20 . The PTO shaft 20 rotates at a rotational speed of n 2 and transmits the output torque MA to the attached implement 54 . An actual slip value X is a function of rotational speeds n 1 and n 2 , of the transmission ratio of the PTO shaft gearbox 18 , of the disturbance magnitude Z 2 , which depends on the friction coefficient or wear condition of the clutch, and of disturbance magnitude Z 3 , which depends on the load of the attached implement 54 . The actual slip value X is compared with a predetermined slip target value Xs of, for example, 0.5%.
[0024] The resulting slip differential value Xd is an input to the controller 40 . Preferably, the response of controller 40 varies depending upon the range of the input value Xd. In response to the slip differential value Xd, the controller 40 supplies to valve 42 a valve current control signal Y. In response to signal Y, valve 42 controls the pressure in clutch 16 and or in the brake 24 . Clutch pressure P is also a function of pressure variations represented by disturbance magnitude Z 1 . Controller 40 is designed to maintain slip difference Xd as small as possible and preferably equal to zero, and to thereby maintain the slip of clutch 16 at the desired constant slip target value Xs.
[0025] Since at a constant controlled slip, a known relationship exists between the drive torque MA operating at the PTO shaft 20 and the current in the valve 42 , which can be determined by tests or by theoretical calculations, the output torque MA can be determined from the existing slip value and the current in the valve 42 .
[0026] Preferably, the controller is optimized with respect to its response to disturbances, and to prevent increased slip. If, however, a sudden increase in the torque occurs during operation at the PTO stub shaft and as a result the slip exceeds the predetermined value, for example, of 0.5%, then the controller reacts accordingly and increases the current to the valve 42 and increases the clutch pressure. During very rapid changes in the power requirement of the attached implement very high undesirable slip can occur for brief periods, so that the control must react sufficiently fast, in order to maintain the slip as constant as possible.
[0027] In order to assure an optimum and rapid control response, the response of controller 40 varies depending upon the magnitude of the actual slip X. For example, controller 40 may have three different sets of control parameters, each for one of three corresponding ranges of actual slip X. Such control parameters may include a proportional amplification parameter, Kp( 1 - 3 ) and a response time parameter Tn( 1 - 3 ), such as defined by DIN 19266, so that the controller will have a proportional and integral performance and will perform dynamically. Preferably, the response of the controller will be faster and more aggressive for higher actual slip values, so that the proportion of time at increased slip values is reduced. Preferably, an operator may manually adjust the controller 40 to optimize its performance in response to sudden disturbances.
[0028] While the present invention has been described in conjunction with a specific embodiment, it is understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the claims.
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A PTO clutch of an agricultural vehicle connects an input driveline to an output driveline for coupling to an attached implement. A method and system for controlling the PTO clutch includes sensors for sensing rotational speeds on both sides of the clutch. Clutch slip is determined from the sensed speeds. A controller receives an actual slip signal and a desired slip signal and controls pressure in the clutch to maintain a constant desired clutch slip in order to avoid overload conditions. The torque transmitted by the clutch is determined as a function of the slip in the clutch and the clutch pressure, and a signal representing this torque is displayed to an operator.
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TECHNICAL FIELD
[0001] The present invention generally concerns the cooling of heat generating electronic circuits and equipment.
BACKGROUND
[0002] A general trend in the different sectors of the electronics industry is that for each generation microprocessors, network processors, signal processors, ASICs and many other circuits show higher performance levels and require higher power. The most critical part of circuit board thermal design is now handling the Hot-Spots, in the form of fewer but hotter components.
[0003] Heat pipes are known to be a very good but expensive solution for handling heat transfer problems. The basic function of a heat pipe is that it moves heat from one place to another. In electronic systems heat pipes are used for transferring heat from a Hot Spot (such as a processor etc.) where the heat dissipation problem is hard to solve, and to a free space that can hold a large heat sink or is very near a fan. Heat pipes are now a mainstream technology used in most laptop computers and volume production has driven the price down. An ordinary heat pipe is now a standard product, available in several diameters and lengths from multiple manufacturers to a cost off less than a dollar. The cost can be expected to go down further in the near future as new manufacturing plants are set up and manufacturing volumes go up.
[0004] Until now, heat pipes have been a low volume niche technology for real high performance systems. They are now getting into the mainstream in the high volume segments. However, the problems with existing heat pipe design solutions are still the same as before, they are tailor-made for each design and they target optimal cooling efficiency rather than flexibility and ease of design.
SUMMARY
[0005] It is a general object of the present invention to provide an improved cooling assembly for cooling individual small series applications of electronic equipment as well as an improved method of manufacturing a low-cost, flexible cooling assembly for electronic equipment.
[0006] It is another general object of the invention to provide an improved method of designing such a cooling assembly for cooling individual small series applications of electronic equipment.
[0007] In particular it is an object of the invention to suggest a cost efficient way to provide flexibility in designing and manufacturing cooling assemblies using heat pipes to remove heat from heat-generating electronic equipment.
[0008] These and other objects are met by the invention as defined by the accompanying patent claims.
[0009] The invention generally relates to the removal of heat from heat-generating electronic equipment mounted on circuit boards by means of heat collectors attached to the equipment and in thermal contact with heat pipes transferring heat to heat sinks spaced from the equipment. It has been recognized that essentially improved, combined heat transfer and cost efficiency may be achieved by providing a simple and robust way of establishing good and reliable thermal contact between heat pipes and heat sinks. A basic idea is to use the circuit board itself for applying the pressure on the thermal interconnect by attaching heat sinks to the circuit board, overlying the heat pipes.
[0010] In accordance with a further aspect of the invention improved cost efficiency in the design and manufacture of cooling assemblies for small series production of such electronic equipment applications, may be obtained by optimizing the assembly for cost and flexibility while still maintaining excellent heat transfer efficiency. A basic idea of this aspect is to provide standardized and modular heat transfer components for such a cooling assembly. Such components primarily include standardized heat sinks that in the required number and/or size are attached as modules to the circuit board, overlying the heat pipes. Said components may likewise comprise standard type heat collectors for attachment to heat-generating equipment and/or heat pipes of standardized length and design for transferring heat from the heat collectors to the heat sinks.
[0011] By forming one or several continuous heat pipe receiving grooves in a bottom surface of the heat sink modules the heat sinks may be attached in optional positions as well as numbers to the circuit board, simultaneously securing the heat pipes to the circuit board.
[0012] In an embodiment that may be specifically preferable for space constrained applications it is preferable to use a heat sink area also on the backside of the circuit board. This is achieved by providing a heat sink consisting of upper and lower parts that are attached to the circuit board from either side and that between them secure the heat pipes to the circuit board.
[0013] In another embodiment a single profile of a suitable material is used for providing a standard range of modular heat sinks, thereby achieving heat sink solutions for a wide power range.
[0014] Preferably, a range of standard heat pipes is provided that includes not only straight pipes but also curved, U-shaped as well as S-shaped heat pipes. Including such heat pipe designs in a standard range not only greatly enhances the flexibility of designing the cooling assembly but also contributes to absorbing vibrations and shock.
[0015] A cooling solution according to the present invention offers a number of advantages, including:
Simple and robust circuit board assembly; Allows for establishing good thermal contact between heat sink and heat pipe; Mechanically robust, thereby meeting requirements on vibration and shock; Minimizes design cost and reduces/eliminates tooling cost, thereby; Supporting low and medium volume products; Scalable in cooling capacity; Standardized parts allows for low cost manufacturing; Short time to market; Reusable solution that fits different chips; Very low profile to support dense board spacing in sub racks.
[0026] Advantages offered by the present invention, in addition to those described above, will be readily appreciated upon reading the below detailed description of embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention, together with further objects and advantages thereof, will be best understood by reference to the following description taken together with the accompanying drawings, in which:
[0028] FIG. 1A is a partly schematical illustration of a first embodiment of a cooling assembly according to the invention, mounted on a circuit board;
[0029] FIG. 1B is a partly schematical section through a standardized heat sink and heat pipe attached to the circuit board in the assembly of FIG. 1A ;
[0030] FIG. 2A is a partly schematical illustration of a second embodiment of a cooling assembly according to the invention, mounted on a circuit board;
[0031] FIG. 2B is a partly schematical section through a standardized heat sink and heat pipes attached to the circuit board in the assembly of FIG. 2A ;
[0032] FIG. 3 is a partly schematical section of a third embodiment of a heat sink and heat pipes attached to a circuit board in an assembly according to the invention;
[0033] FIG. 4 is a partly schematical section of a forth embodiment of a heat sink and heat pipes attached to a circuit board in an assembly according to the invention;
[0034] FIG. 5A is a partly schematical side view of an embodiment of a cooling assembly according to the invention, employing an S-shaped heat pipe;
[0035] FIG. 5B is a schematical top view of the of the cooling assembly illustrated in FIG. 5A ;
[0036] FIGS. 6A-G schematically illustrate further alternative embodiments of the inventive cooling assembly; and
[0037] FIGS. 7A-B illustrate further exemplifying embodiments of heat sinks for use in cooling assemblies according to the invention.
DETAILED DESCRIPTION
[0038] The invention will now be explained with reference to exemplifying embodiments of the cooling assembly of the invention, which are illustrated in the accompanying drawing figures. A first exemplifying embodiment of the invention is illustrated in FIGS. 1A and B, and relates to an application of the inventive solution to a partially and very schematically outlined circuit board 9 containing at least one electronic component 3 in the form of a processor or other heat generating component. It shall be emphasized, though that the illustrations are for the purpose of describing preferred embodiments of the invention and are not intended to limit the invention to the details thereof.
[0039] In accordance with the invention the heat generated by the electronic component 3 is removed from the component and transferred to a free available space 9 A on the circuit board 9 by means of a cooling assembly 1 . Said cooling assembly 1 consists of a heat collector 2 that is attached to the electronic component 3 , in thermal contact therewith. The heat generated by the component is transferred from the area of the component 3 by means of a heat pipe 7 that is positioned with a portion thereof in direct thermal contact with the heat collector 2 . At another portion thereof the heat pipe 7 is positioned in thermal contact with a heat sink 4 that is attached to the circuit board 9 at the free space 9 A, distant from the component.
[0040] Furthermore, in accordance with the invention, the heat collector 2 may be individually selected from a standard range of heat collectors. The size and design of the heat collector 2 is chosen for the specific application, in the applicable case dependent on the chip package, for example the height of the component 3 . The heat pipe 7 and the heat sink 4 are likewise individually selected from a standard range of heat pipe sizes and designs and heat sink sizes and designs, respectively. Specifically, a standard range of heat sinks is provided wherein each heat sink 4 has at least one groove 8 formed in a bottom surface 6 A of a body 6 thereof, said body 6 having cooling fins 5 provided on an opposite surface.
[0041] The groove 8 is extended continuously from one end of the heat sink 4 and to an opposite end thereof, and has a size adapted to the size of the heat pipe 7 of said standard range. Upon assembly, the selected heat sink 4 is attached to the circuit board 9 , overlying the heat pipe 7 that is introduced into the corresponding groove 8 . When mounted, the heat pipe 7 is therefore squeezed between the heat sink 4 and the circuit board 9 . Thereby said heat pipe 7 is secured between the heat sink 4 and the circuit board 9 in direct thermal contact with the heat sink 4 as well as with the circuit board 9 . For easy mounting, the heat sink 4 is simply screwed to the circuit board 9 by means of a screw or bolt 10 , so that the circuit board 9 will itself in effect be used as one part of a fixture for holding the heat pipe 7 . The screw 10 is preferably positioned a small distance from the heat pipe 7 . The fact that the circuit board 9 is elastic and the tension built up in the material by tightening the screw 10 , will be used to apply constant pressure to an applied, below described thermal interface material TIM, so that a good thermal contact will be secured throughout the lifetime of the assembly, even when it is subjected to vibration, shock etc. during transport and operation. This way of securing the heat sink 4 and the heat pipe 7 to the circuit board 9 is much more simple and robust than the use of a spring or flexible clip to apply force.
[0042] Thermal interface material TIM may be used between the heat pipe 7 and heat sink 4 and normally the groove 8 in the heat sink 4 is prepared with such a TIM 11 to simplify board assembly. In particular, in accordance with an advantageous further development of the inventive idea, the TIM 11 is pre-applied to the heat sink 4 and especially in the area of its groove. This means that the heat sink 4 is prepared before the actual assembly of the circuit board and its components. Such thermal interface material TIM may preferably also be provided between the heat pipe 7 and the circuit board 9 , although not specifically illustrated here. By the direct contact between the heat pipe 7 and the circuit board 9 , the circuit board 9 will itself work as an area extension and give some contribution to the cooling effect. The circuit board may also contribute to the heat dissipation in case there is some thermal contact to the power or ground plane, for example with thermal vias.
[0043] For the cooling assembly 1 of the invention, a standard range of heat collector sizes and designs, a standard range of heat pipe sizes and designs and a standard range of heat sink sizes and designs are first provided as modules. Then, the cooling capacity required for the specific application is calculated and the appropriate heat collector, heat sink and heat pipe sizes and designs for that application are individually selected. It will be realized that by means of the suggested individual selection and assembly of the parts of the cooling assembly 1 , desired design flexibility is achieved without any loss of cooling capacity. The described solution is to use standard modular heat sink and heat pipe elements that can be added onto the circuit board 9 to achieve the required cooling capacity. By the manufacturing of a cooling assembly 1 of the invention, the heat pipe 7 and the heat sink 4 are assembled in a cost efficient way that allows for this flexibility. This is done mainly by defining standard components that are optimized for lowest cost of components rather than optimal efficiency and that are made an integrated part of the circuit board solution. In other words, parts of the cooling assembly 1 are assembled as part of the board production instead of the prior art use of pre-fabricated cooling assemblies for each board design. The manufacturing of such prior art tailor-made cooling assemblies will involve high design and tooling costs rendering the assembly expensive unless the manufacturing volumes are very high.
[0044] With the described cooling assembly 1 of the invention, the basic concept of the invention is embodied by a very low cost and flexible heat pipe cooling solution that takes heat pipes from being a niche technology to a standard design element in circuit board design. What makes this possible is on the one hand the higher integration of components that leaves free space on circuit boards for heat sinks, and on the other hand the low cost of the heat pipes.
[0045] Both the heat sink and the heat pipe elements have pricing that depends heavily on volume. Examples of heat pipe pricing show a considerable decrease in cost when going from a volume of 1000 to a volume of 100,000 items. In effect, in such a case the cost per item may be reduced to one third. This means that the ability to reuse the same components is much more important for cost than having an optimal thermal design. For example, it is better to use two heat pipes of a less efficient standardized design that are purchased in volume, than using one that is optimized. The size and number of heat pipes used for specific applications depends on the needed heat transfer capacity, as is exemplified in the second embodiment of the invention illustrated in FIGS. 2A-B as well as in the further exemplifying embodiments of FIGS. 3 , 5 A-B and 6 A-G. In the embodiment of the cooling assembly 101 illustrated in FIGS. 2A-B , two heat pipes 107 A and 107 B are placed in thermal contact with the heat collector 102 on the component 103 and with the heat sink 104 . In this case a bottom surface 106 A of the heat sink 104 is provided with two spaced grooves 108 A, 108 B for receiving the two heat pipes 107 A, 107 B. Furthermore, the illustrated heat pipes 107 A, 107 B are curved to provide additional flexibility to sustain shock and vibration and differences in temperature expansion in the circuit board 109 and the heat pipes 107 A-B in themselves.
[0046] In FIG. 3 is illustrated a further embodiment of a heat sink 204 that is similar to the previously illustrated embodiments, except that it is provided with two grooves 208 A and 208 B having different size to allow for the flexibility of using heat pipes 207 A and 207 B of different size. Furthermore, this embodiment of the heat sink 204 is also used to exemplify that the heat sinks of the provided range may differ in the height of the cooling fins 205 extending from the main body 306 as well as in the pitch between the fins 205 . The height of the fins 205 may be chosen depending on board pitch in a rack and the pitch between the fins 305 may be chosen depending on the available air speed.
[0047] In FIG. 4 is illustrated an alternative embodiment using a heat sink 304 that consists of two main body parts 306 B and 306 C of which the upper part 306 B carries the cooling fins 305 on an upper surface and the heat pipe receiving grooves 308 A-B on its lower surface 306 A. The second heat sink part 306 C is provided on the back of the printed circuit board 309 and is secured to the upper heat sink part 306 B by means of a bolt 310 or other appropriate fastener. Depending on the available space it can be advantageous to have such a heat sink area also on the backside of the circuit board. To be efficient, the heat pipe should then be squeezed between the two parts 306 B, 306 C of the heat sink 304 in the illustrated manner. This provides for the best thermal connectivity. In the illustrated embodiment, an upper surface of the lower heat sink part 306 C is provided with bosses 312 for contacting the backside of the circuit board 309 . In this manner the flexibility of the heat sink material can be used to fasten the heat sink 304 to the circuit board 309 , as is shown in the drawing figure. This mode of fastening is not critical for the operation but may be preferred for avoiding vibrations during transport etc.
[0048] In the embodiment of the cooling assembly 401 illustrated in FIGS. 5A-B , an S-shaped curved heat pipe 407 is used to transfer heat from the heat generating component 403 and the heat collector 402 and to the heat sink 404 . Such an S-shaped heat pipe 407 will block less air and will also make it possible to employ the same heat pipe for components having different height. It will also assist in absorbing vibration and shock.
[0049] The heat pipes may be provided in the same direction as the airflow, which will allow for the advantageous manufacturing of the heat sinks from extruded aluminum. Expressed otherwise, the grooves in the bottom surface of the heat sinks are preferably extended parallel to the heat sink cooling fins, which will allow for the extrusion of the heat sinks with the grooves. Any other orientation of the grooves would require subsequent machining of the grooves or casting of the entire heat sinks. Such alternatives would result in higher manufacturing costs and higher tooling costs, respectively. In a specifically preferred embodiment, a single aluminum profile can be used for achieving heat sink solutions for a wide power range. The profile is then cut up in several modular sizes so that heat sinks of different modular size may be combined for specific applications having specific cooling requirements. Providing such a modular, standard range of heat sinks that are also provided with multiple heat pipe receiving grooves, will make it possible to combine freely different numbers and designs of heat sinks and heat pipes, as is shown in the exemplary embodiments of FIGS. 6A-G . In this case, it may also be practical to pre-apply the TIM to the heat sink profile before cutting it up into the modular sizes. It shall be noted that the schematic illustrations in the drawing figures do not specifically show designs of heat sinks that are intended for extrusion, but only generally illustrate the principles of the invention. Therefore, heat sinks that are adapted to extrusion techniques may have a slightly different actual design.
[0050] FIGS. 6A , 6 B and 6 C illustrate that in addition to the previously illustrated embodiments employing curved heat pipes, the cooling assembly 501 , 601 , 701 of the invention may naturally also be formed using one or several straight heat pipes 507 , 607 A, 607 B and 707 A, 707 B, respectively. In FIGS. 6C-6E is likewise illustrated that more than one heat sink 704 A, 704 B, 804 A-C and 904 A-D may be mounted along the same heat pipe or heat pipes 707 A-B, 807 A-B and 907 A-B, respectively. FIGS. 6D and 6E also illustrate the use of U-shaped heat pipes 807 A-B and 907 A-B, respectively, having heat sinks at both ends to double the cooling capacity. FIGS. 6F and 6G illustrate that the cooling assembly 1001 and 1101 , respectively of the invention may be used for cooling several heat generating components 1003 A, 1003 B and 1103 A, 1103 B, respectively. In the illustrated embodiments heat is transferred from two heat-generating electronic components 1003 A, 1003 B; 1103 A, 1103 B and to a common heat sink 1004 and 1104 , respectively, by separate heat pipes 1007 A, 1007 B; 1107 A, 1107 B. In this case curved and or S-shaped heat pipes 1007 A-B and 1107 A-B are preferably used.
[0051] Finally, FIGS. 7A-B schematically illustrate examples of further variations of the heat sink modules 1204 , 1304 of the cooling assembly according to the invention. In both these examples, the heat sink 1204 , 1304 is formed having a body 1206 , 1306 that is thicker in the area where the heat pipes are located and thinner in all other areas. As is illustrated, this variant may be applied to heat sinks 1204 , 1304 having one or several grooves for receiving the corresponding heat pipes. Such variants are well suited for the above discussed extrusion of the heat sinks, since the costs for making an extrusion die even for a rather complex cross-section shape, is very reasonable.
[0052] In alternative, but not specifically illustrated embodiments of the invention variations of the different illustrated parts of the cooling assembly may be employed without departing from the scope of the invention. One example thereof is the use of a thin “heat plane” instead of heat pipe. A heat plane is similar in function to a heat pipe. Heat planes can be made very thin, less than 2 mm, one or several such heat planes may be squeezed between a circuit board and the heat sink in a similar way as heat pipes of the invention. Heat planes are much more expensive than heat pipes today but may be considered as an economical alternative in the future.
[0053] In another advantageous alternative solution, the thermal interface material TIM is pre-applied to the grooves of the heat sinks. Preferably, in the above described embodiment where heat sinks are cut up from extruded profiles, the TIM is also applied to the extruded profile before cutting it up into the individual heat sinks.
[0054] Specifically, the invention also covers the possibility of providing a range of heat sinks for all applications, said heat sinks being provided with multiple grooves to be prepared for multiple heat pipes, even though only one or a few grooves may be used for a specific application. The circuit board can also allow for thermal connection from the heat pipe to the power/ground planes and thereby contribute as an additional area extension.
[0055] Although the invention has been described and illustrated with specific reference to an application for cooling a chip package, the invention is in no way restricted to such applications. The basic principles of the invention may be applied to provide cooling for any “Hot Spot” on a circuit board.
[0056] The invention has been described in connection with what is presently considered the most practical and preferred embodiments, but it is to be understood that the invention is not limited to the disclosed embodiments. The invention is therefore intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A cooling assembly and method of cooling a heat-generating electronic component on a circuit board. A heat collector collects heat from the electronic component. A heat pipe transfers the heat to a location remote from the electronic component. A heat sink is mounted to the circuit board at the distant location. The heat sink has at least one groove formed on an underside thereof. The heat sink is mounted so that is overlies the heat pipe and the heat pipe is introduced into the groove, thereby securing the heat pipe between the heat sink and the circuit board.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the construction of buildings, and in particular to an improved method of constructing a high-rise or multi-storey building utilizing prefabricated steel panels, and a building made according to this method.
2. Description of the Prior Art
While the use of prefabricated metal panels is known in the prior art, such panels have been limited in their applications to use in the construction of residential or low-rise commercial buildings. Such constructions have been known in the construction industry for several years, but have not been adopted in the construction industry today as being a feasible method of constructing high-rise building structures.
In particular, U.S. Pat. No. 2,076,728 to Keller discloses the use of prefabricated metal structural units which can be transported to the job site, together with a prefabricated floor and roof units, to be erected into a residential type building. This patent, however, does not disclose the direct connection between vertically adjacent panels, but rather utilizes a complicated three-way connection between the vertically adjacent panels and a superimposed prefabricated floor structure situated therebetween. Such a building structure does not provide a shear wall type of construction which is essential today in wall structures utilized for high-rise or multi-storey buildings. By shear wall type, it is meant a construction which will resist lateral forces as well as vertical load bearing. As a result, the structure according to this patent does not provide an effective continuous stiff wall-type of structure from the foundation to the top of the building and could not, therefore, meet the structural requirements associated with wall structures utilized in high-rise construction today.
A similar type of building construction unit to the Keller building structure is disclosed in U.S. Pat. No. 2,191,804 to O'Malley. This patent likewise deals with frame sections which can be utilized for the wall partitions, or other parts of a dwelling house, or other small buildings. As in the Keller patent, this disclosure likewise does not make provision for an effective stiff continuous wall structure from the foundation of the building to the top thereof, utilizing prefabricated building construction units. Both the above patents require expensive and interfering horizontal bridging and diagonal bracing between the vertical studs.
That the prior art methods of utilizing prefabricated metal panels in the erection of a building are not feasible in the construction of high-rise buildings is clearly apparent from the presently utilized methods in the construction industry today. In particular, the present methods of erecting a high-rise or multi-storey structures utilize columns extending the height of the building which are of poured concrete construction. The floors of the building are made from poured concrete and necessitate the erection of a temporary supporting structure to permit the pouring of the concrete and to support the poured concrete in place during curing thereof. The supporting structure most frequently utilized today comprises a large number of the screw-type jacks which are spaced quite closely together, approximately 2 or 3 feet, and support layers of plywood are placed on flat plates situated at the upper end of each jack. This method of construction has a number of drawbacks which, to date, have not been overcome by any known method of constructing high-rise buildings.
One of the obvious drawbacks of the present system of erecting high-rise buildings, noted above, is the fact that the erection of the jacks and the placing thereon of the plywood supporting surface for the concrete is quite time-consuming, and in view of labour costs today, considerably increases the cost of construction of a building. Additionally, due to the close spacing of the screw-type jacks, the area in which the jacks are erected cannot be worked in until the curing of the poured concrete floor thereabove is completed. In this respect, the curing time of such a concrete floor, depending upon the thickness thereof, may be of the order of two to twelve weeks. After the curing process is completed, it is then necessary to dismantle the screw-type jacks and to remove the plywood supported thereby, further adding to the inefficiency of this process.
Additionally, the wall structures within the interior of the building are today manufactured from reinforced concrete or masonry. However, there are a number of drawbacks with the use of wall structures of this kind. In particular, in the case of prefabricated reinforced, concrete walls, handling thereof becomes a problem due to their considerable weight, and they are also subject to damage during handling due to their brittleness. On the other hand, in the case of walls made from concrete blocks at the site, construction thereof is time-consuming and, therefore, expensive. As an additional factor, such concrete block walls necessitate the use of temporary shoring to hold them in place until the floor of the next level is completed. In a situation where shoring is not used to support the masonry wall prior to completion of the floor above, the wall is subject to the varying weather conditions and can be blown over by the wind, thereby necessitating rebuilding of the wall.
A further drawback associated with reinforced concrete and masonry walls is their excessive weight. Since the foundation of the building is built in accordance with the total weight of the building, the cost of the foundation increases considerably due to the additional weight of reinforced concrete and block walls which it must support.
A further factor which detracts from the use of reinforced concrete or block walls is the necessity of heating such wall structures during the winter-time construction thereof in order to permit the proper curing of the concrete or mortar. Certainly, this problem becomes more pronounced in colder climates and adds to the construction of the building which is taking place during the winter months. Proper curing of the concrete or mortar used in the reinforced concrete or block walls is effected by placing tarpaulins around the concrete or masonry block walls and subjecting the same to heat from a temporary source of heat for a period of three to four days during the curing of the mortar or concrete. As well, erection of such walls necessitates the use of skilled labour.
SUMMARY OF THE INVENTION
The present invention proposes to overcome the drawbacks associated with the known existing methods of constructing high-rise or multi-storey building by utilizing prefabricated steel panels of tubular construction which can be erected at the job site by unskilled labour, necessitating only that the workmen tighten down nuts on the portions of the threaded fasteners extending above the upper surface of the lower chord of the panels after the same have been mounted in position. This precludes the necessity of direct contact between vertically adjacent upper and lower panels. After the nuts have been tightened by the workmen, the resulting walls formed from the prefabricated panels are self-supporting laterally and do not require temporary shoring to support them in position, as in the case of reinforced concrete or block walls. Further, cold temperatures do not affect the installation of the prefabricated panels according to the present invention, as in the case of walls which necessitate the curing of concrete or mortar for an extending period of time. As a result, a wall built with prefabricated panels according to the present invention is temporarily self-supporting in the lateral direction during construction and, therefore, not susceptible to the disadvantages of reinforced concrete or block walls. Further, the weight of the walls utilizing the present invention is a small fraction of the weight associated with similar reinforced concrete or block walls which are capable of supporting the same load. Further, walls made from the prefabricated steel tubing are not susceptible to damage during transport and erection, as in the case of prefabricated concrete and prefabricated block walls.
A substantial advantage is derived from using the method and building construction according to the present invention in that a building construction is provided by means of threaded fasteners interconnecting vertically adjacent prefabricated panels such that an effective continuous wall structure is provided from the foundation to the roof of the building. Thus, threaded fasteners not only support the prefabricated panels in place prior to construction of the floor above, but also permit a form of shear transfer between the floor and the resulting wall structures. Shear walls not only support bearing loads from the floors above, as in the case of standard bearing walls, but also act as stiffeners to resist overturning of the building due to wind forces or forces created during an earthquake. The walls provided by the method according to the present invention thus function as stiffener walls by utilizing the threaded fasteners to interconnect vertically adjacent panels as well as supporting the bearing loads of the floors thereabove. In presently constructed buildings, shear walls may be made from poured concrete having a length of approximately 20 feet and a width of 8 inches, and extend continuously the entire height of the building. Such concrete walls likewise function as huge stiffeners to prevent the building from bending about a horizontal axis. However, such a shear wall construction is not only time-consuming to erect, but also adds considerably to the weight of the building and, therefore, to the cost of the foundation to support the additional building weight.
This invention can be used equally in buildings with concrete slab floors, or in buildings with concrete floors supported by steel joists or beams. The advantages of the steel joist method are that no shoring is required since the joists are of course supported by the steel walls. Furthermore, the space between the joists and the depth of the joists permits central mechanical and electrical installation thereby reducing the expense thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment thereof, and in which:
FIG. 1 is a perspective view of a portion of a high-rise or multi-storey building, broken away to illustrate the constructional features thereof;
FIG. 2 is an enlarged vertical section taken along line 2--2 of FIG. 1;
FIG. 3 is an enlarged vertical section taken along line 3--3 of FIG. 1;
FIG. 4 is a side view taken along line 4--4 of FIG. 3;
FIG. 5 is a perspective view of one embodiment of the method of constructing the prefabricated metal panels;
FIG. 6, which is on the same sheet as FIG. 4, is a perspective view of a further embodiment of a portion of a high-rise or multi-storey building fabricated according to the present invention, partly broken away to illustrate the constructional features thereof; and
FIG. 7 is an enlarged vertical section taken along line 7--7 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As best illustrated in FIG. 1, the portion of a high-rise or multi-storey building includes poured concrete floors 10 and 12 formed during the construction thereof. Both poured concrete floors 10 and 12 are supported during the curing of the concrete by temporary shoring indicated generally by reference number 14. The upper surface of each poured concrete floor supports the series of prefabricated steel panels 16 of tubular construction. Each panel 16 includes a lower horizontal chord 18 and an upper horizontal chord 20, the lower and upper chords being interconnected by spaced-apart vertical studs 22 which are welded at opposite ends thereof to the respective horizontal chords.
The lower chord 18 rests on the surface of the concrete floor and, as best illustrated in FIG. 2, includes vertical openings 24 which receive the upper portions of bolts 26 extending above the surface of the concrete floor 10. The bolt 26 is secured to the upper chord 20 of the prefabricated panel situated vertically beneath the panel 16.
After the prefabricated panel 16 is located in position on the upper bolt portions, the prefabricated panels are retained in position by means of nuts 28 which are secured to the upper ends of the bolts 26 and are tightened in position. The lower chord 18 of the panel 16 is provided with reinforcing channel portions 30 in line with vertical openings 24 and also having aligned openings therein for receiving the upper bolt portions. The reinforcing angle portions 30 are welded to the upper surface of the lower chord 18 and stud 22 and are designed to reinforce the lower chord and thereby prevent bending thereof during tightening of the nuts 28.
The upper chord 20 of each panel 16 is also provided with vertical openings 32 for receiving the lower portions of the high-tensile anchor bolts 26. The openings 32 in the upper chord 20 are aligned with the correponding vertical openings 24 in the lower chord 18 of the vertically adjacent panels to permit alignment of the openings during installation of the panels. The lower surface of the upper chords 20 are likewise provided with respective channel portions 34 adjacent vertical openings 32 in the upper chords 20.
The high-tensile anchor bolts 26 also support angle pieces 36 within the reinforcing channels 34. The angle pieces 36 are provided with an opening 38 in the downwardly extending leg portion, the opening 38 designed to support a hook of a chain block 40, illustrated in phantom in FIG. 2, the block and tackle 40 being used to raise or lower shoring used for constructing the upper poured concrete floor.
As best seen in FIG. 2, the high-tensile anchor bolt 26 extends upwardly through the vertical opening in the upper chord 20 of the panel 16, with the nut 42 bearing against one leg of the angle piece 36.
A construction is illustrated in FIGS. 1 and 7. In this construction, panels 16 support permanent steel joists 68, utilized to support the concrete floor 10. The use of steel joists permits the use of a concrete floor having a depth lesser than that using no steel support. The use of steel joists, however, has the disadvantage that the depth of the joists lowers the effective usable vertical space between the lower surface of the joists and the floor situated therebeneath. Nevertheless, the use of steel joists can be utilized depending on the building application. The advantages of the steel joist method are that no shoring is required since the joists are of course supported by the steel walls. Furthermore, the space between the joists and the depth of the joists permits central mechanical and electrical installation thereby reducing the expense thereof.
As shown in FIG. 7, the steel joists 68 have shoe portions 70 which extend outwardly beyond the end of the joist from an upper surface thereof, the lower surfaces of the shoe portions resting on the upper surface of the upper chord 20 of the panel 16. The series of aligned joists are thereby supported by the upper surfaces of the panels 16 at approximately 24 inch centers, with each third or fourth joist being welded in position to the panel 16 to provide rigidity and to support the upper ends of the panels in position. Plywood is then supported in position by the joists and the concrete is then poured over the plywood. The upper portions of the joists are thus supported in the concrete, and the plywood is stripped from the lower surface of the floor after curing of the concrete is completed.
It should further be noted, as illustrated in FIG. 7, that the upper panel 16 can be installed in position prior to pouring of the concrete floor. To achieve this, a third nut 74 is mounted on the high tensile anchor 26 at a distance spaced above the nut 42. The upper surface of the nut 74 corresponds to the floor level of the concrete floor to be poured. The panel 16 can then be placed on the anchor bolt 26 and temporarily held in position by the studs 74 and secured thereto by the nuts 28. In this way, erection of vertically adjacent walls can be effected prior to pouring of the concrete floor between the vertically adjacent walls.
In the embodiment shown in FIGS. 6 and 3, prior to pouring the upper concrete floor, temporary shoring 14 is installed in position. The temporary shoring 14 includes channel members 46 having aligned horizontal slots therein, adjacent the ends thereof, as best seen in FIG. 4. The channels are raised into position utilizing the block and tackle 40 and rest on angle members 48 which are welded on side surfaces of vertical studs 22, as best seen in FIG. 3, at locations spaced from the upper chord 20. The channel members 46 rest on the angle members 48 and two channel members 46 are supported by each vertical stud 22 and are secured together by means of bolts 50 extending through the horizontal slots 46a in the channel members 46, as best seen in FIGS. 3 and 4. The channel members 46 are of such a length as to extend between horizontally adjacent walls comprising the prefabricated steel panels and to extend slightly beyond the wall portions, such that each channel member 46 is releasably secured to its adjacent channel member by means of bolts 50 located on both sides of the stud 22. The arrangement of slot 46a in the channel members 46 permits the use of random lengths of channels 46. Thus, the channels may be reusable without modification. Wood fillers 52 are releasably mounted to the upper surface of the channel members 46 by means of suitable fasteners 54. Plywood 56 is then placed on top of the wood fillers 52 so that the plywood lies loosely on the wood fillers 52. An upper portion of the upper chord 20 projects slightly upwardly of the upper surface of the loose lying plywood 56, so as to provide a keying action with the poured concrete floor, as illustrated in FIG. 2. The channel members 46 can be replaced by wide flange members which have been suitably modified to permit temporary securing together adjacent the ends thereof, in the same manner as illustrated in FIGS. 3 and 4.
The method of attaching the steel studs 22 to the respective chords 18 and 20 will vary depending upon the bearing load to be supported by the panel. For example, under normal loading conditions, the vertical studs 22 rest on the inner surfaces of the upper and lower chords 18 and 20 and are welded to the chords along the width of the respective chords. However, where the panels are to be used in association with heavy bearing loads, the construction such as illustrated in FIG. 5 can be utilized. In this case, a pair of spaced-apart slots 58 are provided in the upper surfaces of the lower chord 18, the spaced-apart slots 58 receiving downwardly projecting wall portions 60 extending downwardly from a lower surface of the vertical stud 22. The height of the projecting wall portions 60 corresponds to the depth of the tubular steel chord 18 such that a lower surface of the projecting wall portions 60 is situated adjacent to the lower surface of the lower chord 18. In this position, the projecting wall portions are welded to the chord. In this way, axial loading in the vertical stud 22 is transferred to the lower surface of the lower chord 18, which rests directly on the surface of the poured concrete floor. As a result, the bearing loads are transferred directly to the concrete floor, thereby preventing collapse of the lower chord in the situation where the lower surface of the vertical stud rests on the upper surface of the lower chord. The same construction is also used for studs connected to upper chord 20 in a reverse manner.
After installation of the temporary shoring and the laying in position of the plywood, concrete is then poured over the plywood surface. By utilizing the channel members 46, it is possible to avoid the use of screw-type jacks to support the plywood in position during pouring and curing of the concrete. The installation of the jacks and the fact that a large number of such jacks are necessary to support the concrete associated with known methods of building construction is avoided by the present invention. After curing of the concrete, the temporary shoring is removed by undoing bolts 50 so as to permit removal of the channel members 46 and the plywood 56, which is supported thereby. Gypsum or plaster board could then be applied to the outer surfaces of the panels 16 by first attaching directly to the vertical studs 22 or by attaching sheet metal channels 62 to the vertical studs 22, as best seen in FIG. 1. The sheet metal channel 62 is attached to the vertical studs by means of suitable fasteners 64 and clips can be utilized for attaching the plaster board 66 to the sheet metal channels 62.
The prefabricated steel panels 16 are made of either rectangular or square cross-sectional tubular members which are welded together. The square or rectangular cross-sectional tubular members provide optimal transfer of bearing loads to the concrete floor, as well as providing flat surfaces to which plaster boards or similar paneling could be attached. Additionally, the most efficient steel section to support heavy loading such as in the present application has been found to be a hollow tubular member which is either square or rectangular in cross-section. The rectangular section provides an optimum strength to weight ratio in comparison to I-beam or channel sections which are much heavier and more expensive and which must be stiffened by horizontal bridging and diagonal bracing.
It is also within the scope of the present invention to utilize prefabricated metal panels which have already been provided with Gyproc prior to installation thereof at the site. In this way, it would be possible to minimize the expense associated with on site construction to simply securing the panels in position by means of nuts.
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A multi-storey building construction utilizing prefabricated metal panels of tubular construction which can be erected at the job site by unskilled labor and adapted to support vertically spaced-apart floors, whereby the plurality of floors are separated by parallel rows of walls, each wall comprising the tubular metal panels. Each row of walls is in vertical alignment but not in direct contact with corresponding rows of walls situated on vertically adjacent floors, and each vertically adjacent row is interconnected by high-tensile strength threaded fasteners rigidly interconnecting the upper and lower chord of each panel to an adjacent chord of a vertically adjacent panel. The rows of vertically interconnected prefabricated metal panels provide effective continuous lightweight shear walls extending from the foundation of the building to the roof. The shear walls support loads imposed on the building and provide stiffness to the building to resist natural forces which otherwise tend to overturn the building.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit and priority of Korean Patent Application No. 10-2012-0081304, filed Jul. 25, 2012. The entire disclosure of the above application is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to an energetic reactive plasticizer for a plastic bonded explosive, and specifically to an energetic reactive plasticizer for a plastic bonded explosive which has high performance and insensitiveness without a migration problem of a plasticizer by being bonded with a polymer binder for a plastic bonded explosive.
BACKGROUND ART
[0003] Currently, efforts to make energetic materials insensitive have been a significant issue in development of explosives and a propellant. As a part of such efforts, plastic bonded explosives (PBXs) having low sensitivity and improved mechanical properties while maintaining high energy properties have been developed. Such PBX now becomes an elementary component of high-energy explosives, polymeric binders and other additives used in a small amount such as a plasticizer or a stabilizer.
[0004] Currently, a polyurethane polymeric binder on the basis of a hydroxyl-terminated polybutadiene (HTPB) has been used as a widely applicable polymeric binder system, together with various additives so as to improve processability, mechanical properties and chemical stability. Although such polymeric binder shows excellent properties in making high-energy materials insensitive, it has been proposed that it generally disadvantageously reduces the energy density of PBX on the whole owing to its low energy potential. In this regard, many studies have been being made to increase the whole energy density through development of energetic binders and plasticizers containing energetic functional groups such as, for example, nitro (C—NO 2 ), nitrate (O—NO 2 ), nitramine (N—NO 2 ), azido (—N 3 ) and difluoroamino (—NF 2 ) and application thereof.
[0005] The term “energetic functional groups” as used herein has common and general meaning as used in the field of molecular explosives, i.e, referring to functional groups, when being applied to a molecular explosive or a plasticizer, known to contribute to the increase in the whole energy level of PBX to which the explosive or plasticizer were applied. Nitro (C—NO 2 ), nitrate (O—NO 2 ), nitramine (N—NO 2 ), azido (—N 3 ), difluoroamino (—NF 2 ) or the like as described above may be mentioned. The term “energetic” as used herein means that the whole energy level of a molecular explosive is more increased by any known methods comprising the introduction of such “energetic” functional groups.
[0006] However, those polymeric binders and plasticizers which comprise such energetic functional groups have problems such as low heat stability, non-compatibility with explosives and low processability. Therefore, it has been an important rising issue to ultimately achieve both high performance and insensitiveness in explosives. Further, when an energetic plasticizer is applied, an additional problem such as a migration of the energetic plasticizer from PBX occurs over a long period of time. Such migration of an energetic plasticizer involves further additional problems in PBX such as increase in sensitivity to impact and decrease in storage stability and long-term stability owing to deterioration in mechanical properties. Therefore, the realization of an explosive having both high performance and insensitiveness still has been an important matter to be achieved in this field of art.
[0007] When a highly energetic polymer which can satisfy both high performance and insensitiveness at the same time is prepared, it is anticipated to obtain a novel energy material which is combined with a molecular explosive and a binder and has an excellent performance and safety.
SUMMARY OF THE INVENTION
[0008] The present invention is to provide an energetic reactive plasticizer which can satisfy the high performance and insensitiveness required in the next-generation explosives without a plasticizer migration and thereby preventing various problems accompanied with such migration.
DETAILED DESCRIPTION OF THE INVENTION
[0009] PBX is majorly composed of a molecular explosive and a prepolymer and a curing agent for the formation of a binder, and additionally comprises other additives such as a plasticizer on necessary. All the components are introduced, mixed together and then loaded into a container for an explosive, this procedure of which is called a casting process. The prepolymer and the curing agent react in the container to form a binder while solidifying the components in the container.
[0010] The ‘reactive plasticizer’ is a high energy alkyne compound having low viscosity, which can be served as a plasticizer during mixing of PBX and attached to a polymer in a casting or curing process as above. The reactive plasticizer acts as a plasticizer in the preparation of PBX, and a part of or the whole plasticizer is bound into a binder by click reaction by itself in a curing process of the final preparation process.
[0011] The present inventors have found that by using a reactive plasticizer in a way of introducing high energy prepolymers in PBX preparation process, it acts as a plasticizer during the casting process, thereby solving the conventional viscosity problem and further it binds to a binder during a curing process, thereby reducing bleeding or migration of a plasticizer, and thus completed the present invention.
[0012] In other words, the present invention provides a novel reactive plasticizer having high energy potential by comprising a high energy functional group as well as a functional group which can react with a corresponding energetic prepolymer/a curing agent during a curing process in the preparation of a binder for PBX, thereby being bound to the high energy polymer binder as a side chain thereof.
[0013] The energetic reactive plasticizer according to the present invention binds with a side chain of a binder via a click reaction between azide and acetylene groups during the curing process. For such reaction, the energetic reactive plasticizer of the present invention comprises acetylene functional groups and the bond between the energetic functional group and the reactive functional group is an ether bond. In this regard, the novel energetic reactive plasticizer according to the present invention may be classified as an ether-based reactive plasticizer having high energy potential, considering the type of bond characteristically formed in the backbone of the compound is an ether bond.
[0014] The ether-based energetic reactive plasticizer is an ether-based compound obtained according to the following reaction scheme 1:
[0000]
[0000] (wherein, n=a natural number selected from 1-10). As seen from the above reaction scheme 1, the reactive energetic plasticizer containing ether groups in the backbone chain is formed by the acetal formation reaction between 2,2-dinitropropanol (DNP—OH) and an acetylene-containing alcohol (AA).
[0015] The acetal formation reaction is carried out by the reaction between aldehyde and an excessive amount of alcohol, under the conventional reaction conditions known in this field of art, so that an energetic reactive plasticizer comprising ether groups in the backbone chain is synthesized by the competitive reaction between DNP—OH and an acetylene-containing alcohol. The acetylene-containing alcohol used in the above reaction includes for example, propargyl alcohol(n=1) and 3-butyn-1-ol(n=2), resulting in 3-((2,2-dinitropropoxy)methoxy)propyne (DNPMPY) or 4-((2,2-dinitropropoxy)methox)-but-1-yne) (DNPMBY), respectively.
BRIEF DESCRIPTION OF DRAWINGS
[0016] FIG. 1 is a plot showing the FT-IR spectroscopy result of DNPMPY.
[0017] FIG. 2 is a plot showing the DSC result of DNPMPY.
[0018] FIG. 3 is a plot showing the FT-IR spectroscopy result of DNPMBY.
[0019] FIG. 4 is a plot showing viscosity changes of GAP polyol prepolymer, prepared DNPMPY and a mixture thereof (1:1 by weight) over temperature, respectively, as measured in the test example 1.
EXAMPLES
Preparation Example 1
[0020] Synthesis and Analysis of 3-((2,2-dinitropropoxy)methoxy)propane(DNPMPY)
[0021] An energetic reactive plasticizer, DNPMPY was synthesized by an acetal forming reaction as shown in the following reaction scheme 2.
[0000]
[0000] 30 mL methylene chloride (MC), DNP—OH (5 g, 33.56 mmol) and propargyl alcohol (PA) (5.64 g, 100.68 mmol) were placed into a 2-neck flask under nitrogen atmosphere, and then 1,3,5-trioxane (2.21 g, 24.61 mmol, or para-formaldehyde) was further placed with stirring. The mixture was stirred at 0° C. for 10 minutes and then BF 3 .OEt 2 (10.48 g, 73.83 mmol) was slowly added dropwise. The reaction temperature was elevated to a room temperature and maintained for further reaction for 3 hours. The reactant was poured into 50 mL distilled water, washed with a NaHCO 3 (10%) solution and then further washed twice or more with distilled water. After removing the solvent under reduced pressure, it was further purified by chromatography (eluted by ethylacetate:hexane=1:5), thus obtaining DNPMPY.
[0022] The conformation of DNPMPY obtained was identified by the following methods. Firstly, 1 H and 13 C NMR were used to identify the molecular structure, resulting in: 1 H NMR (CDCl 3 , d, ppm): 2.20 (—CH 3 ), 2.45 (═C—H), 4.20 (—CH 2 —), 4.30 (—CH 2 —), 4.75 (—CH 2 —). 13 C NMR (CDCl 3 , d, ppm): 20.0, 55.5, 69.0, 79.0, 94.5, 117.5. The elemental analysis (%) regarding the synthesized DNPMPY was carried out, and the results were as follows: calculated for DNPMPY (%): C 38.53, H 4.62, N 12.84, O 44.01, measured: C 38.95, H 4.25, N 13.64, O 43.16.
[0023] As represented in FIG. 1 , synthesis of DNPMPY was identified from the absorption peaks of functional groups in FT-IR spectrum results, and the results were as follows: IR (cm −1 ) 3300 (═C—H), 2930 (aliphatic, C—H), 2300 (—C═C—), 1590 (—NO 2 ).
[0024] Thermal characteristics of the prepared energetic reactive plasticizer, DNPMPY were measured by differential scanning calorimetry (DSC) and the results were represented in FIG. 2 .
[0025] According to the DSC results, the glass transition temperature (T g ) of the prepared energetic reactive plasticizer, DNPMPY was −89° C., which was about 35° C. lower than Tg of glycidal azide polymer (GAP) plasticizer (−55° C.).
Preparation Example 2
[0026] Synthesis and Analysis of 4-((2,2-dinitropropoxy)methoxy)-but-1-yne) (DNPMBY)
[0027] An energetic reactive plasticizer, DNPMBY was synthesized by an acetal forming reaction as shown in the following reaction scheme 3.
[0000]
[0028] 30 mL methylene chloride (MC), DNP—OH (4 g, 26.85 mmol) and 3-butyne-1-ol (BO) (5.52 g, 80.55 mmol) were placed into a 2-neck flask under nitrogen atmosphere, and then 1,3,5-trioxane(1.61 g, 17.9 mmol, or para-formaldehyde) was further placed with stirring. The mixture was stirred at 0° C. for 10 minutes and then BF 3 .OEt 2 (11.44 g, 80.55 mmol) was slowly added dropwise. After stirring at 0° C. for 40 minutes, the reaction temperature was elevated to a room temperature and maintained for further reaction for 5 hours. The reactant was poured into 50 mL distilled water, washed with a NaHCO 3 (10%) solution and then further washed twice or more with distilled water. After removing the solvent under reduced pressure, it was further purified by chromatography (eluted by ethylacetate:hexane=1:7 v:v), thus obtaining DNPMBY. The conformation of DNPMBY obtained was identified by the following methods. Firstly, 1 H and 13 C NMR were used to identify the molecular structure, resulting in: 1 H NMR (CDCl 3 , d, ppm): 2.09 (═C—H), 2.15 (—CH 3 ), 2.44 (—CH 2 —), 3.61 (—CH 2 —O—), 4.35 (—O—CH 2 —O—), 4.68 (—CH 2 —O—). 13 C NMR (CDCl 3 , d, ppm): 20.0, 20.1, 67.1, 69.0, 70.2, 82.1, 96.5, 117.5.
[0029] The elemental analysis (%) regarding the synthesized DNPMBY was carried out, and the results were as follows: calculated for DNPMBY (%): C 41.38, H 5.21, N 12.06, O 41.35, measured: C 41.60, H 5.34, N 12.97, O 40.09).
[0030] As represented in FIG. 3 , synthesis of DNPMBY was identified from the absorption peaks of functional groups in FT-IR spectrum results, and the results were as follows: IR (cm −1 ) 3300 (═C—H), 2930 (aliphatic, C—H), 2300 (—C═C—), 1590 (—NO 2 ). Plasticization properties of the prepared plasticizer used for PBX preparation were determined by measuring decrease in viscosity of a mixture of said plasticizer and a prepolymer as well as decrease in a glass transition temperature, and the results were shown in the following test example.
Test Example 1
[0031] Decrease in Viscosity of a Prepolymer Due to the Plasticizer
[0032] For measuring viscosity, a viscometer, MCR 301 from Anton Paar Physica Co. was used by using a parallel plate having a 1 mm gap (CP25-1-SN9356, diameter=25 mm) at the temperature range of 30-60° C. at a constant shear rate of 1.0 s −1 with a temperature elevation rate of 1° C./minutes. After measuring viscosity of GAP polyol prepolymer per se, viscosity of a mixture of DNPMPY plasticizer obtained by the above preparation example 1 and the GAP polyol prepolymer (1:1 w/w) was measured, so as to determine the plasticization properties represented by the decrease in viscosity. The test results obtained from the case where a plasticizer obtained according to the preparation example 1, i.e. DNPMPY was applied were represented in FIG. 4 . As shown in FIG. 4 , as compared to viscosity of a GAP polyol prepolymer, viscosity of a mixture of the plasticizer prepared according to the present invention and a GAP polyol prepolymer was significantly lower, over the whole temperature range measured, thereby showing the significant plasticizing effect of the synthesized DNPMPY plasticizer according to the present invention.
[0033] The plasticizing effect represented by the decrease in viscosity of a conventionally used energetic plasticizer such as BDNPF/BDNPA; BDNPF/BDNPDF; BDNPF/BDNBF was also shown in the following table 1 for comparison. Viscosity was measured under the same test conditions as described in relation with viscosity measurement of the plasticizer prepared according to the present invention. For reference, viscosity of GAP polyol prepolymer itself was 6,015 cP at 30° C. and 1,035.5 at 60° C., respectively.
[0000]
TABLE 1
Viscosity of a mixture of GAP polyol prepolymer/plasticizer(1:1
w/w) at 30° C. and 60° C.
Composition
Viscosity (cP)
(1:1 w/w)
30° C.
60° C.
GAP:DNPMPY
931
227
GAP:BDNPF/BDNPA
1,441
295
GAP:BDNPF/BDNPDF
1,211
197
GAP:BDNPF/BDNBF
1,351
274
BDNPF: bis(2,2-dinitropropyl) formal
BDNPA: bis(2,2-dinitropropyl) acetal
BDNPDF: bis(2,2-dinitropropyl) diformal
BDNBF: bis(2,2-dinitrobutyl) formal
[0034] As seen from Table 1, it can be confirmed that the DNPMPY plasticizer prepared according to the present invention has an excellent viscosity lowering effect in the GAP polyol prepolymer.
INDUSTRIAL APPLICABILITY
[0035] The energetic reactive plasticizer according to the present invention is designed to be present in a form bound to the polymeric binder through covalent bond with the branch of the polymeric backbone of polymeric binder during a curing process, so as to prevent a conventional migration or exudation problem of an energetic plasticizer from the molded plastic PBX, while ensuring the essential physical properties required in an energetic plasticizer used in plastic PBX preparation, such as increased energy density and enhanced processability by lowered viscosity in a blending process.
[0036] When the energetic reactive plasticizer according to the present invention is applied to the plastic PBX preparation, the conventional plasticizer migration problem from plastic PBX can be prevented, leading to further advantageous effects such as an improvement in long term storage property of PBX and energy density increase in the whole composition.
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Disclosed is an energetic reactive plasticizer for a plastic bonded explosive (PBX), and specifically an energetic reactive plasticizer for PBX which has high performance and insensitiveness without a plasticizer leak by being bonded with a polymer binder for a plastic bonded explosive.
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BACKGROUND OF THE INVENTION
This invention relates to a wave energy converter (WEC) designed to provide improved efficiency under normal operating conditions and to have improved survivability to large amplitude waves.
A WEC, as shown in FIGS. 1A and 1B , may include a float 100 and a shaft/spar 20 with a power take off device (PTO), 30 , connected between the float and shaft. The float is generally designed to move in synchronism with the waves. The shaft 20 may be designed to be stationary (e.g., anchored to the sea bed as shown in FIG. 1A ) or it may be designed so that it can move up and down, in phase with the float but with a time delay relative to the float and/or generally out of phase with the waves and the float, as shown in FIG. 1B , in a configuration which may be referred to as a “dual absorber”. In any case, the PTO is connected between the shaft and the float for converting their relative motion into useful energy (e.g., electrical power or different forms of mechanical energy).
The floats 100 of prior art WECs tend to be formed to be generally symmetrical (e.g., circular or square) about the x-y axes, as shown in FIG. 1C . The WECs used may be of the “point absorber” type where the term “point absorber” is generally defined to mean that the characteristic dimension of the float of the WEC is small in relation to the (longer) wave length of the waves, driving the WEC.
In many situations the amount of power that can be produced by a WEC is a function of the surface area of the float subject to be acted upon (lifted or lowered) by the waves. The buoyant force on the float can be estimated as the change in displaced volume of the float as a wave passes by. For waves having a very long wavelength impinging on a float (e.g., the wavelengths are much longer than the dimensions of the float in width or length), the change in displaced height of the float is essentially the same all over the surface of the float. For this case, the shape of the float is not significant in considering its power producing capability. However, for waves impinging on a symmetrical (e.g. circular) float having a wavelength comparable to the dimension of the float, when one side of the float is under the crest of the wave, the other side or edge of the float is not under the crest. When this occurs there is a cancellation effect. The buoyant forces of the wave do not act (e.g., lift) across the full surface area of the float. In this instance, the amount of power that can be produced is significantly reduced.
This may be better explained with reference to FIG. 1D which illustrates the effect of a wave on a symmetrical float (section B of 1 D) and an asymmetrical float (section C of 1 D). Section A of FIG. 1D shows a wave 901 , having a period of 7 seconds, a wave height of 2 meters and a wavelength of approximately 75 meters. For purpose of illustration, waveform 901 is shown to have a peak value (crest) at point K, a lower value at a point L, which is 5.5 meters away from the crest, and a still lower value at a point M, which is 11 meters away from the crest. Consider now a prior art circular float 100 (as shown in section B of 1 D) having an outer diameter of 11 meters which is subjected to waveform 601 . As shown in the drawing, the left side of the float (K) lines up with the peak of the wave crest. It is evident that, for this wave condition, only part of the float's surface area will be subjected to the full force corresponding to the wave amplitude. The rest of the float will be subjected to a lower force and may even be pushing down, canceling the up-lifting force. Thus, the power developing/producing capability of the float 100 is significantly reduced. For waves whose wavelength is even less than that shown for wave 901 , it is evident that even less power can be developed and produced.
To overcome this problem, it is proposed that the float be made asymmetrical, as per the top view shown in section C of FIG. 1D . For example, there is shown an elliptical float 10 with a length of 22 meters (long side) and a width of 5.5 meters (short side). The area of the symmetrical float in B of FIG. 1D is essentially the same as the area of the asymmetrical float in C of FIG. 1D . As may be seen, essentially the full surface area of the asymmetrical float will be subjected to the full force of the wave 901 . So, from the point of view of power production it is desirable to have an asymmetrical float with its longer side facing the direction from which waves are incident. Clearly, the non-symmetric float has preferred characteristics for wave energy conversion for waves having shorter wave lengths, relative to the size of the float. That is, for waves having shorter wave lengths, relative to the size of the float, a properly oriented non-symmetrical float of similar area to a symmetrical float will convert wave energy to a useful form of electricity more efficiently, i.e., more of the power in the wave will be converted to a useful form of power than for a prior-art symmetrical float.
Therefore, for waves whose wavelengths are within a “normal” range (e.g., ranging from less than a 5 second period to more than a 14 second period), it is desirable to have an asymmetrical float to capture more wave energy and optimize wave power conversion. However, Applicants recognized that a significant drawback exists to the use of the asymmetrical float because: (1) the direction of the incoming waves may vary undoing the benefits sought; and (2) it has greater susceptibility to being damaged under storm conditions. That is, where the typical wave amplitude is less than 4 meters, the WEC is designed to be operational for and survive the typical wave condition. However, under storm conditions where the wave amplitudes are greater than normally expected (e.g., the waves have amplitudes greater than 4 meters) greater buoyant forces are applied to the asymmetrical float and significantly higher forces are developed between the float and spar tending to damage the WEC and its PTO. In consideration of these problems, there is no known WEC system with an asymmetrical float which is raised and lowered by the waves.
Thus, while it is desirable to have the long side of an asymmetrical float facing incoming waves for improved wave energy conversion, there is a problem with the survivability and operability of the WEC under storm and varying wave conditions.
SUMMARY OF THE INVENTION
Applicants' invention resides in part in the recognition of the problems discussed above and, in part, in the recognition that, for power conversion efficiency an asymmetrical float should be used. Applicants' invention also resides in the recognition that: (1) the float should be rotated so its long side faces the incoming waves in order to increase energy capture; and (2) the float should be re-oriented (rotated) so its profile to oncoming storm condition waves is decreased in order to reduce the application of excessive, potentially destructive, forces and in order to increase the survivability of the WEC. Thus, WEC systems embodying the invention include means for rotating the WEC as a function of wave conditions.
Note that the term “normal” wave condition refers to a range of wave amplitudes for which the WEC is designed to be operational (and which are within the range of amplitudes typically encountered at the site where the WEC is intended to be located) and that the term “storm conditions” refers to the conditions existing when the wave amplitudes exceed the normal range.
A WEC embodying the invention includes an asymmetrical float intended to move generally, up and down, in phase with the waves and a spar which is either stationary or which is designed so that it can move up and down, in phase with the float but with a time delay relative to the float, and/or generally, up and down, out of phase relative to the float. A PTO is connected between the float and spar to convert their relative motion into useful energy (e.g., electric power). The asymmetrically shaped float has a longer side and a narrower side. The WEC includes apparatus for orienting the longer side of the float so it faces the incoming waves for increasing the wave energy conversion efficiency of the WEC and for orienting the float so its narrower side faces the incoming waves under storm conditions to improve the survivability of the WEC.
The float has top and bottom surfaces which extend generally parallel to the water surface and the float moves up and down generally in-phase with the waves. The spar extends in a direction generally perpendicular to the surface of the water. The float is “asymmetrical” (e.g., rectangular or oblong). That is, the float will have a “longer” (or “beam”) side and a “narrower” (“shorter” or “head”) side; its length (L) will be greater than its width (W). The longer side is designed to normally face the incoming waves to improve the power conversion efficiency of the WEC to incoming waves whose frequency and wavelength is within a predetermined range.
In accordance with one embodiment, the float may be designed to have a width which is small compared to the range of the normally expected wavelengths of the incoming waves.
To reduce excessive stresses to which the WEC may be subjected during storm conditions, WECs embodying the invention include means for selectively, or automatically, (e.g., actively or passively) re-orienting the asymmetrical float so that during “normal” operating conditions the long side of the float faces the incoming waves and during a “storm” condition the shorter, narrower, side faces the incoming waves. Thus, the long side of the float will be turned towards the waves under those conditions where it is desired to produce power, and the short side of the float will be turned towards the waves under storm conditions to reduce stresses to which the WEC may be subjected.
In accordance with one aspect of the invention, the asymmetrical float may be keyed (interleaved, or engaged) to the spar to allow the float and spar to move up and down relative to each other while blocking relative rotational motion between them. Where the float and spar cannot be disengaged, a means is provided to rotate the float and spar together. There may further be included an anchoring or mooring mechanism to allow the spar/float to rotate without straying too far from a desired position.
In accordance with another aspect of the invention, the asymmetrical float may be coupled to the spar to allow them to move up and down relative to each other while blocking relative rotational motion. To rotate the float, the spar and float are decoupled to allow the float to rotate relative to the spar.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which are not drawn to scale, like reference characters denote like components, and
FIGS. 1A and 1B are highly simplified cross-sectional views of prior art WECs;
FIG. 1C is a top view of a “symmetrical” float which may be used in the WECs of FIG. 1A or 1 B;
FIG. 1D is an idealized simplified drawing illustrating the effect of an incoming wave on a symmetrically shaped float (as per the prior art) and on an asymmetrically shaped float (intended for use in practicing the invention);
FIG. 2 is a highly simplified cross-sectional view of a WEC embodying the invention;
FIG. 2A is a top view of an asymmetric (elliptical) float for use in practicing the invention;
FIG. 2B is a top view of an asymmetric oblong (boxy) float for use in practicing the invention;
FIG. 2C is an isometric view of an asymmetric elliptical float and spar for use in practicing the invention;
FIG. 2 A( 1 ) is an idealized, simplified, top view of an asymmetrical float with its “long” side oriented to capture the oncoming waves for increased power conversion efficiency (maximum energy capture) in accordance with the invention;
FIG. 2 A( 2 ) is an idealized, simplified, top view of an asymmetrical float with its “short” side oriented to face the oncoming waves under storm conditions for reducing the forces to which the WEC is subjected;
FIG. 3 shows a comparison of wave power conversion for a circular float (see FIG. 1A or 1 B) and an elliptical float (see FIGS. 2 , 2 A) with an aspect ratio of 1:4 in a long-axis—facing the incoming waves configuration and in a “head-on” (long-axis—parallel to the incoming waves) configuration;
FIG. 4 is a simplified block diagram of an electro-mechanical system for changing and controlling the orientation of an asymmetrical float;
FIG. 5 is a simplified drawing of a WEC illustrating the use of an electro-mechanical system for changing and controlling the orientation of an asymmetrical float;
FIGS. 6A , 6 B, and 6 C are highly simplified diagrams of apparatus for controlling the orientation of an asymmetrical float in accordance with the invention;
FIGS. 7A , 7 B, and 7 C are highly simplified diagrams of different asymmetrical floats shaped to passively control the orientation of the floats;
FIG. 8A is a top view of a float interleaved with a spar;
FIG. 8B is a highly simplified cross-sectional diagram of a mooring and anchoring mechanism for enabling a float and spar of the type shown in FIG. 8A to rotate together; and
FIG. 8C is a top view of the submerged portion of the spar of FIG. 8B below the float further illustrating the mooring and anchoring arrangement for the WEC shown in FIGS. 8A and 8B .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 is a simplified cross sectional diagram illustrating that a WEC embodying the invention includes: (a) an asymmetrical float 10 ; (b) a spar 20 ; (c) a PTO 30 coupled between the float and the spar to convert their relative motion into useful energy (e.g., electric power); and (d) an apparatus 400 coupled to the float 10 for changing the orientation of and/or rotating the float 10 as a function of certain wave conditions and/or other selected conditions, such as, for example, maintenance.
The asymmetrical float 10 is normally oriented so its longer side faces the incoming waves when the wave amplitudes are within a “normal” range. For the condition where the direction of the incoming waves changes, the asymmetrical float 10 is rotated so its longer side keeps on facing the incoming waves, thus maintaining the improved energy capture. However, when the amplitudes of the waves exceed the “normal range”, the float is re-oriented so its narrower side faces the incoming waves.
In accordance with an aspect of the invention, the asymmetrical float 10 may be rotated (in increments or continuously) as a function of a change in the direction of the incoming waves so that its long axis is kept (or remains) generally perpendicular to the direction of the incoming waves for maintaining improved power producing efficiency.
The asymmetrically shaped float 10 may have an elliptical shape as shown in FIGS. 2A and 2C , or a “boxy” rectangular shape as shown in FIG. 2B , or it may have any number of different suitable shapes. The asymmetrically shaped floats, contemplated for use in practicing the invention, have one side (“axis”) which is greater (longer) than the other side. As shown in FIGS. 2A , 2 B and 2 C, the longer (“beam”) side (or longer axis) of the float has a dimension “L” and the shorter, or narrower, (“head”) side (or shorter axis) has a dimension “W”; where L is greater than W. The length “L” may be expressed as a function of kW; where k is any number greater than one (1); and the upper limit on “k” being the structural viability of the float. When operational, the float has top and bottom surfaces which lie or extend along, and generally parallel to, the surface of the body of water and the float moves up and down generally in phase with the waves. Each of the embodiments of the asymmetrical float provides the benefits associated with the present invention (i.e. increased power in operational waves, decreased sensitivity to storm waves in survival conditions.)
In systems embodying the invention, the spar 20 may be firmly anchored to the sea bed (as shown, for example, in FIG. 1A ) or it may be allowed to move up and down in a generally perpendicular direction to the surface of the body of water (as shown, for example, in FIG. 1B ).
The PTO 30 is coupled between the spar and the float for converting their relative motion into useful power (e.g., electrical power). The PTO may be a rack and pinion device or a linear electric generator or functional equivalents. Note that, typically, a part of the PTO is connected to the float and another part is connected to the spar and that these two parts of the PTO must interact (be engaged) to produce the useful power. When the float is subjected to rotation, it is imperative to ensure that the structural integrity of the PTO be maintained. For certain types of PTO devices where the spar and float are mechanically linked together (and even where they are only electromagnetically coupled) means are required to: (a) decouple the spar from the float to allow the float to move rotationally independently of, and relative to, the spar; or (b) maintain the mechanical coupling between the spar and float while providing mooring apparatus for enabling the spar and float to rotate together.
As shown in the figures, WECs embodying the invention include apparatus 400 for controlling and changing the orientation (“rotation”) of the float 10 . The apparatus 400 may be passive or active, as discussed below. The need for changing the orientation of the float will now be further reviewed. FIG. 2 A( 1 ) shows the asymmetrical float 10 oriented such that its long side (“axis”) is generally perpendicular to the direction of the incoming waves. This configuration ensures that more power is obtained and greater power conversion efficiency is achieved for a broad range of waves of different wavelengths, as compared to the prior art symmetrical floats see FIG. 3 ). This orientation (i.e., as shown in FIG. 2 A 1 ) is intended to be maintained as long as the amplitudes of the waves are within a prescribed range. The prescribed range may be defined as the “normal” range of wave amplitudes for which the WEC is to be operated for the orientation of FIG. 2 A 1 . By way of example, in seas where the expected “normal” range of wave amplitudes is up to 5 meters, the WEC is designed to respond to and operate and withstand the forces resulting from waves of up to 5 meters in amplitude. Thus, for the “normal” expected range of wave amplitudes, the WEC and its PTO 30 are designed to be fully functional and operational for the asymmetrical float orientation shown in FIG. 2 A 1 .
As already noted above and as illustrated in FIG. 3 , the power (see waveform A) generated by a WEC having an asymmetrical float which has its long axis facing (perpendicular to) the incoming waves is greater than: (a) the power (see waveform B) generated by a WEC having a symmetrical float of like surface area; and/or (b) the power (see waveform C) generated by the WEC with the asymmetrical float when its short axis is facing the incoming waves.
However, when the amplitudes of the waves exceed the normally expected range which the WEC was designed to withstand (e.g., there is a storm condition), the forces pushing the float and spar (generally in opposite directions) give rise to stresses which may cause the WEC (and the PTO) to be irreparably damaged. Note that the asymmetrically shaped float captures more of the forces of the waves and thus functions to increase the potentially destructive forces to which the float and the WEC are subjected under storm conditions. This problem has limited the development of WECs with asymmetrical floats or their use in a reliable WEC power producing system. There are two basic problems with using asymmetrical floats: (1) increased stresses to storm conditions; and (2) keeping the long side of the float perpendicular to the oncoming waves and maintaining the structure and operability of PTO.
Applicants recognized the problems and designed a system in which an asymmetrical float: (1) can be rotated to track to maximize the float profile facing the incoming waves to enhance energy capture; and (2) can be rotated to reduce the profile of the float facing the incoming waves to overcome the problem with excessive forces being present under storm conditions. So, for conditions akin to the storm condition, the float is rotated so its narrower portion faces the incoming waves as shown in FIG. 2 A( 2 ). In this configuration there is a decreased frontal area presented to the incoming waves, which results in decreased forces on the WEC. This is significant in, and for, the survivability of the WEC.
But note that there are conditions under which it may be desirable to still operate the WEC after rotation to a ‘head-to-the-waves’ configuration.
Example
In very long waves the decrease in wave forcing is small if the float is rotated (small because the wave is so long.) However, there will be less force on the bearings, so that could have a net improvement on power.
The control apparatus 400 encompasses the means to change and control the orientation of float 10 . The apparatus 400 may be an active system or a passive system or a hybrid system. Also, the apparatus 400 may be designed to cause the float 10 to rotate incrementally or in a continuous manner over a wide angular range.
One embodiment of the apparatus is shown in a highly simplified block form in FIG. 4 . Various wave conditions may be sensed and processed, and based on the processed information and predetermined data, the float and/or the spar may be rotated to re-orient the float with respect to the direction of the incoming waves.
FIG. 4 illustrates that many different sensors may be used to sense the condition of the waves and provide their signals to a controller 430 . By way of example:
(a) a sea state sensor 402 sensing the differential movement between the spar and float may be used to provide signals to the controller; or (b) an accelerometer 404 responsive to the differential movement of the spar and float may be used to provide signals to the controller; or (c) a receptor 406 responsive to satellite or other external source may be used to provide signals pertaining to the waves (or any other system condition) to the controller; or (d) an acoustic doppler profiler 408 or a wave monitoring buoy may be used to supply signals pertaining to the waves (or any other system condition) to the controller 430 ; or (e) an auxiliary wave monitoring buoy 410 may be used to sense and supply signals to the controller.
In FIG. 4 a wave sensor processor 420 is shown connected between the various wave sensors and the controller 430 . The signals from the various sensors can be supplied directly or via wireless connection to the controller 430 . Although not explicitly shown, it should be appreciated that sensors and their signals may be coupled or supplied to the processor 420 or controller 430 by an external (remote or satellite) weather/wave forecast.
In response to the received wave condition signals, the controller 430 supplies a command signal to a motor driver 440 which is coupled to the float and/or the spar to cause the float and/or the spar to rotate to a new position for causing the WEC to produce more power or for reducing forces to which the WEC is subjected so as to increase its survivability. The system of FIG. 4 provides an active mechanism for: (a) rotating the asymmetrical float independently of the spar (e.g., when the float can be disengaged from the spar); and/or (b) rotating the float and the spar together (e.g., where they are keyed to each other to prevent relative rotation between the spar and float while allowing relative up down motion relative to each other.
As noted above, the orientation control 400 can be used to rotate the float on a continuous basis in the event that the direction of the incoming waves changes so as to capture more (or less) of the incoming waves. It should also be noted that the float may also be rotated via control 400 if so needed for purpose of maintenance.
The control system shown in FIG. 4 may be used to control the asymmetrical float of the WEC shown in FIG. 5 . FIG. 5 illustrates that there may be provided an element 105 which includes linear bearings which move up and down the shaft 20 . The element 105 also includes rotational bearings around which the elliptical float 10 may be made to rotate in accordance with the invention. The element 105 contains some or all of the PTO 30 within it. This obviates the need for the PTO to support rotating float/spar components. The rotation of the float takes place around the element 105 . There may be a rotation controller 400 located inside the float.
Another method for mechanically positioning a float 10 is shown in FIGS. 6A , 6 B, and 6 C. This method relies on changing the configuration of mooring legs to change the orientation of the WEC. FIGS. 6A and 6B show the WEC in the operational configuration, so that the long axis of the float 10 is perpendicular to the direction of incidence of the waves. FIG. 6B is a view from the top. Each of the two “upstream” mooring legs 630 includes an anchor 604 , mooring lines 603 , auxiliary surface buoys (ASBs) 602 . There is a mechanism 600 on one or more of the mooring lines 603 . The mechanism 600 can cause the mooring leg on which it is attached to increase or decrease in length, which will have the effect of causing the float 10 to rotate. The manner in which a change in length of the mooring line 603 will lead to rotation of the WEC is indicated by the different configurations shown in FIG. 6C and FIG. 6B .
If the float is moored via mooring lines, as shown in FIG. 6 , then a means to change the orientation of the float with a passive method is to have the mooring mechanism 600 allow movement of the mooring line 603 if the tension exceeds a predetermined level. Movement of the mooring line 603 will lead to rotation of the float so that the float is positioned in the desired orientation relative to the waves. For the rotation to take place in accordance with the invention, only one mooring mechanism 600 need to have a passive payout capability.
Other structures for enabling the orientation of the float to change are shown in FIGS. 7A , 7 B and 7 C. These structures enable the use of passive (and generally automatic) means to orient and/or re-orient the float. In these embodiments, each float may be moored via a bearing mechanism 105 . If so, then asymmetrical floats such as those shown in FIG. 7A , 7 B, or 7 C can be caused to passively self-orient by allowing the bearing mechanism to rotate freely.
FIG. 7A shows a WEC having an asymmetrical float 10 to which is attached a fin, or vane, 170 , for passively causing a rotation (re-orientation) of the float under storm conditions. A spar/shaft 20 and a set of rotating bearings 105 are located at the center of the float. The vane 170 can assist with passive orientation of the float under storm conditions. Under “normal” wave conditions, the vane 170 will not significantly affect the operation and/or orientation of the float 10 . The vane 170 will simply move up and down with the float, and not have significant hydrodynamic interactions. In storm conditions, if the waves are incident such that the crests are parallel with the longer axis of the float (which is not the desired orientation) then there will be a large force on the vane 170 which will tend to cause the float 10 to rotate so that the vane is oriented away from the direction of the incoming waves. This will cause the float 10 to rotate to the desired orientation for storm conditions. It should be appreciated that this mechanism may be used to correctly position the float passively, or it may be used to assist a mechanical positioning mechanism, or it could serve as a fail-safe method for positioning the float in the event of a failure of a mechanical (active) positioning mechanism.
FIG. 7B shows an embodiment in which the central shaft 20 , and the rotating bearing 105 are not centered on the float. The offset is intended to help orient the float in storm conditions as a passive positioning mechanism as discussed for the float shown in FIG. 7A .
FIG. 7C shows an embodiment in which the float 10 is not symmetric about the central shaft 20 . The float is tapered having a greater width at one end and then decreasing to a point at its other end. This embodiment is intended to provide the benefits of having a longer and shorter axis and the benefit of passive orientation but with an improvement over the shape indicated in FIG. 7B . The embodiment shown in 7 B may have relatively large bearing loads on the central shaft 20 in operational conditions. These large bearing loads come about because the waterplane area (and hence buoyant force) on one side of the central shaft is so much greater than on the other. The embodiment shown in FIG. 7C is intended to address this bearing issue.
FIGS. 8A and 8B illustrate a WEC having a spar 20 interleaved with a float 10 such that they can move up and down (in heave) relative to each other while preventing any significant rotational motion of the spar relative to the float. For this configuration, it is impractical if not impossible to decouple the float and spar. Therefore, when the float is rotated for optimizing the power conversion efficiency, it is necessary that the spar also rotate together with the float. FIGS. 8B and 8C illustrate a mooring and anchoring mechanism which allow the spar to rotate together with the float while preventing the WEC from drifting. As shown in FIG. 8B , a PTO 30 connected between the float and spar can, at all times, convert their relative up/down motion into electrical energy. The rotation control 400 is coupled to the float and/or spar to cause them to rotate in unison. The spar is allowed to rotate but held in place in a vertical direction by means of a sleeve 801 shown extending below the float and along a submerged portion of the spar. FIGS. 8B and 8C show 3 anchors 803 attached to the sleeve 801 to keep it in place. The lower portion of the spar is shown to be terminated in a plate 805 which can function as a heave plate and to hold the sleeve above a certain part of the spar. The particular mooring and anchoring mechanism shown in the figures is for purpose of illustration and any other suitable arrangement may be used which allows the spar to rotate together with the float.
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A wave energy converter (WEC) having an asymmetrically shaped float and a spar which move relative to each other in response to the waves. The asymmetrical float has one side longer than the other. A power take off device (PTO) is coupled between the asymmetric float and the spar for converting their relative motion into useful power. Apparatus is coupled to the WEC for: (a) orienting and rotating the longer side of the float to face and receive oncoming waves to increase energy capture when the waves have an amplitude below a predetermined value for improving the power generation of the WEC; and (b) rotating the float to orient the narrower side of the float to face and receive the incoming waves when the waves have an amplitude above a predetermined value, so as to reduce the forces to which the WEC is subjected.
There is no known WEC system with an asymmetrical float which is raised and lowered by the waves.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a snow shover or pusher having a pair of elongated handles pivotally secured to the rearward side of a blade. More particularly this invention relates to a snow shover wherein each of the handles thereof is length adjustable. Even more particularly, this invention relates to a snow shover which is designed to laterally move large volumes of snow.
2. Description of the Related Art
Many types of snow shovels and snow blades have been previously provided. For example, U.S. Pat. No. 1,746,859 illustrates a scraper which is V-shaped and which pushes the snow in both directions from the center. This design makes it very difficult to scrape driveways or sidewalks next to a building or fence. U.S. Pat. No. 2,826,835 discloses a snow shovel wherein the pushing force is directed to the center of the scraper blade and is designed to push the snow directly forwardly. U.S. Pat. No. 7,681,933 discloses a shovel with a crossbar handle. It appears that this shovel is very heavy with many moving parts.
U.S. Published Patent Application 2005/001232448 A1 discloses a snow shoveling device which is apparently designed to move snow only directly forwardly. The movement of snow directly forwardly, as in this device, is only possible for short distances before it become impossible to proceed due to the weight of the snow.
SUMMARY OF THE INVENTION
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter.
A snow shover is disclosed which includes an elongated blade having a concave front side, a convex rear side, an upper edge, a lower edge, a first end and a second end. A first upper mount is secured to the rear side of the blade inwardly of the first end thereof below the upper edge thereof and which extends rearwardly from the rear side of the blade. The lower end of the first upper mount has a cylindrical opening formed therein which extends upwardly thereinto. A first lower mount is secured to the rear side of the blade directly below the first upper mount and which extends rearwardly from the rear side of the blade above the lower edge of the blade. The first lower mount has a vertically disposed bore, having upper and lower ends, formed therein which extends therethrough. An upstanding first pivot shaft is disclosed which has upper and lower ends. The upper end of the first pivot shaft is pivotally received in the cylindrical opening in the lower end of the first upper mount.
A first mounting structure is disclosed which includes a first tee fitting is provided which has an open upper end, an open lower end, and an open side end. The open upper end of the first tee fitting is secured to the lower end of the first pivot shaft above the first lower mount. The open lower end of the first tee fitting is pivotally received in the bore of the first lower mount. A generally vertically disposed first shaft has its upper end secured to the lower end of the first tee fitting. A first 90 degree elbow, having first and second ends, has its first end secured to the lower end of the first shaft. The second end of the first elbow extends laterally rearwardly. The forward end of a horizontally extending second shaft is secured to the second end of the first elbow and extends rearwardly therefrom. The forward end of a second elbow, which is a 45 degree elbow, is secured to the rearward end of the second shaft. The rearward end of the second elbow is secured to the lower end of a third shaft. A third elbow, which is a 90 degree elbow, has its lower end secured to the upper end of the third shaft. A fourth shaft has its lower end secured to the upper end of the third elbow. The upper end of the fourth shaft is secured to the side end of a second tee fitting. The lower end of the second tee fitting has the upper end of a fifth shaft secured thereto. The lower end of the fifth shaft is secured to the rearward end of a fourth elbow, which is a 45 degree elbow. A sixth shaft connects the forward end of the fourth elbow to the side end of the first tee fitting. The lower forward end of an elongated first push handle is secured to the upper rearward end of the second tee fitting. Preferably, the first push handle is length adjustable.
Although the first mounting structure is described as including several individual parts or components, it is preferred that all the parts or components of the first mounting structure as well as the first pivot shaft be of one-piece or single-piece construction.
A second upper mount is secured to the rear side of the blade inwardly of the second end thereof below the upper edge thereof and which extends rearwardly from the rear side of the blade. The lower end of the second upper mount has a cylindrical opening formed therein which extends upwardly thereinto. A second lower mount is secured to the rear side of the blade directly below the second upper mount. The second lower mount has a vertically disposed bore, having upper and lower ends, formed therein which extends therethrough. An upstanding second pivot shaft is disclosed which has upper and lower ends. The upper end of the second pivot shaft is pivotally received in the cylindrical opening in the lower end of the second upper mount.
A second mounting structure is disclosed which includes a third tee fitting is provided which has an open upper end, an open lower end, and an open side end. The open upper end of the third tee fitting is secured to the lower end of the second pivot shaft above the second lower mount. The open lower end of the third tee fitting is pivotally received in the bore of the second lower mount. A generally vertically disposed seventh shaft has its upper end secured to the lower end of the third tee fitting. A fifth elbow, which is a 90 degree elbow with first and second ends, has its first end secured to the lower end of the seventh shaft. The second end of the fifth elbow extends laterally rearwardly. The forward end of a horizontally disposed eighth shaft is secured to the second end of the fifth elbow and extends rearwardly therefrom. The forward end of a sixth elbow, which is a 45 degree elbow, is secured to the rearward end of the eighth shaft. The rearward end of the sixth elbow is secured to the lower end of a ninth shaft. A seventh elbow, which is a 90 degree elbow, has its lower end secured to the upper end of the ninth shaft. A tenth shaft has its lower end secured to the upper end of the seventh elbow. The upper end of the tenth shaft is secured to the side end of a fourth tee fitting. The lower end of the fourth tee fitting has the upper end of an eleventh shaft secured thereto. The lower end of the eleventh shaft is secured to the rearward end of an eighth elbow, which is a 45 degree elbow. A twelfth shaft connects the forward end of the eighth elbow to the side end of the third tee fitting. The lower forward end of an elongated second push handle is secured to the upper rearward end of the fourth tee fitting. Preferably, the second push handle is length adjustable.
Although the second mounting structure is described as including several individual parts or components, it is preferred that all the parts or components of the second mounting structure as well as the second pivot shaft be of one-piece or single-piece construction.
It is therefore a principal object of the invention to provide an improved snow shover.
A further object of the invention is to provide a snow shover wherein first and second length adjustable push handles are secured to a scraper blade inwardly of the opposite ends thereof.
A further object of the invention is to provide a snow shover of the type described which enables the scraper blade thereof to be angularly disposed with respect to the direction of movement of the snow shover.
A further object of the invention is to provide a snow shover of the type described which is lightweight and easy to maneuver.
A further object of the invention is to provide a snow shover of the type described which enables the snow shover to be pivotally moved above an obstruction in the surface being cleared.
A further object of the invention is to provide a snow shover of the type described wherein the push handles thereof maybe folded from operative to inoperative or storage positions.
These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
FIG. 1 is a perspective view of the snow shover of this invention;
FIG. 2 is a lower perspective view of one of the upper mounts of this invention;
FIG. 3 is an upper perspective view of one of the lower mounts of this invention;
FIG. 4 is a partial sectional view of the snow shover of this invention;
FIG. 5 is a top elevational view of the snow shover of this invention;
FIG. 6 is a view similar to FIG. 5 except that the blade is shown in an angled position with the broken lines indicating the blade in another angled position;
FIG. 7 is a side view illustrating the snow shover pushing snow;
FIG. 8 is a view similar to FIG. 7 except that the snow shover has been moved upwardly to pass over an obstruction in the surface being cleared of snow; and
FIG. 9 is a perspective view illustrating the push handles in a folded position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments are described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense in that the scope of the present invention is defined only by the appended claims.
The snow shover or pusher of this invention is designated by the reference numeral 10 . Snow shover 10 generally includes a blade 12 , a first pivot mount assembly 14 , a second pivot mount assembly 14 ′, a first mounting structure 15 , a second mounting structure 15 ′, a first handle assembly 16 and a second handle assembly 16 ′. Inasmuch as pivot mount assemblies 14 and 14 ′ are identical, only pivot mount assembly 14 will be described in detail with “′” indicating identical structure on pivot mount assembly 14 ′. Inasmuch as mounting structures 15 and 15 ′ are identical, only mounting structure 15 will be described in detail with “′” indicating identical structure on mounting structure 15 ′. Inasmuch as handle assemblies 16 and 16 ′ are identical, only handle assembly 16 will be described in detail with “′” indicating identical structure on handle assembly 16 ′.
Blade 12 includes a concave front side 18 and a convex back side 20 . Although it is preferred that front side 16 be concave in shape and that back side 18 be convex in shape, the front and back sides could have other arcuate shapes. Blade 12 has an upper end 22 , a lower end or edge 24 , a first or left end 26 and a second or right end 28 . Blade 12 may be comprised of any material such as aluminum, steel, or PVC.
The first pivot mount assembly 14 includes an upper mount 30 and a lower mount 32 . Upper mount 30 has a forward end 34 which has a shape complementary to the back side 20 of blade 12 . The forward end 34 of mount 30 is secured to the back side 20 of blade 12 by any convenient means such as adhesive, screws, etc. Mount 30 is positioned below the upper end 22 of blade 12 inwardly of end 26 of blade 12 . Mount 30 has a cylindrical opening or bore 36 extending upwardly into mount 30 from the lower end 38 thereof.
Lower mount 32 has a forward end 42 which has a shape complementary to the back side 20 of blade 12 . The forward end 42 of lower mount 32 is secured to the back side 20 of blade 12 by any convenient means such as adhesive, screws, etc. Mount 32 is positioned directly below mount 30 . Mount 32 has a generally vertically disposed cylindrical opening or bore 44 extending therethrough which is directly below opening 36 in mount 30 .
Mounting structure 15 includes a generally vertically disposed pivot shaft 46 having an upper end 48 and a lower end 50 . The upper end 48 of pivot shaft 46 is pivotally received in sleeve 40 . The lower end 50 of pivot shaft 46 is secured to the upper end 52 of a tee fitting 54 . The lower end 56 of tee fitting 52 is partially received in bore 44 . A shaft 58 has its upper end received in and secured to the lower end 56 of tee fitting 52 . The lower end of shaft 58 is received by and secured to the upper end 60 of an elbow 62 .
The forward end of shaft 64 is received by and secured to the lower end of the 90 degree elbow 62 . The rearward end of shaft 64 is secured to the forward end of a 45 degree elbow 66 . The rearward end of elbow 66 receives a shaft 68 which is secured thereto. One end of a 90 degree elbow 70 is secured to the upper end of shaft 68 as seen in FIG. 4 . A short shaft 72 is received in the upper end of elbow 70 and has a tee fitting 74 secured thereto. A short shaft 76 has one end received by the tee fitting 74 as seen in FIG. 4 . The other end of shaft 76 is received by and is secured to one end of a 45 degree elbow 78 . A shaft 80 interconnects elbow 76 and the tee fitting 54 as seen in FIG. 4 . Although mounting structure 15 is shown as being comprised of several parts or components, it is preferred that mounting structure 15 be of single unit construction for ease of manufacture.
Handle assembly 16 includes an elongated, tubular portion 82 , the lower end of which is received in tee fitting 74 and which is secured thereto. Tubular portion 82 includes a plurality of spaced-apart openings 84 formed therein. Handle assembly 16 also includes an elongated, tubular portion 86 which selectively slidably receives tubular portion 82 therein. Tubular portion 86 has a pin 88 which extends through a pin opening 90 in tubular portion 86 into one of the openings 84 in tubular portion 82 to permit the length of handle assembly 16 to be selectively changed. A D-shaped handle grip 92 is secured to the outer end of tubular portion 86 . The primary reason for having the handle assembly 16 length adjustable is to accommodate persons of different heights. In the drawings, the numeral 94 refers to a concrete surface which has snow thereon. The numeral 96 refers to a raised portion in the concrete surface 94 .
The snow shover is used as follows. If the blade 12 is going to be used in an angularly disposed manner, which is usually the case, such as seen in FIG. 6 , the length of handle assembly 16 may be increased if so desired so that the handle grips 92 and 92 ′ will be aligned. Normally, the handle assemblies 16 and 16 ′ will not have their lengths adjusted in response to an angular position of the blade 12 . The operator then pushes the blade 12 forwardly so that snow will be pushed to the right from blade 12 , as seen in FIG. 6 . If snow is to be pushed to the left, the blade 12 is angled as shown by broken lines in FIG. 6 . The pivot shafts 46 and 46 ′ enable the handle assemblies to be parallel to the direction of travel even though the blade 12 is angularly disposed.
If the blade 12 should engage an obstruction 96 , the operator simply lowers the handle assemblies 16 and 16 ′ so that elbows 66 and 66 ′ engage the surface 94 to pivotally move blade 12 upwardly to avoid the obstruction 96 .
It can therefore be seen that the snow shover of this invention is extremely easy to use with the blade 12 being angled as desired. The push handle assemblies 16 and 16 ′ may be easily pivoted from a working position to the storage position of FIG. 9
Thus it can be seen that the invention accomplishes at least all of its stated objectives.
Although the invention has been described in language that is specific to certain structures and methodological steps, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures and/or steps described. Rather, the specific aspects and steps are described as forms of implementing the claimed invention. Since many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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A snow shover including a scraper blade with a pair of spaced-apart push handles extending rearwardly therefrom. The push handles are pivotally secured to the blade about generally vertical axes. The push handles are length adjustable.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to anti-recoil devices for guns and mortars and more precisely to anti-recoil devices which comprise a recoil brake and, associated with that brake, a compensator and a recuperator.
It is known to reduce the effects of the recoil of a gun or a mortar by means of a recoil brake. It is known to adjoin a compensator and a recuperator to the recoil brake: the German patent DE 103 975 of Aug. 18, 1898 proposes an anti-recoil device wherein a brake equipped with a compensator functions, in addition to functioning as a brake, as a recuperator.
SUMMARY OF THE INVENTION
The device according to this, patent can be described as being an anti-recoil device which comprises a recoil brake serving as a recuperator and a compensator coupled to the brake by a duct, the brake comprising a principal cavity, a principal piston pierced with holes and a principal rod with one end integral with the piston and one end outside of the cavity, the piston forming an imperfect barrier which subdivides the cavity into a small chamber inside of which the rod passes and a big chamber, the compensator comprising a subsidiary cavity, a subsidiary fluid-tight piston to delimit a subsidiary chamber inside the subsidiary cavity, and a return system which acts on the subsidiary piston in such a way as to tend to reduce the volume of the subsidiary chamber, the device having its principal cavity and its subsidiary chamber filled with liquid, the duct interconnecting the small chamber and the subsidiary chamber and the system being provided in order to be used with the small chamber which increases in volume during the recoil.
In the device according to the patent DE 103 975, in order that the speed of displacement of the principal piston may be braked during the return to the firing position, the subsidiary chamber is not directly connected with the duct but via channels pierced in a fixed piston; the subsidiary piston slides between the fixed piston which it surrounds and the lateral walls of the subsidiary cavity which surrounds it; the speed reduction is obtained by means of valves which close, but only partially, the channels during the return.
The assembly formed by the subsidiary piston and the fixed piston with its channels and its valve is complicated to produce, costly and relatively fragile.
The purpose of the present invention is to avoid these disadvantages.
This purpose is achieved, in particular, by mounting the valve on the principal piston of an anti-recoil device such as defined in claim 1 .
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood and other features will appear with the help of the following description and of the figures relating to it which show:
FIG. 1, is a recoil brake seen in cross section,
FIGS. 2 a , 2 b , 2 c , and 2 d , show the different ways of using a recoil brake,
FIG. 3, is a cross-sectional view of a recoil brake associated with a compensator,
FIG. 4, is a cross sectional view of a recuperator,
FIG. 5, is a cross sectional view of a device according to the invention,
FIGS. 6 a , 6 b , 6 c , and 6 d , show the device of FIG. 5 in four positions which it occupies successively during a firing of the weapon system with which it is incorporated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the various figures, corresponding elements are denoted by the same references. Furthermore, it should be noted that all of the figures correspond to weapon systems which, by convention, are disposed to fire munitions in a direction parallel to the small sides of the page and oriented towards the large left-hand side of the page; furthermore, in order to simplify the figures, the tubes which are used for firing the munitions and which will be referred to as firing tubes below, have not been shown.
FIG. 1 is a diagrammatic longitudinal cross sectional view of a recoil brake. This brake comprises a cavity 1 filled with a liquid 4 , a piston 2 which can move in a direction XX inside the cavity and a rod 3 integral with the piston; the liquid 4 is generally oil. The cavity has a longitudinal axis XX parallel with the direction of fire of the weapon system in question; this cavity is of constant cross section, generally circular. The rod is parallel with the direction XX and its first end is fixed to the piston; it traverses the wall of the cavity through an opening whose fluid-tightness is provided by a seal, in such a way as to have its second end outside of the cavity and to allow a displacement of the piston inside the cavity, without loss of liquid. The piston defines two chambers in the cavity; these chambers are generally called the small chamber in the case of the one, 11 , located on the same side of the piston 2 as the rod 3 and the big chamber in the case of the other one, 12 . The piston is pierced with holes, such as the hole 20 , whose dimensions are calibrated to ensure the desired intensity of braking; the smaller the total transverse cross section of these holes, the greater the resistance to exchanges of fluid between the two chambers.
In FIG. 1 it is assumed that, at the moment the brake is observed, the relative movement of the piston 2 with respect to the cavity 1 is that during which the length of the rod located outside of the cavity is increasing whilst the volume of the small chamber is reducing and that of the big chamber is increasing; in FIG. 1, the displacement of the rod with respect to the cavity is symbolized by an arrow D and the transfer of liquid caused, through the piston 2 , by the changes in volume of the chambers is symbolized by an arrow Dp.
Brakes can be used in four different configurations depending on whether the firing tube is integral with the rod or with the wall of the cavity and depending on whether, during the recoil, the displacement of the rod with respect to the cavity causes a reduction in the volume of the small chamber or an increase in that volume. FIGS. 2 a to 2 d illustrate these four configurations in simplified diagrams where the cavity 1 is drawn in cross section in order to show the piston 2 and the rod 3 . In these diagrams arrows, T, oriented from right to left indicate the firing direction and therefore symbolize the firing tube; these arrows are connected, by a length of straight dashed line, either to the rod or to the cavity depending on whether the rod or the cavity is integral with the firing tube and therefore depending on whether the cavity or the rod is integral with the support of the weapon system in question: an arrow D associated with the part of the brake which is integral with the firing tube indicates the displacement of that part of the brake during the recoil. In correlation with the arrow T associated with the mobile part of the brake, a cross-hatched rectangle, M, is associated with the fixed part of the brake and symbolizes the support of the weapon system.
In the case of FIG. 2 a , the cavity 1 is fixed and the recoil causes a reduction in the volume of the small chamber; the rod 3 works in tension.
In the case of FIG. 2 b , the cavity is also fixed but the recoil increases the volume of the small chamber; the rod 3 then works in compression.
In the case of FIG. 2 c , the rod 3 is fixed and the recoil causes a reduction in the volume of the small chamber; the rod works in tension.
In the case of FIG. 2 d , the rod 3 is also fixed but the recoil causes an increase in the volume of the small chamber; the rod 3 therefore works in compression.
The displacement of the piston-rod assembly inside the cavity causes a variation of the volume available for the liquid in the big and small chambers. FIG. 3 shows how a compensator can be associated with a brake of the type which has been described with reference to FIG. 1 in order to compensate for these variations in volume and, at the same time, compensate for the variations in the volume of liquid due to thermal expansions.
The assembly according to FIG. 3 comprises a brake similar to that shown in FIG. 1 except that it has an opening, A, in the wall of the cavity 1 in the vicinity of that of the two ends of the cavity which is located in the big chamber. This assembly also comprises a subsidiary cavity 1 ′, of longitudinal axis YY parallel to XX; a piston 2 ′ can slide in this cavity, where, with the help of a seal 20 ′, it constitutes a fluid-tight barrier between, on the one hand, a compensation chamber 13 and, on the other hand, a subsidiary chamber 14 . The compensation chamber is filled with the same liquid, 4 , as the cavity 1 with which it is connected by the opening A. The subsidiary chamber 14 is connected with the ambient atmosphere through a hole V; this subsidiary chamber serves as a housing for a coil spring, R; this spring which creates a pressure inside the compensation chamber 13 , absorbs, by action on the piston 2 ′, the variations in volume of the compensation chamber 13 .
Thus, when the displacement of the rod with respect to the cavity, in the direction of an arrow D, reduces the length of the rod 3 which is inside the cavity, there is produced:
a flow of liquid from the small chamber to the big chamber because of the reduction in the volume of the small chamber; an arrow Dp symbolizes this flow
an increase in the overall volume available for the liquid in the cavity, because the volume occupied by the rod in the cavity reduces; this results in an increase in the pressure of the liquid in the chamber 11 and, consequently, a displacement of the piston 2 ′ under the action of the spring R in order to reduce the volume of the compensation chamber; an arrow Dc symbolizes this displacement of the piston 2 ′ and an arrow Dt symbolizes the resultant flow of the liquid from the compensation chamber 13 to the big chamber 12 .
It should be noted that, among other variants of the assembly according to FIG. 3, the subsidiary chamber 14 can have no connection with the outside atmosphere and the spring can be replaced by a gas under pressure or the spring R can be located in the compensation chamber and work in tension. Similarly, it is in no way essential that the subsidiary chamber 1 ′ should have its axis YY parallel with the axis XX of the cavity 1 ; it can even be directly mechanically connected with the cavity 1 only by a duct which, like the opening A according to FIG. 3, would connect the big chamber and the compensation chamber.
The replacing of a firing tube into its initial position, after it has fired a munition and recoiled during that firing, is generally carried out by a hydro-pneumatic recuperator; the function of the recuperator is to store a portion of the recoil energy in order subsequently to return it in order to bring the tube back to its initial position.
FIG. 4 is a diagram of an example embodiment of such a recuperator. This figure shows two cavities 1 a , 1 b having longitudinal axes X′X′ and Y′Y′ and constant cross sections; these cavities, seen in longitudinal cross section in FIG. 4 are connected to each other by a duct W in the vicinity of their first ends; the first ends of the cavities 1 a and 1 b are obturated whilst only the second end of the cavity 1 b is obturated.
In the cavity 1 a can slide a piston 2 a integral with a rod 3 a of axis parallel with the axis X′X′; the axis X′X′ must be parallel with the direction of recoil of the firing tube but this is not obligatory for the axis Y′Y′ which can make any angle with the direction of recoil of the firing tube. The piston 2 a is provided with a seal in order to form a fluid-tight barrier inside the cavity 1 a ; similarly the rod 3 a traverses the first obturated end of the cavity 1 a through an orifice provided with a seal to ensure the fluid-tightness of the passage.
In the cavity 1 b a piston 2 b can slide along the axis Y′Y′; this piston is provided with a seal in order to form a fluid-tight barrier between the two chambers 15 and 16 which it delimits inside that cavity. The space contained between the pistons 2 a , 2 b and which includes the inside of the duct W and the chamber 15 is filled with a liquid 4 whilst the chamber 16 contained between the piston 2 b and the second end of the cavity 1 b is filled with a gas under pressure 5 and whilst the face of the piston 2 a on the opposite side to the rod 3 a is at atmospheric pressure; the liquid is generally oil and the gas is generally nitrogen.
When a munition is fired, the recoil is manifested by a displacement of the rod 3 a with respect to the cavity 1 a starting from an initial firing position; this relative displacement is symbolized by an arrow D; the recoil injects oil, via the duct W and in the direction of the arrow Ds, into the space of the cavity 2 b contained between the duct W and the piston 2 b . The piston retracts in the direction of the arrow Dr compressing the nitrogen contained in the chamber 16 . The compressed nitrogen can then expand, pushing back the piston 2 b which pushes back the oil toward the cavity 1 a and therefore returns the piston-rod assembly 2 a - 3 a to the initial firing position defined by a stop which is not shown.
Here again, like when the recoil brake is used alone or with a compensator, the firing tube can be integral either with the rod 3 and therefore the cavities 1 a , 1 b are fixed, or with the cavities 1 a , 1 b and therefore the piston-rod assembly 2 a - 3 a is fixed. Furthermore, it should be noted that the cavities 1 a , 1 b have been shown separated in FIG. 4 but this is not obligatory; they could be adjoining like the two cavities of the brake with compensator shown in FIG. 3 .
As a variant of the recuperator shown in FIG. 4, the gas under pressure in the cavity 16 can be replaced by a spring which works in compression during the recoil or by a spring in the cavity 15 , the latter spring working in tension during the recoil.
FIG. 5 is a view in longitudinal cross section of a brake with compensator which is designed to act as a recuperator. Apart from improvements, which are not essential to its functioning, this brake corresponds to the recuperator shown in FIG. 4, wherein the end of the cavity 1 a on the opposite side to the rod would be obstructed, wherein the piston 2 a would intentionally not be fluid-tight and wherein the entire cavity la would be filled with liquid. However, in order to be able to function as a recuperator, the brake thus constituted must have its rod working in compression during the recoil, that is to say in any one of the configurations shown in FIGS. 2 b , 2 d ; these configurations are those in which the effect of the recoil is to compress the gas or the spring inserted in place of the gas or of expanding the spring which, as stated with reference to FIG. 4, could be placed in the chamber 15 .
In FIG. 5 there is therefore a principal cavity 1 having an axis XX, with a piston 2 , a rod 3 , a small chamber 11 , a big chamber 12 and a secondary cavity 6 having an axis YY, with a piston 60 , a secondary chamber 61 connected, through an orifice C, with the small chamber 11 and a compression chamber 62 filled with gas under pressure 5 . The piston 2 is made such that it is not fluid-tight by means of holes such as 20 .
It should be noted that there is a control rod 7 in the big chamber 12 and a hollow section in the piston-rod assembly 2 - 3 facing the rod 7 . The rod 7 , which is integral with the cavity 1 , is profiled as a truncated cone and penetrates more or less into the hollow section of the rod 3 depending on the position of the piston 2 in the cavity 1 . This control rod-hollow section assembly constitutes a conventional system for obtaining a braking pressure as constant as possible throughout the recoil.
It should also be noted, in the small chamber 11 and linked with the piston 2 , that there is a valve 21 provided with a return spring 22 . The valve is pierced with holes such as 210 which have a cross section of the order of four times smaller that of the holes such as 20 and the spring 22 tends to press the valve 21 against the piston 2 . As long as the valve is pressed against the piston, each hole such as 210 emerges into a hole such as 20 and vice versa. Now the valve 21 is pressed against the piston 2 as long as the pressure in the big chamber 12 is less than the pressure in the small chamber increased by the pressure applied by the spring 22 the valve; the valve opens above this pressure.
FIGS. 6 a to 6 d again show the drawing of the brake with compensator shown in FIG. 5 in a configuration according to FIG. 2 d , that is to say with the rod 3 fixed and the cavities 1 , 6 mobile; this is symbolized by a solid block bearing the reference Ml in FIG. 6 a.
Furthermore, a rubber shock-absorber occupies a fixed position; it is symbolized by a rectangle pressed against a solid block. These elements which bear the references N and M 2 respectively in FIG. 6 a determine a return, after recoil, to a firing position which will be called the initial position; the position in which the cavities 1 , 6 come into contact with the shock absorber N.
When a munition is fired, the firing tube integral with the cavities 1 , 6 , drives the latter in its recoil. The cavities are in the initial position according to FIG. 6 a at the moment the firing is initiated; the recoil brings them to a maximum rearward position as shown in FIG. 6 c.
FIG. 6 b shows the brake as it is during the recoil of the firing tube, in an intermediate position between the initial position and the maximum rearward position. An arrow D symbolizes the displacement of the cavities 1 , 6 during the recoil; the recoil gives rise to a great increase in pressure in the big chamber 12 and hence to an opening of the valve 21 which allows a rapid passage of liquid from the big chamber to the small chamber 11 ; an arrow Dp symbolizes the flow of the liquid through the piston 2 . The increase in pressure in the big chamber causes: a flow of liquid, symbolized by an arrow Dr, from the small chamber to the secondary chamber 61 —a thrust on the piston 60 which compresses the gas enclosed in the compression chamber 62 .
When the increase in pressure due to the recoil stops, the cavities 1 , 6 are in the position shown in FIG. 6 c with the valve 21 closed again; the pressure in the compression chamber 62 is at a maximum and will therefore push back the piston 60 and because of this will even cause a ref lux of liquid which results in a displacement of the cavities 1 , 6 during which the En length of the rod 3 located inside the cavity 1 reduces.
FIG. 6 d shows the brake as it is during the return to the initial position; the drawing corresponds to an intermediate position and, in this drawing, the displacements are symbolized by an arrow D′ for the cavities 1 , 6 and by two arrows Dr′ and Dp′ for the liquid; these three arrows correspond, but with opposite directions, to the three arrows D, Dr and Dp shown in FIG. 6 b.
The return is completed by the cavities 1 , 2 coming into contact with the shock absorber N, that is to say when the brake has returned to the position shown in FIG. 6 a.
It should be noted that, due to the valve, the flow of liquid which passes from the small chamber to the big chamber is reduced and that therefore the speed of displacement, during the return, is reduced; the regulation that the brake applies to the speed of displacement of the firing tube during the return is therefore independent of the regulation that it applies to this speed during the recoil.
Here again, different variants can be proposed; in particular:—not using a control rod and using a conventional piston-rod assembly as shown in FIGS. 1 and 3 —replacement of the gas by a spring working in compression in the compression chamber 62 or in tension in the secondary chamber 61 , the chamber 62 then being connected to the atmosphere—secondary cavity 6 without a common wall with the primary cavity 1 and/or whose longitudinal axis has a direction different from that of the longitudinal axis of the principal cavity—piston not pierced with holes but having a cross section smaller that of the cavity in order to allow the exchange of liquid, at its periphery, between the small chamber and the big chamber.
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The invention relates to anti-recoil devices for guns and martars.
The anti-recoil device has a brake with a principal cabity which houses a principal piston pierced with holes. The small chamber of the brake is connected by an opening to a subisdiary chamber closed by a fluid-tight piston. The principal cavity and the subsidiary chamber are filled with a liquid whilst a gas under pressure, located on the other side of the fluid-tight piston with respect to the subsidiary chamber, tends to push back the subsidiary piston. A valve partially obturtes the holes of the principal piston, during the return to firing position, in order to brake that return.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. application Ser. No. 10/376,969, filed on Feb. 28, 2003, now U.S. Pat. No. 6,762,246, which in turn is a divisional application of U.S. application Ser. No. 09/924,194, filed on Aug. 8, 2001, now issued as U.S. Pat. No. 6,562,906, which in turn claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Appln. No. 60/224,668, filed on Aug. 11, 2000, and to U.S. Provisional Appln. No. 60/279,023, filed on Mar. 27, 2001. Each of the above identified applications is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to partially or fully neutralized mixtures of carboxylate functionalized ethylene copolymers or terpolymers (Mw between 80,000 and 500,000) with carboxylate functionalized ethylene low copolymers (Mw between 2,000 and 30,000). It also relates to the use of such ionomeric compositions in injection or compression molded applications such as golf ball components.
2. Description of Related Art
There is a need for highly resilient thermoplastic compositions that have good processibility without loss of properties or improved properties (improved resilience and lower stiffness) without loss of processibility.
There is a need in the golf ball art for balls that have a high resilience at high speed impact such as when struck by a driver and lower resilience at low speed impact such as when struck with a putter. High resilience at high speed impact would allow longer driving distance while lower resilience at low speed would provide better putting control.
BRIEF SUMMARY OF THE INVENTION
The highly resilient thermoplastic compositions of this invention provide improved balance of properties and processibility. Also, based on testing of spheres, they appear to be useful as compositions in golf ball applications, particularly as cover and/or intermediate layer material or as core and/or center material or as a one-piece ball, to achieve high resilience at high impact speed and relatively lower resilience at lower impact speed.
The thermoplastic compositions are partially or fully neutralized “bi-modal blends” of high copolymers/low copolymers. That is to say, they are melt-blends of ethylene α,β ethylenically unsaturated C 3-8 carboxylic acid copolymers having weight average molecular weights (Mw) of about 80,000 to about 500,000 (high copolymers) with ethylene α,β ethylenically unsaturated C 3-8 carboxylic acid low copolymers having Mw of about 2,000 to about 30,000 (low copolymers). The high copolymers may be blends of high copolymers and the low copolymers may be blends of low copolymers.
It has been found that, by proper selection of the low copolymer (AC540 has been found to be particularly useful), the thermoplastic compositions of this invention have demonstrated both enhanced melt processibility and enhanced heat stability. This combination of the property enhancements is contrasted to the reduction in heat stability that would be expected with higher melt flows. These unique bi-modal ionomer compositions are highly useful to the injection molding applications, including golf ball, foot wear, etc.
Further, with this proper selection of the low copolymer, the thermoplastic compositions of this invention are expected to have enhanced abrasion and scuff resistance. This property enhancement, together with the other property improvements described above, would be highly useful to injection molding, films applications, including golf ball, packaging films, flooring, protective coating, etc.
Preferably the weight percent high copolymer is about 50 to about 95 wt. % and the weight percent low copolymer is about 5 to about 50% based on the total weight of the high copolymer and the low copolymer. Preferably about 40 to 100%, alternatively about 50 to about 85%, of the acid moieties are neutralized by alkali metal or alkyline earth metal cations.
Optionally, the composition may contain up to 100 parts by weight of organic acid salts, up to 200 parts by weight thermoplastic elastomers, up to 170 parts by weight fillers based on 100 parts by weight of the “bi-modal” ionomer of high copolymer/low copolymer be blend.
The compositions described above or their blends could be applied in broad end-uses applications, including injection molding applications, golf ball applications, etc. More specifically the compositions described above are most suited for golf ball applications such as the cover, intermediate layers, core, and center of 2- or multiple-piece balls, and as thermoplastic 1-piece balls.
BRIEF DESCRIPTION OF FIGURES
FIGS. 1 through 6 are plots of coefficient of restitution versus impact speed for the individual bi-modal ionomers and the base ionomers used in Examples 23 through 28, respectively.
FIG. 7 is a plot of the data from Examples 23 though 29 depicting the differences in COR at the three velocities determined by subtracting the COR of the base ionomer from the COR of the bi-modal ionomer in each case.
FIG. 8 is a plot of resilience versus impact speed of neat spheres based on blends with or without the bi-modal ionomers.
FIG. 9 is a plot of the relative COR differences at different impact velocities between the bi-modal ionomer, i.e. BMI-1 or BMI-2, containing blends and the reference ionomer blend, i.e.ionomer-1/ionomer-2 (50:50 by weight).
DETAILED DESCRIPTION
All references disclosed herein are incorporated by reference.
“Copolymer” means polymers containing two or more different monomers. The terms “bipolymer” and “terpolymer” mean polymers containing only two and three different monomers respectively. The phrase “copolymer of various monomers” means a copolymer whose units are derived from the various monomers.
“Low copolymer” is used herein to differentiate the lower Mw materials, those with Mw of about 2,000 to about 30,000, from the higher Mw high copolymers, those with Mw of about 80,000 to about 500,000.
“High copolymer” is used herein to differentiate the higher Mw materials, those with Mw of about 80,000 to about 500,000, from the lower Mw low copolymers, those with Mw of about 2,000 to about 30,000.
“Mw” means weight average molecular weight. “Mn” means number average molecular weight.
“Bi-Modal Blends” means blends of high copolymers and low copolymers wherein the Mw of the high copolymer and the Mw of the low copolymer are sufficiently different that two distinct molecular weight peaks can be observed when measuring Mw of the blend by GPC with high resolution column.
“Ethylene (meth) acrylic acid” means ethylene acrylic acid and/or ethylene methacrylic acid. Thus, the shorthand notation “E/(M)AA” used to identify, describe and/or claim a copolymer means ethylene acrylic acid and/or ethylene methacrylic acid copolymer wherein “(M)” denotes “(meth)” and “AA” denotes “acrylic acid”.
According to the present invention, ethylene α,β ethylenically unsaturated C 3-8 carboxylic acid high copolymers, particularly ethylene (meth)acrylic acid bipolymers and ethylene, alkyl (meth)acrylate, (meth)acrylic acid terpolymers, having molecular weights of about 80,000 to about 500,000 are melt blended with ethylene α,β ethylenically unsaturated C 3-8 carboxylic acid low copolymers, particularly ethylene (meth)acrylic acid low copolymers (more particularly the bipolymers), of about 2,000 to about 30,000 by methods well known in the art.
Preferably the Mw of the high copolymers is separated from the Mw of the low copolymers sufficiently that the peaks for the high copolymers are distinctly separated from the peaks for the low copolymers when the blend molecular weight distribution is determined by GPC with high resolution column. Preferably, high copolymers with lower Mw's are blended with low copolymers with lower Mw's (e.g. high copolymers with Mw of 80,000 with low copolymers with Mw of 2,000). This becomes less important as the Mw's of the high copolymers increase.
Preferably the low copolymers are present in the range of about 5 to about 50 weight percent based on the total weight of the high copolymers and the low copolymers in the blend.
Preferably the high copolymers and low copolymers are partially or fully neutralized by alkali metal or alkyline earth metal cations. Preferably, about 40 to about 100%, alternatively about 50 to about 85%, alternatively about 50 to about 90%, alternatively about 60 to about 80% of the acid moieties in the high copolymers and low copolymers are neutralized. Cations are lithium*, sodium*, potassium, magnesium*, calcium, barium, lead, tin, or zinc* (*=preferred), or a combination of such cations.
Neutralization can be effected by first making an ionomer of the high copolymer and/or of the low copolymer and then melt-blending them. To achieve desired higher or full neutralization the resulting blend of ionomers can be further neutralized. Preferably the high copolymers and low copolymers are melt-blended and then neutralized in situ. In this case desired higher or full neutralization can be achieved in one step.
Optionally, the composition may contain up to 100 parts by weight of organic acid salts, up to 200 parts by weight thermoplastic elastomers, up to 170 parts by weight fillers based on 100 parts by weight of the “bi-modal” ionomer of the high copolymer/low copolymer blend. Other additives such as stabilizers and processing aids can be included.
The components of the blends of the present invention are more fully described below.
High Copolymers
The high copolymers of this invention are preferably ‘direct’ acid copolymers (as opposed to grafted copolymers) having an Mw of about 80,000 to about 500,000. Preferably they have polydispersities (Mw/Mn) of about 1 to about 15.
They are preferably alpha olefin, particularly ethylene, /C 3-8 α,β ethylenically unsaturated carboxylic acid, particularly acrylic and methacrylic acid, copolymers. They may optionally contain a third softening monomer. By “softening”, it is meant that the polymer is made less crystalline. Suitable “softening” comonomers are monomers selected from alkyl acrylate and alkyl methacrylate, wherein the alkyl groups have from 1-12 carbon atoms, and vinyl acetate.
The ethylene acid copolymers can be described as an E/X/Y copolymers where E is ethylene, X is the α,β ethylenically unsaturated carboxylic acid, and Y is a softening comonomer. X is preferably present in 2-30 (preferably 5-25, most preferably 8-20) wt. % of the polymer, and Y is preferably present in 0-35 (alternatively 3-25 or 10-25) wt. % of the polymer.
The ethylene-acid copolymers with high levels of acid (X) are difficult to prepare in continuous polymerizers because of monomer-polymer phase separation. This difficulty can be avoided however by use of “co-solvent technology” as described in U.S. Pat. No. 5,028,674 which is incorporated herein by reference or by employing somewhat higher pressures than those at which copolymers with lower acid can be prepared.
Specific acid-copolymers include ethylene/(meth) acrylic acid bipolymers. They also include ethylene/(meth) acrylic acid/n-butyl (meth) acrylate, ethylene/(meth) acrylic acid/iso-butyl (meth) acrylate, ethylene/(meth) acrylic acid/methyl (meth) acrylate, and ethylene/(meth) acrylic acid/ethyl (meth) acrylate terpolymers.
Examples of high copolymers and their molecular weights are shown in the following table.
Mn Mw Polydispersity Composition/MI (10 3 ) (10 3 ) (Mw/Mn) E/23.5nBA/9MAA/25MI 26.6 176.5 6.6 E/15MAA/60MI 17.6 112.4 6.4 E/4MAA/3MI 31.7 365.5 11.5 E/5.8AA/1.5MI 31.5 162.1 5.1 E/9AA/10MI 24.3 186.4 7.7 E/10MAA/500MI 16.0 84.0 5.3 E/10MAA/35MI 19.6 160.8 8.2
Low Copolymers
The low copolymers of this invention are preferably ‘direct’ acid copolymers having an Mw of about 2,000 to about 30,000. Preferably they have polydispersities (Mw/Mn) of about 1 to about 10. They are preferably alpha olefin, particularly ethylene, /C 3-8 α,β ethylenically unsaturated carboxylic acid, particularly acrylic and methacrylic acid, copolymers. Preferably the acid moiety in these copolymers is about 3 to about 25 (preferably 5-15, most preferably 5-10) wt. % of the polymer.
Often these low copolymers are referred to as acid copolymer waxes available from Allied Signal (e.g., Allied wax AC143 believed to be an ethylene/16-18% acrylic acid copolymer with a number average molecular weight of 2,040, and others indicated in the following table with their molecular weights).
Mn Mw Polydispersity Composition/MI (10 3 ) (10 3 ) (Mw/Mn) AC540 E/5AA/575 cps 4.3 7.5 1.7 Brookfield @ 140 C.** AC580 E/10AA/650 cps 4.8 26.0 5.4 Brookfield @ 140 C.** AC5120 E/15AA/650 cps 3.0 5.2 1.7 Brookfield @ 140 C.** **No MI data available; Brookfield data defined by Honeywell or formally Allied Signal
Ionomers
Ionomers of the high copolymers and of the low copolymers when made separately can be made by methods well known in the art. The degree of neutralization and the acid level should be selected so that the resulting ionomers of the high copolymers and the ionomers of the low copolymers remain melt processible.
The bi-modal ionomers of high copolymer/low copolymer blends can be made by melt blending the melt processible ionomers separately made and then optionally further neutralizing with same or different cations to achieve desired higher or full neutralization of the resulting blend of ionomers. Preferably the non-neutralized high copolymers and low copolymers are melt-blended and then neutralized in situ. In this case desired higher or full neutralization can be achieved in one step.
In either case, the neutralization can be effected by alkali metal or alkaline earth metal cations. Such cations are lithium*, sodium*, potassium, magnesium*, calcium, barium, lead, tin, or zinc* (*=preferred), or a combination of such cations. Preferably the acid moieties in the resulting bi-modal ionomer of the high copolymers and low copolymers are partially or fully neutralized to a level of about 40 to about 100%, alternatively about 50 to about 85%, alternatively about 50 to about 90%, alternatively about 60 to about 80%.
Organic Acid Salts
The salt of organic acid of the present invention comprises the salts, particularly the barium, lithium, sodium, zinc, bismuth, chromium, cobalt, copper, potassium, strontium, titanium, tungsten, magnesium or calcium salts, of fatty acids, particularly stearic, behenic, erucic, oleic, linoleic, Preferably, the fatty acid salt is selected to have the lowest volatility. It is chosen so as to maximize COR while minimizing stiffness or compression, which has often been called “PGA Compression” in the golf ball art.
Thermoplastic Elastomers
The thermoplastic polymer component of the invention is selected from copolyetheresters, copolyetheramides, elastomeric polyolefins, styrene diene block copolymers and thermoplastic polyurethanes, these classes of polymers being well known in the art.
The copolyetheresters are discussed in detail in patents such as U.S. Pat. Nos. 3,651,014; 3,766,146; and 3,763,109. They are comprised of a multiplicity of recurring long chain units and short chain units joined head-to-tail through ester linkages, the long chain units being represented by the formula
and the short chain units being represented by the formula
where G is a divalent radical remaining after the removal of terminal hydroxyl groups from a poly (alkylene oxide) glycol having a molecular weight of about 400-6,000 and a carbon to oxygen ratio of about 2.0-4.3; R is a divalent radical remaining after removal of carboxyl groups from a dicarboxylic acid having a molecular weight less than about 300; and D is a divalent radical remaining after removal of hydroxyl groups from a diol having a molecular weight less than about 250; provided said short chain ester units amount to about 15-95 percent by weight of said copolyetherester. The preferred copolyetherester polymers are those where the polyether segment is obtained by polymerization of tetrahydrofuran and the polyester segment is obtained by polymerization of tetramethylene glycol and phthalic acid. Of course, the more polyether units incorporated into the copolyetherester, the softer the polymer. For purposes of the invention, the molar ether:ester ratio can vary from 90:10 to 10:90, preferably 80:20 to 60:40; and the shore D hardness is less than 70, preferably less than about 40.
The copolyetheramides are also well known in the art as described in U.S. Pat. No. 4,331,786, for example. They are comprised of a linear and regular chain of rigid polyamide segments and flexible polyether segments, as represented by the general formula
wherein PA is a linear saturated aliphatic polyamide sequence formed from a lactam or amino acid having a hydrocarbon chain containing 4 to 14 carbon atoms or from an aliphatic C 6 -C 9 diamine, in the presence of a chain-limiting aliphatic carboxylic diacid having 4-20 carbon atoms; said polyamide having an average molecular weight between 300 and 15,000; and PE is a polyoxyalkylene sequence formed from linear or branched aliphatic polyoxyalkylene glycols, mixtures thereof or copolyethers derived therefrom said polyoxyalkylene glycols having a molecular weight of less than or equal to 6,000 and n indicates a sufficient number of repeating units so that said polyetheramide copolymer has an intrinsic viscosity of from about 0.8 to about 2.05. The preparation of these polyetheramides comprises the step of reacting a dicarboxylic polyamide, the COOH groups of which are located at the chain ends, with a polyoxyalkylene glycol hydroxylated at the chain ends, in the presence of a catalyst such as a tetra-alkyl ortho-titinate having the general formula Ti(OR) 4 , wherein R is a linear branched aliphatic hydrocarbon radical having 1 to 24 carbon atoms. Again, the more polyether units incorporated into the copolyetheramide, the softer the polymer. The ether:amide ratios are as described above for the ether:ester ratios, as is the shore D hardness.
The elastomeric polyolefins are polymers composed of ethylene and higher primary olefins such as propylene, hexene, octene and optionally 1,4-hexadiene and or ethylidene norbornene or norbornadiene. The elastomeric polyolefins can be functionalized with maleic anhydride.
Thermoplastic polyurethanes are linear or slightly chain branched polymers consisting of hard blocks and soft elastomeric blocks. They are produced by reacting soft hydroxy terminated elastomeric polyethers or polyesters with diisocyanates such as methylene diisocyanate (MDI) or toluene diisocyanate(TDI). These polymers can be chain extended with glycols, diamines, diacids ,or amino alcohols. The reaction products of the isocyanates and the alcohols are called urethanes and these blocks are relatively hard and high melting. These hard high melting blocks are responsible for the thermoplastic nature of the polyurethanes.
Block styrene diene copolymers are composed of polystyrene units and polydiene units. The polydiene units are derived from polybutadiene, polyisoprene units or copolymers of these two. In the case of the copolymer it is possible to hydrogenate the polyolefin to give saturated rubbery backbone segments. These materials are usually referred to as SBS, SIS or SEBS thermoplastic elastomers and they can also be functionalized with maleic anhydride.
Fillers
The optional filler component of the subject invention is chosen to impart additional density to the bi-modal ionomers or blends of them with other materials. Preferred densities depend on the application. In golf balls, they will include densities in the range starting with the density of unfilled polymer to 1.8 gm/cc. Generally, the filler will be inorganic having a density greater than about 4 gm/cc, preferably greater than 5 gm/cc, and will be present in amounts between 0 and about 60 wt. % based on the total weight of the composition. Examples of useful fillers include zinc oxide, barium sulfate, lead silicate and tungsten carbide, tin oxide, as well as the other well known corresponding salts and oxides thereof. It is preferred that the filler materials be non-reactive or almost non-reactive with the polymer components described above when the ionomers are less than completely neutralized. If the ionomers are fully neutralized, reactive fillers may be used. Zinc Oxide grades, such as Zinc Oxide, grade XX503R available from Zinc Corporation of America, that do not react with any free acid to cause cross-linking and a drop in MI are preferred, particularly when the ionomer is not fully neutralized.
Other Components
Other optional additives include titanium dioxide which is used as a whitening agent or filler; other pigments, optical brighteners; surfactants; processing aids; etc.
Uses of Composition in Golf Balls
The bi-modal ionomers of this invention are useful in combination with other materials in specific combinations which, in large part, will be dependent upon the application. The bi-modal ionomers may be substituted for one or more materials taught in the art at the levels taught in the art for use in covers, cores, centers, intermediate layers in multi-layered golf balls, or one-piece golf balls. Sufficient fillers can be added to one or more components of the golf ball to adjust the weight of the golf ball to a level meeting the limits set by the golfer's governing authority. See, for example, U.S. Pat. Nos. 4,274,637; 4,264,075; 4,323,247; 4,337,947, 4,398,000; 4,526,375; 4,567,219; 4,674,751; 4,884,814; 4,911,451; 4,984,804; 4,986,545; 5,000,459; 5,068,151; 5,098,105; 5,120,791; 5,155,157; 5,197,740; 5,222,739; 5,253,871; 5,298,571; 5,321,089; 5,328,959; 5,330,837; 5,338,038; 5,338,610; 5,359,000; 5,368,304; 5,810,678; 5,971,870; 5,971,871; 5,971,872; 5,973,046; 5,810,678; 5,873,796; 5,757,483; 5,567,772; 5,976,443; 6,018,003; 6,096,830; and WO 99/48569.
Three-Piece Golf Ball
As used herein, the term “three-piece ball” refers to a golf ball comprising a center, a traditional elastomeric winding wound around the center, and a cover made from any traditional golf ball cover material such as Surlyn® ionomer resin, balata rubber or thermoset/thermoplastic polyurethanes and the like. These three-piece golf balls are manufactured by well known techniques as described in U.S. Pat. No. 4,846,910 for example. The bi-modal ionomer may be used in the cover or the center of such balls in combination with other materials typically used in these components.
Two-Piece Golf Ball
As used herein, the term “two-piece ball” refers to a golf ball comprising a core and a cover made from any traditional golf ball cover material as discussed above. These two-piece balls are manufactured by first molding the core from a thermoset or thermoplastic composition, positioning these preformed cores in injection molding cavities using retractable pins, then injection molding the cover material around the cores. Alternatively, covers can be produced by compression molding cover material over the cores. The bi-modal ionomer may be used in the cover or the core of such balls alone or in combination with other materials typically used in these components.
Multi-Layer Golf Ball
As used herein, the term “multi-layer ball” refers to a golf ball comprising a core, a cover made from any traditional golf ball cover material, and one or more mantles between the core and the cover. These multi-layer balls are manufactured by first molding or making the core, typically compression or injection molding a mantle over the core and then compression or injection molding a cover over the mantle. The bi-modal ionomer may be used in the cover, the one or more mantles or the core of such balls alone or in combination with other materials typically used in these components.
One-Piece Golf Ball
As used herein, the term “one-piece ball” refers to a golf ball molded in toto from a thermoplastic composition, i.e., not having elastomeric windings nor a cover. The one-piece molded ball will have a traditional dimple pattern and may be coated with a urethane lacquer or be painted for appearance purposes, but such a coating and/or painting will not affect the performance characteristics of the ball. These one-piece balls are manufactured by direct injection molding techniques or by compression molding techniques. The bi-modal ionomer may be used in such balls in combination with other materials typically used in these balls.
EXAMPLES AND COMPARATIVE EXAMPLES
The resins used in the examples were as follows:
Mn*
Mw*
Polydispersity*
Composition/MI
(E3)
(E3)
(Mw/Mn)
AC540
E/5AA/500 cps Brookfield
4.3
7.5
1.7
@ 140 C.**
AC580
E/10AA/650 cps
4.8
26.0
5.4
Brookfield @ 140 C.**
AC5120
E/15AA/650 cps
3.0
5.2
1.7
Brookfield @ 140 C.**
HCP 1
E/23.5nBA/9MAA/25MI
26.6
176.5
6.6
HCP 2
E/8.3AA/17nBA
Ionomer-1
E/23.5nBA/9MAA, 51%
Mg neutralized/1.1MI
Ionomer-2
E/19MAA, 37% Na
neutralized/2.6MI
Ionomer-3
E/11MAA, 37% Na
neutralized/10MI
Ionomer-4
E/11MAA, 57% Zn
neutralized/5.2MI
Ionomer-5
E/15MAA, 53% Zn
neutralized/5.0MI
Ionomer-6
E/15MAA, 51% Na
neutralized/4.5MI
*MW and MWD Comparison (by GPC)
**No MI data available
Examples 1-6
Blends of E/9MAA/23.5nBA (HCP 1) and E/10AA (AC580) at 90:10 (Example 1) and 80:20 (Example 2) ratios were neutralized on a single screw extruder with a Mg(OH) 2 concentrate into bi-modal ionomers with the level of neutralization indicated in the following table. The ionomers of Example 1 and Example 2 together with reference Ionomer-1 (Comparative Example 3) were injection molded into spheres and tested for the golf ball properties. Improved COR's are measured for the bi-modal ionomers over the reference. When bi-modal ionomer of Example 1 was further modified with Magnesium Stearate, dramatic property enhancements were achieved (Examples 4, 5 and 6).
Ex. 1
Ex. 2
Comp. Ex. 3
E/MAA/nBA, wt %
90
80
100
E/AA, wt %
10
20
0
Nominal Neut., %
70
75
51
MI at 190° C.
1
1
1.1
PGA compression
86
90
58
Drop Rebound, %
59.8
56.3
56.6
COR-125
0.671
0.670
0.644
COR-180
0.628
0.628
0.596
Ex. 4
Ex. 5
Ex. 6
Ex. 1 Bi-modal
85
70
60
ionomer, wt. %
MgSt., w %
15
30
40
MI at 190° C.
1.5
1.6
2.5
PGA compression
85
83
91
Drop Rebound, %
68.3
75.2
77.1
COR-125
0.728
0.761
0.773
COR-180
0.678
0.703
0.718
Examples 7-12
A pellet blend of 90 wt. % Ionomer-2 and 10 wt. % E/15AA (AC5120) was melt blended and neutralized in the presence of a specific amount of Na 2 CO 3 concentrate to a nominal neutralization level of 60% in a twin screw extruder to achieve the bi-modal ionomer (BMI-2). A pellet blend of 90 wt. % Ionomer-1 and 10 wt. % E/10AA (AC580) was melt blended and neutralized in the presence of a specific amount of Mg(OH) 2 concentrate to a nominal neutralization level of 70% in a twin screw extruder to achieve the bi-modal ionomer (BMI-1). Ionomer blends were then prepared by melt blending on a twin screw extruder at 50:50 ratio the bi-modal ionomers, i.e. BMI-2, BMI-1 and the conventional ionomers, i.e. Ionomer-2 and Ionomer-1. The base ionomers and blends depicted in the table were injection molded into spheres and tested for the golf ball properties. The resilience enhancement of the blends containing the bi-modal ionomers was clearly illustrated.
Ex. 7
Ex. 8
Ex. 9
Comp. Ex. 10
Ex. 11
Comp. Ex. 3
Comp. Ex. 12
BMI-2, wt %
50
50
—
—
100
—
BMI-1, wt %
50
—
50
—
—
—
Ionomer-2
—
—
50
50
—
100
Ionomer-1
—
50
—
50
—
100
—
MI
0.6
0.6
NA
NA
0.6
1.1
2.0
Neat Sphere Property
PGA
130
125
132
126
150
58
158
compression
Drop
67.3
66.7
66.7
64.6
76
56.6
80.3
Rebound, %
COR-125
0.707
0.697
0.689
0.671
0.740
0.644
0.750
COR-180
0.659
0.651
0.640
0.621
0.692
0.596
0.693
Examples 13-18
Bimodal ionomers based on Na and Zn ionomers containing 11% MAA, i.e. Ionomer-3 and Ionomer-4, and E/10AA at 90:10 ratio were prepared on the twin screw extruder under the blending/neutralization conditions similar to the above examples using a Na 2 CO 3 concentrate or a ZnO concentrate. The base ionomers and the bi-modal ionomers were injection molded into spheres and tested for the golf ball properties. The bi-modal ionomers and their blends showed lower PGA compression and improved COR.
Comp.
Comp.
Comp.
Ex. 13
Ex. 14
Ex. 15
Ex. 16
Ex. 17
Ex. 18
BMI-3
100
50
BMI-4
100
50
Ionomer-3
100
50
Ionomer-4
100
50
Nominal
75
75
37
57
75
47
Neut, %
MI
1
2
10
5
1.8
NA
PGA
130
134
146
139
134
146
Comp.
Drop
67.7
59
64.5
60.4
66.3
66.7
Rebound, %
COR-125
0.702
0.621
0.649
0.615
0.691
0.669
COR-180
0.660
0.580
0.601
0.569
0.651
0.622
Examples 19-22
Blend of E/8.3AA/17nBA (HCP 2) and E/10AA (AC580) at 90:10 weight ratio was neutralized on a single screw extruder with a Mg(OH) 2 concentrate into a bi-modal ionomer with 2MI and a nominal neutralization level of 63% (Examples 20). A reference (Comparative Example 19) was also prepared under the similar conditions to a nominal neutralization level of 53% with HCP 2 alone. The ionomers are injection molded into spheres and tested for the golf ball properties. Improved COR's are measured for the bi-modal ionomers over the reference. When bi-modal ionomers of Example 20 were further modified with MgSt. (Examples 21 and 22) dramatic property enhancements were achieved.
Comp. Ex. 19
Ex. 20
Ex. 21
Ex. 22
MgSt. Mod., w %
0
0
15
40
MI
2
2
1.9
1.3
PGA Comp.
108
111
108
108
Drop Rebound, %
60.9
61.9
69.2
79.4
COR-125
0.673
0.676
0.728
0.794
COR-180
0.631
0.636
0.686
0.745
Examples 23-29
Bi-modal ionomers of this invention achieve performance improvement over the conventional base ionomer references in the relative relationship between resilience and impact speed, i.e. high relative resilience at high impact speed and lower relative resilience at low impact speed when compared with conventional ionomer counterparts. This performance combination is highly desirable in the golf ball application to enable greater driving distance and better putting control.
COR Difference between
BM Surlyn and Ref. Surlyn
Example
23 ft/s
125 ft/s
180 ft/s
23
BMI-3 - Ionomer-3
0.020
0.053
0.059
24
BMI-4 - Ionomer-4
−0.009
0.006
0.011
25
BMI-5*** - Ionomer-5
−0.008
0.016
0.023
26
BMI-6**** - Ionomer-6
−0.022
−0.010
0.001
27
BMI-2 - Ionomer-2
−0.024
−0.010
−0.001
28
BMI-1/20* - Ionomer-1
−0.002
0.026
0.032
29
BMI-1/10** - Ionomer-1
0.021
0.027
0.032
*BMI-1/20: 80:20 blend of ionomer of HCP 1 and E/10AA (AC580) and further neutralized with Mg.
**BMI-1/10: 90:10 blend of ionomer of HCP 1 and E/10AA (AC580) and further neutralized with Mg.
***BMI-5: Blend of ionomer-5 and E/15AA (AC5120) at 90:10 by weight and further neutralized with Zn.
****BMI-6: Blend of ionomer-6 and E/15AA (AC5120) at 90:10 by weight and further neutralized with Na.
FIGS. 1 through 6 are plots of coefficient of restitution versus impact speed for the individual bi-modal ionomers and the base ionomers used in Examples 23 through 28, respectively. The impact speed of 23 feet/second was achieved by a drop rebound test (dropping sphere from a height of 100 inches onto a hard, rigid surface such as a thick steel plate or a stone block). The COR was then calculated from the impact velocities based on the drop height and the rebound height measured. COR's at 125 and 180 feet/second speeds were measured by firing the sphere from an air cannon at a velocity determined by the air pressure. The outbound velocity generally employed is between 125 to 180 feet/second. The ball strikes a steel plate positioned three feet away from the point where outbound velocity is determined, and rebounds through a speed-monitoring device. The return velocity divided by the outbound velocity is the COR.
FIG. 7 is a plot of the data in the table. It is a plot of the differences in COR at the three velocities determined by subtracting the COR of the base ionomer from the COR of the bi-modal ionomer in each case.
FIG. 8 is a plot of resilience versus impact speed of neat spheres based on blends with or without the bi-modal ionomers. The bi-modal stiff ionomer and blends property characterization is provided in the following table.
Bi-modal Stiff Ionomer and Blends Property Characterization
Ionomer-2
100
50
50
Ionomer-1
50
50
BMI-2
100
50
50
BMI-1
50
50
MI, g/10 min
2
0.6
NA
0.6
NA
0.6
Neat Sphere Property
PGA
158
150
126
125
132
130
Compression
Drop
80.3
76
64.6
66.7
66.7
67.3
Rebound, %
COR-23
0.896
0.872
0.804
0.817
0.817
0.820
(Calc)
COR-125
0.75
0.74
0.671
0.697
0.689
0.707
COR-180
0.693
0.792
0.621
0.651
0.64
0.659
FIG. 9 is a plot of the relative COR differences at different impact velocities between the bi-modal ionomer, i.e. BMI-1 or BMI-2, containing blends and the reference ionomer blend, i.e.ionomer-1/ionomer-2 (50:50 by weight). While the bi-modal ionomer containing blends exhibit higher COR at higher impact velocities, they exhibit comparable COR at 23 ft/second to allow good putting control, in combination with long drive distance.
23 ft/sec
125 ft/sec
180 ft/sec
COR at Different Impact Speeds
Ionomer-2/Ionomer-1
0.804
0.671
0.621
BMI-2/Ionomer-1
0.817
0.697
0.651
Ionomer-2/BMI-1
0.817
0.689
0.64
BMI-2/BMI-1
0.82
0.707
0.659
COR Difference Relative to
Ionomer-2/Ionomer-1 Blend
BMI-2/Ionomer-1
0.013
0.026
0.03
Ionomer-2/BMI-1
0.013
0.018
0.019
BMI-2/BMI-1
0.016
0.036
0.038
Examples 30 to 33
Bi-modal ionomers of this invention achieve performance improvement over the conventional base ionomer references in the heat stability, as measured by the resistance to deformation at the elevated temperature and under stress. E/9MAA/23.5nBA (HCP 1) was partially neutralized (about 51%) with Mg(OH) 2 concentrate on a single screw extruder and was subsequently blended with E/5AA (AC540) at 90:10 (Example 30) and 85:15 (Example 31) ratios and further neutralized with Mg(OH) 2 concentrate to maintain approximately 51% neutralization.
E/9MAA/23.5nBA (HPC 1) was also partially neutralized (about 51%) with ZnO concentrate on a single screw extruder and subsequently blended with E/5AA (AC540) at 90:10 (Example 32) and 85:15 (Example 33) ratios.
The bi-modal ionomers consistently demonstrated lower deformations than the conventional base ionomer references after subjecting to 70° C. and 1 Newton force for 1400 minutes reflecting enhanced resistance to heat induced deformation, i.e. heat stability. This performance enhancement is highly desirable in the golf ball application to enable ball stability when stored in hot environment under load.
Ex.
Ex.
Comp.
Comp.
Ex. 1
30
31
Ex. 3
Ex. 32
Ex. 33
Ex. 34**
MI
1
1.8
2.7
0.95
0.48
0.77
0.28
% Deform.*
17.3
10.2
9.9
22.1
15
9.7
20.6
*Deformation = % Height Change under 1 Newton/70° C. for 1400 minutes.
**Resin used in Comp. Ex. 34: E/9MAA/23.5nBA/25MI about 51% neutralized with ZnO.
|
The present invention relates to compositions and preparative process of partially or fully neutralized mixtures of carboxylate functionalized ethylene high copolymers or terpolymers (Mw between 80,000 and 500,000) with carboxylate functionalized ethylene low copolymers (Mw between 2,000 and 30,000) and organic acid salts and injection or compression molded applications such as golf ball components thereof.
| 2
|
BACKGROUND OF THE INVENTION
The present invention relates to a PTC (Positive Temperature Coefficient) thermistor element and more particularly to a PTC element used to protect against electrical circuit overcurrent surges.
Conventional PTC elements used to protect an electrical circuit use polymer dispersed carbonaceous conductive particles for PTC properties and a metal electrode affixed to the polymer. Polyethylene is conventionally used for the polymer component. Electrical stability is difficult to attain with these PTC elements, however, because the difficulty of joining or attaching the metal electrode to the polyethylene with sufficient bonding strength makes the resulting bond unpredictable. A second major drawback of these PTC elements is their tendency to peel during repeated use. This peeling is due to a difference in the coefficients of thermal expansion between the metal and polyethylene.
A further problem with PTC elements of the prior art is the fact that polyethylene is slightly permeable to gases, and the metal electrodes are impermeable. Thus, gases attempting to escape the polyethylene may collect under the metal electrodes, and encourage degradation of the bond.
Many methods for overcoming these problems have been used. For example, Japanese Patent Laid-Open No. 38162/1982 discloses a method wherein the surface of an electrode is treated with a titanate coupling agent where it is joined to the PTC element. The electrode is then bonded to the PTC element by thermal compression.
For another example, Japanese Patent Laid-Open No. 196901/1985 discloses a polymeric PTC thermistor wherein, prior to bonding, a surface of an electrode is roughened at the point where it joins the PTC element. The roughened surface contributes to mechanical keying, and thus improves the bond.
In yet another example, Japanese Patent Laid-Open No. 229679/1987 discloses a resistor composed of resin and conductive particles whose electrode is one of the following:
a low resistance compound produced by blending conductive particles in the same resin as the resistor, or in a resin capable of thermal fusion with the resistor;
a metal or carbon fiber coated with the low resistant compound.
Further, Japanese Patent Laid-Open No. 265401/1988 discloses a polymeric PTC thermistor using carbon fiber or activated carbon fiber as its electrode.
However, attaching a metal leaf electrode firmly to a conventional polyethylene PTC element remains problematic, and attaining electrical stability remains uncertain.
PTC elements that use metal electrodes have still another drawback. The electrodes of these PTC elements tend to peel during and after a thermal shock.
A metal electrode presents yet another problem. During cross-linking by gamma ray irradiation after attachment to a PTC element, an electrode may trap decomposition gas from the PTC element. This tends to destroy the bond.
Japanese Patent Laid-Open No. 229679/1987 discloses a PTC element, that consists of carbonaceous conductive particles and a polyethylene polymer. This PTC element is used with an organic electrode consisting of the same resin and conductive particles as the PTC element. This approach yields sufficient adhesion, but the use of similar resins for both the PTC element and the electrode causes other problems.
The resin composition of the PTC element is designed to open or trip at a predetermined temperature to protect an electronic circuit. Because the electrodes are formed of the same PTC composition as the PTC element, they are subject to thermal deterioration as they rise in temperature. As a result, these electrodes can fail at temperatures lower than the designed tripping temperature of the PTC element.
Because carbonaceous conductive particles are used for the organic electrode, the electrical resistance of the electrodes is high relative to a metal electrode. A commonly used conductive carbon black is Ketjen black. Although Ketjen black has a volume resistivity of about 1 ohm.cm, at a minimum, the volume resistivity of the electrode is considerably higher than this value. If the ratio of carbon black in the electrode is increased to a significant degree in an attempt to reduce the volume resistivity of the electrode, the composition of the electrode is weakened to the point where it is no longer usable.
Another problem with organic electrodes is that they cannot be attached to metal holders. This is not a problem with, for example, metal electrodes.
Yet another problem is that a polymer having a low affinity with the crystalline polymer used in the PTC element cannot be used for an organic electrode.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a PTC element for the protection of an electrical circuit that overcomes the drawbacks of the present art.
It is a further object of the present invention to provide a self-recovery PTC element with increased physical adhesiveness between a PTC element and an electrode.
It is a still further object of the invention to provide a self-recovery PTC element that, using an organic electrode, yields sufficient electrical stability and greater physical durability than a conventional organic electrode.
Briefly stated, the present invention provides a self-recovery PTC element for overcurrent protection of electrical circuits that is made with a polymer/metal powder composition electrode that displays stable resistivity over a broad range of contact forces. Secure bonding of electrodes to a PTC element is achieved because both components are polymer composites, eliminating the problems associated with attempts to bond metal electrodes to a polymer PTC element. Swelling of metal electrodes, that results from outgassing by a PTC element, is also eliminated, because polymer electrodes are gas permeable.
According to an embodiment of the invention, the present invention provides a PTC element comprising: a PTC element formed of a PTC composition, at least two electrodes formed of an electrode composition, the electrode composition being a polymer containing metal particles, and at least two electrodes being integrally affixed to the PTC element.
According to a feature of the invention, there is provided a PTC element comprising: a PTC element formed of a PTC composition, at least two electrodes formed of an electrode composition, the electrode composition being a polymer containing metal particles, the at least two electrodes being integrally formed with the PTC element, the electrode composition being a polyolefin derivative graft-polymerized with a monomer having a functional group onto the backbone of the polymer, and the PTC composition and the electrode composition are cross-linked.
According to a further feature of the invention, there is provided a PTC element comprising: a PTC element formed of a PTC composition, at least two electrodes formed of an electrode composition, the electrode composition being a polymer containing metal particles, the at least two electrodes being integrally formed with the PTC element, the electrode composition has a higher melting point than the PTC composition, and a volume resistivity of the at least two electrodes is less than about 4.0×10 -1 ohm.cm.
According to a still further feature of the invention, there is provided a method for making a PTC element comprising: mixing together a carbon black and a first polymer to produce a PTC composition, the carbon black and the first polymer being of a type providing a PTC characteristic, forming the PTC composition into a PTC element, cross-linking the first polymer in the PTC element, mixing together a metal powder and a second polymer to produce an electrode composition, and molding the electrode composition to the PTC element.
The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a PTC device according to an embodiment of the present invention.
FIG. 2 is a plot of the volume resistivity of an electrode with reference to Table 1.
FIG. 3 is a plot of the resistance value of a PTC device with a PTC element composed with reference to Table 2 and electrodes composed with reference to Table 1.
FIG. 4 is a front view of a PTC device in a holding fixture.
FIG. 5 is a curve showing the relationship between resistance value and contact load for two electrodes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a PTC device 10 is a flattened parallelepiped comprising a PTC element 1 sandwiched between two electrodes 2.
PTC device 10 is made by compression molding electrodes 2 onto the broad surfaces of a preformed PTC element 1. The electrode composition is produced by blending and kneading a mixture of ingredients listed in Table 1 using a mixing roll for 30 minutes at 200° C.
PTC element 1 is made of ingredients listed in Table 2 and cross-linked by 60 Mrad of gamma irradiation prior to the molding on electrodes 2. In addition to gamma radiation, cross-linking may be accomplished by other means such as, for example, heat and chemical treatment. Chemical treatment may be, for example, the addition of an organic peroxide to the mixture. The techniques for cross-linking may be used in combination, without departing from the spirit and scope of the invention.
TABLE 1______________________________________Electrode Composition conductive particlespolymer carbonaceous con-admar*.sup.1 metal powder ductive particles weight weightsample No. grade ratio kind ratio kind weight ratio______________________________________A QF551 100 Ni*.sup.2 400 -- --B QF551 100 Ni 500 -- --C QF551 100 Ni 600 -- --D QF551 100 Ni 700 -- --E QB540 100 Ni 600 -- --F QF550 100 Ni 600 -- --G QF550 100 Ni 600 CB*.sup.4 30H QF551 100 Cu*.sup.3 600 -- --______________________________________ *.sup.1 Manufactured by Mitsui Petrochemical Industries Adhesive polyolefine QF551: Melting point 135° C. QF550: Melting point 165° C. QB540: Melting point 150° C. *.sup.2 Manufactured by Fukuda Metal Foil & Powder Co., Ltd. INCO Type 287 Nickel Powder *.sup.3 Manufactured by Fukuda Metal Foil & Powder Co., Ltd. Cu--S (3L3) *.sup.4 Manufactured by Cabot Corporation BLACKPEARLS 2000 Specific surface area: 1475 (m.sup.2 /g) Average particle diameter: 15 nm
TABLE 2______________________________________Composition of PTC Element weightname of material grade manufacturer ratio______________________________________high density Hi-Zex 1300J Mitsui petro- 100polyethylene* chemical industriesporous black** asahiPB#400 Asahi carbon 32alumina A32 Nippon light metal 81dicumylperoxide percumyl D-40 Nippon oil & fats 0.8______________________________________ *Melting point: 131° C. **Produced from carbon black by increasing its specific surface area by vapor etching. It is less dependent on temperature when in actual use and maintains excellent PTC characteristics.
Typical dimensions for a PTC device 10 of FIG. 1 are as follows: 11=13 mm, 12=13 mm and 13=2 mm. The volume resistivity of electrodes 2, shown in FIG. 2, and respective resistance values of PTC element 1 and a comparison example I, shown in FIG. 3, were obtained in a first embodiment test. Table 3 summarizes the results shown in FIGS. 2 and 3. In FIGS. 2 and 3 the letter entries (A-I) along the horizontal axis correspond to letter designators A through I of Tables 1 and 3.
Referring to FIG. 4, a fixture 12 is used to measure the resistance value of PTC device 10. A frame 3 supports an upper holder 4 and a lower holder 5 in vertical opposition. A spring 6 is biased between frame 3 and upper holder 4 to provide a constant contact force of, for example, 800 gms between upper holder 4 and lower holder 5 and electrodes 2 of PTC device 10. Upper holder 4 and lower holder 5 each have a metal terminal (not shown) for providing low-resistance connection to electrodes 2.
The resistance of PTC device 10 is measured across the metal terminals of upper holder 4 and lower holder 5 by passing a current therebetween and measuring the voltage drop across PTC device 10.
Spring 6 may be replaced by a weight 7 applying force on upper holder 4 by gravity. It is contemplated that only one of these is used.
TABLE 3______________________________________Element Resistance electrode PTC elementsample No. volume resistivity ρ(Ωcm) resistance value (Ω)______________________________________A 4.25 × 10.sup.-1 1200B 1.96 × 10.sup.-1 29.9C 1.19 × 10.sup.-1 19.3D 8.09 × 10.sup.-2 17.2E 1.26 × 10.sup.-1 21.2F 9.46 × 10.sup.-2 20.6G 1.58 × 10.sup.-1 19.3H 2.30 × 10.sup.6 --I electrolytic 21.8 nickel foil______________________________________
Sample H of Table 1, using copper powder for its conductive particles, shows a large increase in volume resistivity. This is due to active oxidization on the surface of copper powder in the blended mixture. Therefore, copper powder should not be used alone. Treatment to retard surface corrosion resistance is necessary when copper powder is used.
In a second embodiment, electrodes 2 were produced in the same manner as for the first embodiment. These electrodes 2 were made using ingredients A and F of Table 1. PTC element 1 was made using the PTC composition given in Table 2 that is previously cross-linked by 60 Mrad of gamma irradiation. These PTC devices 10 are inserted between upper holder 4 and lower holder 5 of fixture 12 as shown in FIG. 4. Their resistance values are measured with a contact load applied as described earlier. The resultant measurements are given in FIG. 5.
Electrode 2 (ingredients A) of the comparison example has a volume resistivity of 4.25×10 -1 ohm.cm, which is greater than 4.0×10 -1 ohm.cm. The resistance value of its PTC element 1 cannot be reliably measured because it varies with contact load. On the other hand, electrode 2 (ingredients F) of this embodiment has a volume resistivity of 9.46×10 -2 ohm.cm. This is smaller than 4.0×10 -1 ohm.cm. The resistance value of electrode 2 (ingredients F) can be reliably monitored because it does not vary significantly with contact load.
In a third embodiment, PTC device 10 was produced in the same manner as the first embodiment, using electrodes 2 (ingredients B, D and G) of the first embodiment (see Table 1). An electrolytic nickel foil electrode 2, sample I of Table 3, is used for comparison. All of the PTC devices 10 were made with PTC element 1 consisting of the PTC composition shown in Table 4.
TABLE 4______________________________________PTC Element Composition weightname of material grade manufacturer ratio______________________________________high density Hi-Zex 1300J Mitsui petro- 82polyethylene chemical industrieslow density mirason 9* Mitsui petro- 18polyethylene chemical industriesporous black AsahiPB#400 Asahi carbon 37.5aluminium hydroxide B703.ST Nippon light metal 50dicumylperoxide percumyl D-40 Nippon oil fats 0.375______________________________________ *Melting point: approximately 100-110° C.
Cross-linking treatment was then applied using 60 Mrad of gamma irradiation. Each of these samples are subjected to three thermal shock tests consisting of 20, 50 and 100 sequential cycles of thermal shock, respectively. Each cycle of thermal shock consists of application of 75° C. for 30 seconds and 125° C. for 30 seconds. The result of the test is shown in Table 5.
TABLE 5______________________________________Thermal Shock Test ResultsNo. of cyclessample No. 20 cycles 50 cycles 100 cycles______________________________________B No change No change No changeD No change No change No changeG No change No change No changeI Wrinkles are pro- Wrinkling Wrinkling and duced, and spaces worsened, peeling between electrode resulting in further and PTC ele- peeling of worsened ment appeared electrode______________________________________
In a fourth embodiment, PTC devices 10 were formed as for the third embodiment, and then cross-linked by means of 130 Mrad of gamma irradiation.
Swelling of the electrodes does not occur even though the greater irradiation causes a greater outgassing from PTC element 1. This is because electrodes 2 are themselves permeable to gas.
According to the present invention, electrode 2 is formed of a polymer with metal powder or a mixture of metal powder and carbonaceous conductive particles dispersed within. Because electrode 2 and PTC element 1 are both polymers they can be firmly bonded together. The probability of peeling during or after thermal shock, as occurs with metallic leaf electrodes 2, is eliminated. Swelling and peeling generally experienced with metallic electrodes 2 during cross-linking is also eliminated by the use of gas permeable polymer electrodes 2.
As the volume resistivity of electrode 2 is set at or less than 4.0×10 -1 ohm.cm, according to the present invention, it is possible for PTC device 10 to retain a stable resistance value as voltage decreases under a contact load of several hundred grams.
The electrode composition used in the current invention includes a polymer whose melting point is higher than that of the crystalline polymer of the PTC element composition used. This prevents electrode 2 from acting as a PTC element.
Polymers used for the composition of electrode 2 according to the present invention are derivatives produced by graft-polymerization of acrylic acid or maleic anhydride, as the monomers having functional groups, onto polyolefins or olefin-copolymers such as polypropylene polyethylene or ethylene-vinyl acetate copolymer, for example, those sold under the brand names "Admer" (manufactured by Mitsui Petrochemical Industries) and "Duran." The crystalline polymer of PTC element 1 has a good compatibility with these polymers.
Nickel is the preferred metal powder used for the electrode composition since the resistance of nickel to oxidation minimizes changes in volume resistivity due to oxidization of the metal in the polymer mixture.
Because metal powder is blended into the electrode composition, PTC device 10 with this type of electrode 2 can be inserted directly into a holder equipped with metal terminals. Used as an overcurrent protection element, the resistance of PTC device 10 is stable during normal operation. PTC element 1 is connected through electrode 2 to a metal holder. Should a PTC anomaly of PTC device 10 occur (PTC device 10 reaches its tripping temperature as a result of an overcurrent condition), the PTC anomaly may be relieved by removing, and thereby cooling, the element without switching off the current. Because PTC device 10 self-recovers, when cooled, it returns to its nominal operating resistance value.
Furthermore, as PTC composition for electrical circuit protection consists of conductive particles such as, for example, carbon black or porous black, and of a polymer such as, for example, polyethylene, the composition bonds well with the polymer of the electrode. PTC device 10 also displays a strong affinity for a holder having a metal terminal because of the metal powder contained in electrode 2. By adding carbonaceous conductive particles to the ingredients of the electrode, the electrode is given an affinity for the carbon black and/or porous black contained in PTC element 1.
Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
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A self-recovery PTC device for overcurrent protection of electrical circuits is made with a polymer/metal powder composition electrode that displays stable resistivity over a broad range of contact forces. Secure bonding of electrodes to a PTC element is achieved because both components are polymer composites, eliminating the problems associated with attempts to bond metal electrodes to a polymer PTC element. Swelling of metal electrodes, that results from outgassing by a PTC element, is also eliminated, because polymer electrodes are gas permeable.
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FIELD OF THE INVENTION
[0001] The present invention relates to a system for supplying AC power to a display via a low voltage cable, such that a dedicated AC power outlet is no longer necessary.
BACKGROUND OF THE INVENTION
[0002] It is frequently desirable to install displays, such as flat screen TVs and the like, on concrete or masonry walls or in other locations lacking existing AC power outlets. Installing AC power outlets and running high voltage power cables to supply AC power to displays in such locations is often expensive and unsightly. In some cases, due to a historical nature of buildings, it is not possible to install electrical outlets and avoid damaging surrounding walls. In addition, installing AC power outlets requires a licensed high voltage contractor to do the installation. The same is true when a display is placed or installed temporarily with no power outlets within convenient reach. At the same time, low voltage cables, such as CAT5, CAT6 and CAT7 type cables, are frequently used to supply audio visual content, network and control signals to displays. These CAT type cables are small in diameter and are easy to route and feed through a wall, ceiling and floors. The CAT type cables can be installed by a low voltage contractor who is already on installation site and is involved in installation of audio visual equipment.
[0003] Therefore, there is a need for a system for supplying AC power to a display via a low voltage cable, such that a dedicated AC power outlet connected by high voltage power cable is no longer necessary.
SUMMARY OF THE INVENTION
[0004] The system for supplying AC power to a display via a low voltage cable according to this invention satisfies this need. It comprises a transmitter connected to an AC power outlet and generating DC voltage transmitted by a low voltage cable, comprising at least two wires, to a receiver. The receiver then converts the DC voltage, to AC voltage and supplies AC power to the display. A limiting circuit in the transmitter limits power transmitted by the low voltage cable to a predetermined wattage, depending on the feedback from the receiver, which insures safe operation of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 shows a schematic of a system according to this invention;
[0006] FIG. 2 shows a schematic of a transmitter according to this invention;
[0007] FIG. 3 shows a schematic of a receiver according to this invention;
[0008] FIG. 4 shows a schematic of a transmitter with the limiting circuit in a disengaged position;
[0009] FIG. 5 shows a schematic of a transmitter with the limiting circuit in an engaged position;
[0010] FIG. 6 shows a schematic of a CAT5, CAT6 or CAT7 cable connecting the transmitter and receiver according to the preferred embodiment of this invention.
DETAILED DESCRIPTION
[0011] This invention will be better understood with reference to the drawing FIGS. 1 through 6 . The same numerals refer to the same elements on all drawing figures.
[0012] Viewing FIG. 1 , numeral 10 indicates a transmitter. Numeral 20 indicates a receiver. Numeral 30 indicates a low voltage cable. Numeral 40 indicates a display. Numeral 140 indicates a first voltage. Numeral 150 indicates a third voltage. Transmitter 10 is energized by first voltage 140 . Transmitter 10 generates a second voltage energizing receiver 20 by way of low voltage cable 30 connecting transmitter 10 and receiver 20 . Receiver 20 generates third voltage 150 and supplies same to display 40 . First voltage 140 is AC, the second voltage is DC and third voltage 150 is AC.
[0013] Viewing now FIG. 2 , numeral 50 indicates a first converter circuit. First converter circuit 50 converts first voltage 140 into a DC second voltage. Numeral 60 indicates a limiting circuit. Limiting circuit 60 has engaged and disengaged positions, such that the disengaged position limits power transmitted via low voltage cable 30 to a first wattage and the engaged position allowing up to a second wattage to be transmitted via low voltage cable 30 .
[0014] Numeral 70 indicates an interrogating circuit interrogating circuit 70 controls limiting circuit 60 by way of interrogating receiver 20 with an interrogating signal at a predetermined frequency. Interrogating circuit 70 places limiting circuit 60 in the engaged position if receiver 20 is in communication with transmitter 10 . Interrogating circuit 70 places limiting circuit 60 in the disengaged position if receiver 20 is not in communication with transmitter 10 . Interrogating circuit 70 generates the interrogating signal. The interrogating signal is in a digital format and is transmitted as a data packet to receiver 20 . The data packet contains information that allows receiver 20 to know that a specific transmitter type is sending this data. Upon receipt of this signal, receiver 20 will acknowledge it and will send back confirmation identifying itself as capable of receiving the second wattage. Once interrogating circuit 70 receives the acknowledgment signal from receiver 20 , it will place limiting circuit 60 into the engaged position to increase power output.
[0015] The interrogation occurs at least one time per second. This is done to assure that if low voltage cable 30 is disconnected from receiver 20 or accidently cut, the power available from transmitter 10 is reduced to the first wattage. If the interrogating signal is not received by receiver 20 within one second, receiver 20 automatically shuts down third voltage 150 to maintain safety interlock.
[0016] Viewing now FIG. 3 , numeral 90 indicates a second converter circuit. Second converter circuit 90 converts the second voltage to the fourth voltage. Numeral 100 indicates an inverter circuit. Inverter circuit 100 converts the fourth voltage to the third voltage. The fourth voltage is DC and is substantially double the second voltage.
[0017] In the preferred embodiment described with the reference to the drawing FIGS. 1 through 6 , the first voltage is substantially between 100V and 240V; the second voltage is substantially 60V; the third voltage is substantially between 95V and 120V.
[0018] Viewing now FIG. 4 , limiting circuit 60 is shown in the disengaged position, thus only the first wattage is available to low voltage cable 30 . In the preferred embodiment described with the reference to the drawing FIGS. 1 through 6 , the first wattage is substantially 100 W. Further, in the preferred embodiment, limiting circuit 60 further comprises a first fuse indicated by numeral 60 a, a second fuse indicated by numeral 60 b and a relay indicated by numeral 60 c. The fuse type is a polyfuse that disconnects current flow when current limit of the fuse is exceeded and reconnects current back when current flow is below the current rating of the fuse.
[0019] First fuse 60 a is connected serially to first converter circuit 50 . Second fuse 60 b is connected serially to first fuse 60 a. Relay 60 c is connected in parallel with first fuse 60 a between first converter circuit 50 and second fuse 60 b. FIG. 4 shows relay 60 c being open. Relay 60 c is open in the disengaged position and closed in the engaged position. First fuse 60 a has lower current limit rating than second fuse 60 b. When relay 60 c is open, current passes through both first fuse 60 a and second fuse 60 b, as indicated by a heavy dashed line in FIG. 4 . Accordingly, power transmitted via low voltage cable 30 is limited to the first wattage, which is in this case 100 W.
[0020] Viewing now FIG. 5 , limiting circuit 60 is shown in the engaged position, thus allowing up to the second wattage to be transmitted via low voltage cable 30 . In the preferred embodiment described with the reference to the drawing FIGS. 1 through 6 , the second wattage is substantially 172 W.
[0021] National Electrical Code (NEC) dictates that the maximum power transmitted over a CAT type cable is 100 W. In the same Code, there is an exemption that if the receiver is known then the power can be increased to about 200 W. When using CAT type cables, special connectors are used to connect cables and equipment. The connectors are referred to as RJ-45. The RJ-45 connectors are rated to maximum 172 W and this is the limitation of the second wattage.
[0022] When relay 60 c is closed, current bypasses first fuse 60 a and passes only through second fuse 60 b, as indicated by a heavy dashed line in FIG. 5 . Accordingly, power transmitted via low voltage cable 30 is allowed up to the second wattage, which in this case is 172 W.
[0023] In the preferred embodiment, interrogating receiver 20 by interrogating circuit 70 further comprises receiving, by interrogating circuit 70 , a positive or negative authentication signal. The positive authentication signal is received when receiver 20 is capable of accepting the second wattage (i.e., 172 W). The negative authentication signal is received when receiver 20 is not capable of accepting the second wattage and can only accept first wattage. Interrogating circuit 70 places limiting circuit 60 in the engaged position in the event the positive authentication signal is received and places limiting circuit 60 in the disengaged position in the event the negative authentication signal is received.
[0024] Interrogating circuit 70 generates interrogating signal. This signal is in digital format and is transmitted as a data packet to receiver 20 . The data packet contains information that allows receiver 20 to know that a specific transmitter type is sending this data. This information may contain model number, manufacturer name and serial number of transmitter 10 . Upon receipt of this signal, receiver 20 will acknowledge it and will send back confirmation identifying itself as capable of receiving the second wattage. Once interrogating circuit 70 receives the acknowledgment signal from receiver 20 , it will place limiting circuit 60 in the engaged position to increase power output.
[0025] Viewing now, simultaneously, FIGS. 2 , 4 and 5 , numeral 80 indicates a first combiner circuit. First combiner circuit 80 is connected serially to second fuse 60 b and is in communication with interrogating circuit 70 . First combiner circuit 80 combines the second voltage and the interrogating signal and separates the second voltage from the positive or negative authentication signal.
[0026] Combiner circuit 80 comprises a transformer that separately passes DC voltage for power and a high frequency digital signal for interrogation. These two signals simultaneously pass through the transformer and are available at receiver 20 . The interrogation signal can pass bidirectionaly between transmitter 10 and receiver 20 .
[0027] Viewing again FIG. 3 , numeral 110 indicates a responding circuit. Responding circuit 110 communicates either the positive or negative authentication signal to interrogating circuit 70 in response to the interrogating signal. Numeral 120 indicates a second combiner circuit. Second combiner circuit 120 is connected serially to second converter circuit 90 and is in communication with responding circuit 110 . Second combiner circuit 120 combines the second voltage with the positive or negative authentication signal and separates the second voltage from the interrogating signal.
[0028] Combiner circuit 120 comprises a transformer that separately passes DC voltage for power and a high frequency digital signal for interrogation to responding circuit 110 . These two signals simultaneously pass through the transformer and are available at receiver 20 . The interrogation signal can pass bidirectional between transmitter 10 and receiver 20 .
[0029] Numeral 130 indicates a current managing circuit. Current managing circuit 130 increases voltage to display 40 at a predetermined rate. In the preferred embodiment, the predetermined rate is substantially between 10 and 50 volts per second.
[0030] All displays have capacitors on the power input. These capacitors are used to maintain steady voltage after AC power is received and rectified. Mere presence of these capacitors creates an in-rush current that can exceed 100 amps when AC power is applied to the monitor. This inrush current, if not managed, would exceed the current limit established for RJ-45 connectors and the current limit of the second voltage 50 . To reduce the inrush current, third voltage 150 on the input to display 40 needs to be slowly increased. This slow voltage rise allows display 40 input capacitors to charge at a slower rate and reduce inrush current to acceptable level. Depending on the display type and input capacitance, the rate of voltage increase can vary between 10 to 50 volts per second and still maintain acceptable inrush current.
[0031] Further, current managing circuit 130 disconnects power from display 40 if a pre-programmed power consumed by display 40 is exceeded. In the preferred embodiment, the preprogrammed power is substantially 150 W.
[0032] The total power transmitted over low voltage cable 30 is 172 W. The cable resistance loss, circuitry and efficiency of the voltage conversion in receiver 20 will use about 22 W, therefore the maximum power available for display 40 is substantially 150 W. If receiver 20 circuitry power consumption is decreased and conversion efficiency from the second voltage to the fourth voltage and to third voltage 150 is increased, then the output power can be increased above 150 W.
[0033] Further, current managing circuit 130 disconnects power from display 40 if third voltage 150 falls below a predetermined threshold. In the preferred embodiment, the predetermined threshold is substantially 50 volts.
[0034] As low voltage cable 30 length is increased, the power available to receiver 20 is decreased, since there is the power loss in low voltage cable 30 . Once voltage drops to about 50 volts, converter 90 is not capable of producing the voltage necessary fir display 40 to operate properly. Convertor 90 produces the third voltage that needs to be substantially 95 to 120 volts. If third voltage 150 is below 95 volts, it will not produce enough voltage for display 40 to operate.
[0035] Viewing now FIG. 6 , low voltage cable 30 is selected from the group consisting of a CAT5 cable, CAT6 cable and CAT7 cable. In the preferred embodiment shown in FIG. 6 , a CAT7 cable comprising eight wires indicated by numerals 30 a, 30 b, 30 c, 30 d, 30 e, 30 f, 30 g and 30 h is used.
[0036] Wires 30 a, 30 b, 30 c and 30 d transmit the positive side of the second voltage and wires 30 e, 30 f, 30 g and 30 h transmit the negative side of the second voltage.
[0037] While the present invention has been described and defined by reference to the preferred embodiment of the invention, such reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled and knowledgeable in the pertinent arts. The depicted and described preferred embodiment of the invention is exemplary only, and is not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.
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A system for supplying AC power to a display via a CAT7 or similar low voltage cable comprises a transmitter connected to an AC power outlet and generating DC voltage transmitted by the CAT7 cable to a receiver. The receiver converts the DC voltage to AC voltage and supplies AC power to the display. A limiting circuit limits power transmitted by the CAT7 cable to a predetermined wattage, depending on the feedback from the receiver, which insures safe operation of the system. Power from the display is disconnected if a pre-programmed power consumed by the display is exceeded or falls below a predetermined threshold.
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FIELD OF THE INVENTION
The invention relates to battery driven user terminal devices in general, and in particular it relates to an indicator device for displaying a battery charge status of an electronic battery powered user terminal device.
BACKGROUND OF THE INVENTION
In general, a terminal for electronically generating, processing, exchanging and reproducing information or data for a user is denoted as user terminal device. For example, the data or information can be text, voice, music, pictures, animations, films or multimedia data. Known mobile battery driven user terminal devices are in particular mobile stations for a communication via a mobile telecommunication network according to the GSM (Global System for Mobile Communication) or UMTS (Universal Mobile Telecommunications System) standard, MP3 player (playback devices for audio data according to the Moving Pictures Experts Group Audio Layer 3 Format), PDAs (Personal Digital Assistants), Laptops, digital cameras, camcorder and navigation systems.
These user terminal devices increasingly provide multiple applications to a user. For example, mobile stations meanwhile usually comprise a digital camera and a MP3 player. Further examples are MP3 player and navigation systems which permit displaying digital pictures or videos, PDAs comprising mobile telephony or mobile stations with integrated navigation system. In addition many user terminal devices provide interfaces, for example according to the Bluetooth or USB (Universal Serial Bus) standard for using functions or applications of external devices.
Usually a single-use battery or a rechargeable accumulator is used as battery in a battery powered user terminal device. The battery status is displayed to a user by means of a battery status indicator. In this way the user is enabled to exchange a battery or recharge an accumulator in due time. Furthermore, the user can coordinate the usage of the user terminal device with the battery status.
In order to avoid an adverse complete discharge, a so-called deep discharge, of an accumulator and to terminate active applications secure and without data loss an automatic power-off of the user terminal is typically carried out at a predetermined threshold value. In addition, an early deactivation of applications or functions with low priority is well-known with battery driven user terminal devices providing multiple applications. These applications or functions are deactivated before reaching the above-mentioned threshold value in order to achieve a longer remaining runtime of the battery for important applications. For this procedure, for example, further threshold values can be used. Current mobile telephones, for example, firstly deactivate or switch off a camera, then a Bluetooth interface, and finally telephony and thereby the mobile telephone. In this way a longer runtime of the preferred telephony application of the mobile station is achieved.
The European patent specification EP 1 202 457 B1 describes a method for switching off battery supplied mobile stations. For this purpose the current battery voltage is periodically detected. The current state of the battery can be symbolically displayed to the user by a battery symbol on a display of the mobile station. The voltage supply is switched off when falling under a pre-set shut down voltage. This action is previously indicated to a user by an alarm signal, for example a flashing battery symbol. Different pre-set shut down voltages are possible for different operation states like talking mode or TX transmission burst.
The known user terminal devices with multiple applications and a deactivation of an individual application depending on the battery status have the disadvantage that it is irreproducible for the user if and when an individual application or functions is deactivated. These user terminal devices have a battery status indicator showing the user a charging status of the battery and indicating upcoming deactivation to the user. But it is not recognizable for a user by means of the battery status indicator, when and which application of the user terminal device is deactivated, because a deactivation depends on power requirement of active applications and the usage behavior of the user.
Thus it has been a long felt and unsolved need to avoid disadvantages of the prior art and to inform a user in an effective and user-friendly way about a deactivation of individual applications.
SUMMARY OF THE INVENTION
The invention relates to an indicator device for displaying a battery charge status of an electronic battery powered user terminal device, which is adapted to provide a plurality of applications to a user, wherein:
the user terminal device includes:
a plurality of electric components performing the applications, a battery supplying power to the electric components, and a power supply control deactivating the electric components of individual applications at a predetermined battery charge status respectively, and
the indicator device comprises:
a detection device detecting the battery charge status of the user terminal device, and a display displaying the battery charge status.
Furthermore, the invention relates to an electronic battery powered user terminal device,
which is adapted to provide a plurality of applications to a user, wherein the user terminal device includes:
a plurality of electric components performing the applications,
a battery supplying power to the electric components,
a detection device detecting a battery charge status of the user terminal device,
a power supply control deactivating the electric components of individual applications at a predetermined battery charge status respectively,
a display displaying the battery charge status.
The invention further relates to a method for displaying a battery charge status of an electronic battery powered user terminal device, which is adapted to provide a plurality of applications to a user and thereto comprises a plurality of electric components performing the applications and a battery supplying power to the electric components, the includes the following:
detecting the battery charge status by a detection unit, deactivating the electronic components of individual applications at a predetermined battery charge status by a power supply control respectively, and displaying the battery charge status on a display.
One aspect of the invention provides an indicator device for displaying a battery charge status of an electronic battery powered user terminal device, which is adapted to provide a plurality of applications to a user, by charging state means determining and displaying an application-specific battery charge state of at least one of the applications.
Another aspect of the invention provides an electronic battery powered user terminal device which is adapted to provide a plurality of applications to a user. Charging state means are provided for determining and displaying an application-specific battery charge state of at least one of the applications.
A still another aspect of the invention provides a method for displaying a battery charge status of an electronic battery powered user terminal device, which is adapted to provide a plurality of applications to a user by determining and displaying an application-specific battery charge state of at least one of the applications by charging state means.
The invention is based on the principle of respectively displaying a application-specific battery charge state for each of several applications, which are deactivated on different predetermined battery charge status and thus at different times. The application-specific battery charge state differs from the battery charge status by considering the deactivation of the application depending on the battery charge status. For example, if an application is deactivated by the power supply control on half-full battery, the application-specific battery charge state of this application indicates an insufficient charge state or an “empty” battery on half-full battery.
An application-specific battery charge state for each application is indicated to the user by the indicator device according to the invention and the user terminal device according to the invention. This information very effectively indicates an upcoming deactivation of an application to a user. User-friendly, the user will be able to adapt his usage behavior according to the determined and displayed application-specific battery charge state. In particular the user will not be surprised by a deactivation of an application although the battery charge status of the user terminal device indicates sufficient battery charge for operating the user terminal device.
Corresponding advantages are achieved by the inventive method for displaying a battery charge status of an electronic battery powered user terminal device. In turn the user is informed in good time about a deactivation of an application and can arrange his usage behavior accordingly.
Preferably in one modification of the indicator device according to the invention the charging state means are adapted to determine the application-specific battery charge state of an application using the battery charge status and a predetermined deactivation priority of the application. In doing so the indicator device according to the invention is particularly suitable for user terminal devices, which assign different priorities to several applications and deactivate individual applications in each case in dependence of a battery charge status and a priority. With this modification the determination of the application-specific battery charge state in such user terminal devices can be performed easily and quickly.
A further preferred modification of the indicator device according to the invention is achieved by runtime determination means determining and displaying a remaining runtime of the application depending on the application-specific battery charge state and a power consumption of active applications. In this way a user is very user-friendly informed about remaining runtimes of individual applications and can adapt his usage behavior accordingly. The user is provided with information on the moment of deactivation of an application at all times for different applications. Thus, a deactivation surprising the user is effectively avoided.
An advantageous modification of the indicator device according to the invention is achieved by providing switching means for activating or deactivating at least one application by the user. This measure provides the user with an extensive influence on the deactivation of applications. A deactivation of not required applications is feasible as needed. This leads to a longer runtime of the remaining active applications. Further on, an activation of an already deactivated application is possible, if the user wants to use such an application urgently.
A further advantageous modification of the indicator device according to the invention provides means for displaying a battery capacity utilization of an application. Depending on the energy demand different applications or electric components of the user terminal device used by an application burden the battery differently. By indicating the battery capacity utilization or the energy demand of an application the user obtains important information according to which he can adapt his usage behavior. For example, a decision of disusing or deactivating an application is considerably simplified.
Further on, a favorable modification of the indicator device according to the invention is achieved by providing adjusting means for predetermining or changing the deactivation priority of an application. A customization of the deactivation priority of an application depending on the battery charge status is permitted user friendly. A sequence of automatic deactivations of different applications can be advantageously set up by the user according to his needs and wishes.
In a preferred modification of the inventive battery driven user terminal device the charging state means are adapted to determine the application-specific battery charge state of an application using the battery charge status and a predetermined deactivation priority of the application. On the basis of a predetermined priority an application is deactivated by a power supply control on a predetermined battery charge status. In doing so a contemporaneous deactivation of multiple applications having the same priority is possible. By utilization of the priority of an application and a battery charge status of the user terminal device an efficient determining of application-specific battery charge states is feasible.
In an advantageous modification of the invention the user terminal device is a mobile station for a mobile telecommunication network. Modern mobile stations usually provide multiple applications to a user, for example telephony, text messages, games, generating and displaying photos and videos and playing back music. Thus, the invention can be applied particular advantageously to mobile stations. A user terminal device being a mobile station informs the user about an application-specific battery charge state of the applications and hence, about upcoming deactivations of individual applications at all times.
A preferred modification of the method according to the invention for displaying a battery charge status of an electronic battery powered user terminal device also uses the battery charge status and a predetermined deactivation priority of the application for determining the application-specific battery charge state of an application. Thus, corresponding to the respective modification of the inventive user terminal device and the inventive indicator device a quick and efficient determination of application-specific battery charge states is enabled.
Further modifications of the user terminal device and the method respectively correspond with the modification of the indicator device described above.
BRIEF DESCRIPTION OF THE DRAWING
Exemplary embodiments of the invention are described below in greater detail with reference to the accompanying drawings, in which,
FIG. 1 is a diagram of an exemplary embodiment of an indicator device according to the invention for a user terminal device; and
FIG. 2 is a principle diagram which shows a section of a display of the exemplary embodiment according to FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , the numeral 10 denotes an electronic battery powered user terminal device. A rechargeable battery 12 is provided as energy supply for the user terminal device 10 . Alternatively, the usage of a single-use battery is also possible. In this embodiment the user terminal device 10 is designed as a mobile station and, among other components known by a person skilled, in particular comprises a mobile radio module 14 for transmitting and receiving data via a mobile telecommunication network according to the GSM (Global System for Mobile Communication) or the UMTS (Universal Mobile Telecommunications System) standard.
In other embodiments the user terminal device 10 , for example, is a MP3 player (play back device for audio data in the Moving Picture Experts Group Audio Layer 3 format), a PDA (personal digital assistant), a laptop, a digital camera, a camcorder or a navigation system. In general the electronic battery powered user terminal device 10 is characterized by electronically generating, processing, exchanging and playing back information or data for a user. Thus, it is an interface between a user and electronically available data or information. For example, the data or information can be text, voice music, pictures, animations, movies or multimedia data.
The user terminal device 10 provides multiple applications to the user and comprises the necessary electronic components for this purpose. Possible applications for example are: telephony; WAP (Wireless Application Protocol), SMS (Short Message Service), EMS (Enhanced Messaging Service) and MMS (Multimedia Messaging Service) applications; email, Internet, WWW (World Wide Web); organizer; address book; image and video recording; playing back music, pictures or videos; games; satellite based navigation and different interfaces for utilizing applications of external devices, for example USB (Universal Serial Bus), Bluetooth or IrDa (Infrared Data Association).
In the following only three exemplary applications of the user terminal device 10 are contemplated in order to simplify matters. First of all the user terminal device 10 permits a recording of pictures or videos and therefore comprises a digital camera 16 as electric component. Secondly, an application of external devices is accomplishable via a Bluetooth interface 18 as electric component. Thirdly the user terminal device 10 enables telephony for the user and for this purpose comprises a microphone 20 , a loud speaker 22 , the mobile radio module 14 and all other necessary electric components.
A control unit 24 and a display 26 are provided for controlling and using the user terminal device 10 by the user. Besides controlling, status and operating information of the user terminal device 10 the display 26 can also show application data like pictures or videos.
A power supply for the electric components of the user terminal device 10 is controlled by a power supply control 28 . On the one hand, the power supply control 28 switches off the user terminal device 10 at a predetermined minimum load of the battery 12 and terminates all applications or deactivates all electronic components of the user terminal device for this purpose. In this way all applications are correctly terminated and a damaging total discharge of the battery 12 is avoided. On the other hand individual applications or the corresponding electronic components are deactivated before reaching the minimum load at further predetermined remaining loads of the battery 12 by the power supply control 28 in order to increase the runtime of important applications. For this purpose the power supply control 28 uses predetermined priorities of the applications and remaining load values of the battery 12 associated with them. When reaching one of those remaining load values all applications with the corresponding priority are deactivated.
The charging status of the battery 12 is detected as battery charge status by a detecting device 30 . To this end, for example, a continuous or periodical examination of the battery voltage can be carried out. For example the battery charge status can be available in percentage and the reaches from 100% for a completely loaded battery 12 to 0% for a discharged battery 12 . By comparing the actual battery charge status with predetermined battery charge status as predetermined remaining load values the power supply control 28 determines if individual applications or the complete user terminal devices 10 has to be deactivated. In this exemplary embodiment the battery charge status is displayed to the user as a bar 32 on the display 26 . A completely filled bar 32 corresponds to a completely charged battery 12 and a bar 32 without filling corresponds to a discharged battery 12 .
Furthermore the user terminal device 10 comprises charging state means 34 for determining and displaying an application-specific battery charge state of each application. The application-specific battery charge state differs from the battery charge status by consideration of the deactivation of an application depending on the battery charge status. This circumstance is described in greater detail further below. The charging state means 34 determine the application-specific battery charge state of an application by means of the actual battery charge status and the predetermined priority of the respective application.
A remaining runtime of each application is determined and displayed on the display 26 for the user by remaining runtime determination means 36 using the application-specific battery charge state of an application and a power consumption of active applications. In addition a battery capacity utilization or power consumption of an application is displayed on the display 26 for the user by means 38 for displaying the battery capacity utilization of an application (see FIG. 2 ).
Adjusting means 40 are provided in the user terminal device 10 for predetermining or changing the priority of an application by the user. Furthermore, activating or deactivating of individual applications by the user is possible by using switching means 42 . The adjusting means 40 and the switching means 42 are operated by the user by means of the control unit 24 and the display 26 . For this purpose, for example, menus, icons or soft keys can be used on the display 26 , which are selected by the user via the control unit 24 .
The detecting device 30 , the display 26 , the charging state means 34 , the remaining runtime determination means 36 , the means 38 for displaying the battery capacity utilization, the priority adjusting means 40 and the switching means 42 all together set up an indicator device 44 for displaying a battery charge status and application-specific battery charge states. Instead of the display 26 of the user terminal device 10 another display can be used. The same applies for the detecting device 30 .
In the following the functionality of the indicator device 44 is described together with an according exemplary method for displaying a battery charge status and application-specific charge states. Thereby reference is made to FIG. 1 and FIG. 2 . In FIG. 1 and FIG. 2 corresponding elements are denoted with the same reference numerals. As mentioned above, three applications and their electronic components are exemplary considered, namely the digital camera 16 , the Bluetooth interface 18 and telephony. The indicator device 44 and the method can also be used with less or more applications.
When using the user terminal device 10 the battery charge status is permanently shown to the user by bar 32 , see FIG. 1 . For obtaining more information, in particular about a deactivation of applications, the user invokes the indicator device 44 using the control unit 24 . For this purpose, for example, the bar 32 can be a selectable icon or soft key. Thereupon the indicator device 44 displays amongst others the application-specific battery charge states, remaining runtimes and battery capacity utilizations of individual applications on the display 26 for the user.
FIG. 2 schematically shows an exemplary section of the display 26 with this information. Besides the bar 32 of the battery charge status an application-specific battery charge state of the digital camera 16 is displayed as bar 50 a together with a symbol or text 52 a as designator. Since the digital camera 16 has a low priority and is deactivated previous to the Bluetooth interface 16 and telephony by the power supply control 28 , the application-specific battery charge state 50 a of the digital camera 16 differs from the battery charge status 32 .
Furthermore, a remaining runtime 54 a until deactivation and a battery capacity utilization 56 a of the digital camera 16 is displayed. The battery capacity utilisation 56 a describes the power consumption of the digital camera 16 . All these values can be shown symbolical or as text. In addition, a symbol 58 a as status of the digital camera 16 indicates, whether the digital camera 16 is activated or deactivated. Simultaneously, the symbol 58 a is a selectable symbol or soft key used by the user for operating the switching means 42 for activating or deactivating the digital camera 16 .
Accordingly, an application-specific battery charge state 50 b , a designator 52 b , a remaining runtime 54 b , a battery capacity utilisation 56 b and a status and switching symbol 58 b of the Bluetooth interface 18 and an application-specific battery charge state 50 c , a designator 52 c , a remaining runtime 54 c , a battery capacity utilisation 56 c and a status and switching symbol 58 c for telephony is displayed. The Bluetooth interface 18 has a medium priority and telephony has a high priority. Because of this telephony is deactivated together with the user terminal device 10 by the power supply control 28 at the minimum load of the battery for operation. Thus, the application-specific battery charge state 50 c of telephony is equal to the battery charge status 32 . Since the Bluetooth interface 18 is deactivated by the power supply control 28 at a remaining load value of the battery 12 between the remaining load value of the digital camera 16 and the minimum load of the battery, the application-specific battery charge state 50 b of the Bluetooth interface 18 differs from the one of the digital camera 16 and the one for telephony.
The user is provided with substantial information by the indicator device 44 and the according method in order to be prepared for upcoming deactivations of individual applications and to arrange his user behavior accordingly. Furthermore, an extensive influence on the deactivation and activation of applications by the user terminal device 10 is enabled for the user by the priority adjusting means 40 and the switching means 42 provided in the indicator device 44 .
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The invention relates to an indicator device for displaying a battery charge status of an electronic battery powered user terminal device, which is adapted to provide a plurality of applications to a user. The user terminal device comprises a plurality of electric components performing the applications, a battery supplying power to the electric components and a power supply control deactivating the electric components of individual applications at a predetermined battery charge status respectively. The indicator device comprises a detection device for detecting the battery charge status of the user terminal device and a display for displaying the battery charge status. A charging state arrangement is provided for determining and displaying an application-specific battery charge state of at least one of the applications.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to internal combustion engines and is particularly applicable to such engines of the Diesel or stratified charge type.
2. Description of the Prior Art
Despite their greater economy in amount and cost of fuel used, Diesel engines have made little headway in replacing spark-fired gasoline engines as the power unit of automobiles. This has been due largely to the relatively lower efficiency of existing Diesel engines on a power to weight ratio, their higher initial cost, lower maximum speed and special fuel requirements, without any offsetting advantage in noxious emissions. Heavy duty Diesel engines for other applications suffer from similar problems. It is believed that the greatest weakness of today's Diesel engine is its lack of an adequately effective fuel injection-ignition system.
Early Diesel engines utilized compressed air to vaporize and inject fuel into the combustion chambers at the top of the cylinders. This system worked well, but required multi-stage compressors to compress the air to from 800 to 1300 p.s.i., which added to the complexity, weight, power drain and cost of the engine. Consequently, manufacturers of modern Diesel engines have discarded air pressure fuel injection in favor of pressurized fuel injection systems, in which the required hydraulic pressure of several thousand p.s.i. on the fuel can be generated with less costly, heavy and power consuming equipment. But the "solid" pressurized fuel jet so produced does not produce as rapid and uniform burning of the fuel as would be desirable. Studies indicate that ignition tends to develop at the air-jet interface of the air envelope about the jet, with the fuel not yet adequately mixed with air, so that some ignition "pockets" are overrich in fuel and tend to generate smoke and odor due to insufficient oxidation, fuel cracking and carbonization. Other ignition pockets are too lean in fuel, tending to generate unburned hydrocarbons and odorous compounds. Both conditions impair engine performance, which ideally needs combustion at nearly a constant fuel-air ratio to the lean side of the stoichiometric, without delays due to erratic burning.
To alleviate these difficulties with pressurized fuel injection, it has been proposed, as in U.S. Pat. No. 2,046,003, to provide a cone of compressed air surrounding the jet as it passes into the combustion chamber, the compression being provided by individual pumps for each cylinder, operated by the cam shaft. The arrangements proposed have not been such as to provide compressed air at a pressure or temperature much above that prevailing in the combustion chamber. Adequacy and speed of combustion in the area surrounding the jet are possibly improved, but the internal, relatively "solid" area of the jet is not greatly effected, and this still gets ignited without adequate mixing with air.
SUMMARY OF THE INVENTION
An object of this invention is to provide an improved fuel injection system for internal combustion engines in which compressed air at high pressure and temperature injects the fuel into the combustion chamber in atomized state thoroughly mixed with the air, so that ignition occurs substantially uniformly and without the burning irregularities which have characterized and impaired the performance of pressurized fuel injection systems. Another object is to provide such a system which utilizes relatively simple, inexpensive apparatus that has low cost and power drain advantages comparable to those of pressurized fuel injection systems.
A fuel injection system attaining the foregoing objects has a pressurizing device adjacent the combustion chamber of each cylinder, this device having a compression chamber and compression means operative to suddenly further compress in the compression chamber a relatively small part of the air precompressed in the combustion chamber by the cylinder piston to a substantially higher pressure and temperature than the peak air pressure and temperature of air compression by the cylinder piston. Fuel feed means supplies combustible fuel to the compressed body of air in the compression chamber, and nozzle means, communicating the compression chamber with the combustion chamber, substantially confines the air in the compression chamber during the compression thereof and then discharges the air mixed with fuel as a jet into the combustion chamber.
In preferred embodiments, the combustion chamber is a bowl in the end of the cylinder piston; the air in the compression chamber is compressed to a pressure at least 100 p.s.i. above the peak pressure, and at least 200° F. above the peak temperature, of air precompressed in the combustion chamber by the cylinder piston; the compression means is a piston reciprocable in the compression chamber and operated by the engine cam shaft or hydraulically; and the nozzle means is an orifice in the chamber in constant communication with the combustion chamber, the diameter of the orifice being so small in relation to the volume of the compression chamber as to substantially confine the air displaced in the compression chamber during the sudden compression stroke of the piston therein, thereby permitting the temperature and pressure of the air to increase as indicated above.
Also, in preferred embodiments the fuel is metered onto a conical surface surrounding the nozzle orifice in the compression chamber so that the air compressed by the piston is forced over the fuel to atomize and mix with it as it ejects from the orifice; and the compression piston is provided with structure which produces a swirling motion in the compressed air as it discharges from the compression chamber. The fuel metering system may advantageously include a metering piston and control sleeve coaxial with the compression piston and operated in conjunction therewith.
The jet supplied is at high temperature, substantially above that in the combustion chamber, and its great energy insures that as it expands into the combustion chamber it is thoroughly mixed, so that ignition will occur within rather than peripherally of the jet, and burning proceeds more uniformly with less differential of overrich and overlean pockets than in pressurized fuel injection. In addition, the high temperature of the injected mix provides earlier ignition than would otherwise occur. In consequence, not only can the efficiency of the engine be improved but also its emissions deleterious to the ecology are greatly diminished, the engine operates more smoothly, starts more easily, and may operate with poorer fuels. The required apparatus is not costly or complicated to manufacture as compared with conventional pressurized fuel injection equipment. Its power drain can be less than 1% of engine shaft power at maximum drive speed, which may be substantially compensated by power no longer required for pressurizing fuel for injection.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a transverse section view, with some parts omitted, through a diesel engine of conventional form but modified by inclusion of a fuel injection system according to the invention;
FIGS. 2-4 are enlarged partial vertical section views through the upper part of the apparatus shown in FIG. 1, illustrating successive positions of the piston in the compression chamber and of the fuel metering equipment relative to cylinder piston during a fuel injection cycle;
FIG. 5 is a side elevation view of the tip of the air compression piston, showing a preferred construction;
FIG. 6 is a bottom plan view of the piston tip construction of FIG. 5;
FIGS. 7A to 7E are diagrammatic views of the piston tip of FIG. 5, illustrating the action thereof at successive positions during a fuel injection cycle; and
FIG. 8 is a diagrammatic elevation view, partly in section, of an alternative arrangement for powering the fuel injection apparatus of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the Diesel engine therein shown is a four stroke engine in which fuel injection takes place on every other stroke. Its crankshaft rotates about an axis centered on the dash line circle 10, and the cylinder shown, designated generally 12, has a connecting rod 14 reciprocable therein, pivotally mounted on one of the eccentric arms 16 of the crankshaft, opposite crankshaft counterbalance 17. Piston 18 is pivotally mounted by wrist pin 20 on connecting rod 14 and has formed at its outer end a bowl shaped combustion chamber 22 in which air is compressed on the upstroke of the piston by virtue of the close fit with the internal bore lining 24 of the cylinder.
The crankshaft housing or engine block 26 which carries the cylinders is supported on crank case 28 having the usual lubricating oil pump pickup 30. A cooling jacket 32 around the cylinder is connected to a source of circulated cooling water (not shown). Air inlet pipe 34 and exhaust pipe 36 are exposed to the cylinder interior at proper intervals by the usual poppet valves (not shown) operated by the crankshaft, and are as usual connected respectively to intake and exhaust manifolds (not shown). At top dead center position shown in FIG. 1, the piston has close clearance with the underside of the cylinder head 38 so that essentially all the air between the piston and the cylinder head is compressed in the combustion chamber 22 during the upstroke of the piston to top dead center. The peak pressure and temperature of air so obtained in the combustion chamber may be of the order of 500 to 1000 p.s.i. and degrees F., respectively.
The fuel injection system according to the invention includes a piston assembly designated generally 40, operating in a fixed sleeve 42 fixedly mounted in cylinder head 38 immediately above cylinder 12, there being one such assembly provided for each cylinder of the engine, one only being shown and described herein as they are all alike. The lower end of sleeve 42 forms the compression chamber 44 of the system. The piston assembly 40 is operated in this embodiment by a cam 46 on the engine cam shaft 48 rotatably mounted on support structure 50 on the cylinder head 38, and which is connected for rotation at one-half the speed of the crank shaft. Cam 46 acts on ball 52 which is rotatable in a socket in the end of piston stem cap 54. The detail of construction and operation of the psiton assembly will be better understood from the enlarged views of FIGS. 2-4, to which reference will now be had.
Referring particularly to FIG. 2, cap 54 has fixed internally thereto the reduced end of the stem of a fuel metering piston 56. Cap 54 has a hollow portion 58 surrounding the end of piston 56 secured thereto, in which one end of a coil spring 60 is seated. A pin 62 secured to a support 64 on structure 50 (see FIG. 1) extends into a longitudinal groove 66 in cap 54 and is slidable therein while retaining piston 56 against rotation. The opposite end of spring 60 is received in a hollow portion 68, surrounding the stem of piston 56, of a cap 70 secured to the upper end of an air compression piston 72 having a longitudinal bore 74 in which the stem of piston 56 is axially slidable. The other end of cap 70 is secured to one end of a coil spring 76 the other end of which is seated in a cavity 78 (FIG. 1) in cylinder head 38, spring 76 having greater resistance to compression than spring 60.
As shown in FIG. 1, sleeve 42 is received in a tubular casing 80 formed in cylinder head 38 extending through the head from the bottom of cavity 78, and is provided near its top with an annular mounting flange 82 which seats in the bottom of cavity 78 and on which one end of spring 76 rests. A clamp sleeve 84 bolted to the cylinder head retains sleeve 42 in position. A port 86 in cylinder head 38 receives a connection from a fuel pump (not shown) and communicates by a passage 88 in head 38 with a passage 90 in flange 82.
Piston 72 is axially slidable in sleeve 42. It is provided with a peripheral annular slot 92 that communicates with passage 90 at all positions of piston 72, and similarly communicates with a passage 94 in flange 82 which in turn communicates with a passage 96 in cylinder head 38 leading to a return line (not shown) to the fuel tank. The arrangement contemplates constant circulation of fuel from the fuel pump through the passages 88, 90, 92, 94, 96 and back to the fuel tank. A port 98 in the shank of piston 72 communicates at times, as hereinafter described, with a peripheral slot 100 in the shank of piston 56, slot 100 having an upper wall curved helically about the piston axis so that the slot widens around the piston clockwise in FIG. 2 for a purpose hereinafter described. A central bore 102 in the shank of piston 56 communicates slot 100 through the head of piston 56 with the bottom of bore 74 which forms the fuel metering chamber 103.
The inner base 104 of sleeve 42 is conically dished with an air-fuel jet discharge port 106 at its apex. The solid head 108 of piston 76, provided with peripheral pressure sealing rings 110, has a complementary conically convex tip 112. One or more passages 114 in sleeve 42 communicate tangentially at one end with base 104 and at the other end communicate at times as hereinafter explained with fuel metering chamber 103 via port 116 in the surrounding portion of piston 72.
A rack 118 arranged to be reciprocated transversely to the piston assembly axis by operator control of the throttle, has a toothed face 120 which meshes with a toothed pinion ring 122 on the periphery of cap 70 of piston 72. Reciprocation of rack 118 therefore rotates piston 72 about piston 56 (held against rotation by pin 62) so that port 98 can be moved between the position shown in the Figures opposite the narrow end of slot 100 (which corresponds to maximum fuel charge), and a position opposite the wide end of slot 100 (which corresponds to minimum fuel charge).
FIGS. 2 to 4 illustrate the operation of the piston assembly as the crankshaft moves piston 18 from minus 40° of top dead center (FIG. 2), to top dead center (FIG. 3), to top dead center plus 40° (FIG. 4). In FIG. 2, ball 52 is on a low point of cam 46, which is rotated counterclockwise in the Figures. Pistons 56 and 72 are held in their upper positions by their respective springs 60 and 76. Metering compartment 103 is in communication with the fuel supply system through bore 102, slot 100, port 98, slot 92, and passages 90 and 88, all of which are filled with fuel. Further rotation of the crankshaft toward top dead center rotates a steeply inclined lobe 46a of cam 46 against ball 52. This initially projects piston 56 downwardly relatively to piston 72 because of the lesser resistance to compression of its spring 60 as compared with that of spring 76, and because, port 98 being in communication with slot 100, piston 56 can displace fuel from the metering compartment 103 back through bore 102, slot 100, port 98, passage 92, and return passages 94 and 96, port 116 not being in communication with passage or passages 114. It will therefore be appreciated that piston 56 meters the amount of fuel in metering chamber 103 according to how much fuel it pumps out of the chamber before slot 100 is moved out of communication with port 98, which in turn depends on the width of slot 100 opposite port 98. Therefore, if piston 72 is rotated by rack 118 to move port 98 toward the wider end of groove 100, less fuel will remain in metering compartment 103 for ultimate injection.
Wen piston 56 has been forced down sufficiently to move slot 100 below port 98 closing the port, piston 56 is no longer able to move relative to piston 72 and forces piston 72 down, exposing port 116 to passage 114, so that piston 56 is again able to move relative to piston 72 by displacing fuel, and completes its stroke to the bottom of metering chamber 103, forcing the metered amount of fuel therein through port 116 and passage 114 onto conical surface 104. Piston 72 is forced suddenly by the steep slope of cam lobe 46 through its main compression stroke to the position shown in FIG. 3, in which it has compressed substantially to half volume the air in the compression chamber 44.
As cam lobe 46a moves from its position in FIG. 3 to its position in FIG. 4 its outward slope is more gradual, so that it forces piston 72 to the downward limit of its stroke shown in FIG. 4 more slowly than in its initial compression movement but rapidly enough, at least at high speed, to maintain its displacement substantially equal to the rate of air flow out of orifice 106, so that the air pressure is held nearly constant. The hot, high pressure air forced over the fuel film on surface 104 atomizes and partially vaporizes the fuel and thoroughly mixes with it as it discharges. Cam lobe 46a is substantially radial to the cam axis for about 180° rotation from its position in FIG. 4, so that the pistons 56 and 72 remain in the FIG. 4 position during the next crankshaft revolution, and the cam then, being reverse sloped to a smaller radius, permits the springs to return these pistons to the FIG. 2 position.
In a typical example, compression chamber 44 has a displacement of 1.5 cm 3 ; orifice 106 has a diameter of 1.55 mm; the cylinder displacement is 500 cm 3 and its clearance volume at top dead center is about 25 cm 3 ; piston 18 compresses the air above it to a peak pressure of about 600 p.s.i. and to a peak temperature of about 1000° F.; and piston 72, in moving from its position of FIG. 2 to its position of FIG. 3, further compresses the air in compression chamber 44 to a pressure of about 1500 p.s.i. and a temperature of about 1400° F., either at high speed or at low speed (r.p.m.) of the engine. At the beginning of the compression stroke of piston 72, the air/fuel flow through orifice 106 rapidly rises to between 20 and 25 grams per second at which "choked" or "solid" air/fuel flow through orifice 106 is attained. At high speed (e.g., 4500 r.p.m.) choked flow is maintained as piston 72 moves from its FIG. 3 to near its FIG. 4 position, since the peak pressure of about 1500 p.s.i. is maintained. At lower speeds, the slower movement of piston 72 between its FIG. 3 and FIG. 4 positions allows the peak air pressure attained in the compression chamber to decay toward the pressure in the cylinder, and the flow rate through orifice 106 correspondingly declines. The mass ratio of air to fuel may be about 1 at maximum fuel charge, and the bulk of the air/fuel injection into the bowl 22 takes place during about 30° rotation of the crankshaft or less.
In the foregoing specific example, the displacement volume of the compression chamber 44 is about 6% of the clearance volume of piston 18 at top dead center, and it is preferred that such displacement volume be between 3% and 12% of such clearance volume. The diameter of orifice 106 is about 1/7th the cube root of the volume of compression chamber 44 and is between 1/25th and 1/100th of the diameter of the bore of piston 18, as is preferred.
FIGS. 5 to 7E show a preferred construction for the tip 112 of head 108 of piston 72, which has a desired action on the air/fuel jet produced thereby into bowl 22. As shown in FIGS. 5 and 6, the conical tip 112 has formed therein grooves 130, four being shown, extending generally helically about the tip from its base toward its axis. On the compression stroke of the piston 72 (FIg. 2 to FIG. 3; FIG. 7A to FIG. 7B) air is compressed in grooves 130. This compressed air in the grooves 130 does not affect the jet J in its initial stages, which starts as a pencil like stream in FIG. 7B expanding somewhat to a cone in FIG. 7C as piston head 108 moves further downward.
However, as piston head 108 approaches the limit of its exhaust stroke in FIGS. 7D and 7E, the pressure in compression chamber 44 rapidly decays, with the result that the air compressed in grooves 130 is released at high pressure and angular momentum, creating a swirl in the chamber which assists in mixing the air with the fuel and increases the angular momentum of the jet, so that it expands to a large angle cone, nearly coextensive with bowl 22. This expansion action improves the uniformity of the combustible mixture in bowl 22 and with which the mixture ignites and burns.
It will be appreciated that fuel can be supplied to base surface 104 of compression chamber 44 by means other than the arrangement shown, such as a connection between fuel inlet passage 114 to surface 104 and a source of metered fuel exterior to piston 72. However, the arrangement shown, utilizing metering piston 56, is preferred. Also, the fuel could be admitted as a jet into compression chamber 44, but the arrangement shown is preferred, since the highly compressed and heated air is able to atomize and mix with the fuel of the film on surface 104 thoroughly and uniformly. It is preferred that fuel injection into the compression compartment take place before piston 72 has completed the compression part of its stroke, but it may occur at least partially during the further exhaust stroke of that piston. A valve could be provided in outlet 106, although the simpler structure shown is preferred.
As stated previously herein, the fuel injection system may be powered hydraulically rather than from the cam shaft if desired. FIG. 8 shows such an arrangement in outline and rather diagrammatically, since the changes from cam shaft to hydraulic operation can be made rather simply and with commercially available equipment.
In FIG. 8, the same parts shown as in FIG. 1 have the same reference numerals. These include the cylinder 12, its piston 18 and operating connections, and cylinder head 38; also, sleeve 42 and compression chamber 44 therein. The piston assembly 40' may be the same as in the previous figures except that its upper part, above flange 82 in FIG. 1, is encased in a cylinder 150 the upper part of which forms an hydraulic pressure cylinder in which a piston (not shown), connected to cap 54 of piston 56 in place of ball 52, is reciprocable. An inlet 152 to this cylinder receives hydraulic fluid under pressure through tubing 154 from an hydraulic pressure fluid delivering pump 156 operated by a cam shaft 48'.
Pump 156 may be a conventional pressurized fuel delivering pump or similar thereto. It may be of the single delivery piston type with a rotary distributor which distributes the fluid to the several cylinders 150 according to the operating cycle, or of the multiple piston type, with a piston for each cylinder 150. In either case, pump 156, as controlled by cam shaft 48', delivers appropriate hydraulic fluid to each cylinder in a pressure pattern which operates the pistons 56 and 72 in the same manner as they are operated by cam 46 acting on ball 52 in the previous figures. A return line (now shown) from cylinders 150 to pump 156 may be provided if needed.
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A fuel injection system is disclosed for an internal combustion engine having at least one cylinder and a piston operating therein to define with the cylinder head a combustion chamber wherein air is compressed while the piston is moving to one end of its stroke. The system has pressurizing means adjacent the combustion chamber which suddenly further compresses in a compression chamber a small part of the air precompressed in the combustion chamber to a substantially higher pressure and temperature than the peak pressure and temperature of air in the combustion chamber. Fuel feed means supplies fuel to the compression chamber, and nozzle means is operative to substantially confine the air in the compression chamber during its compression and to discharge the compressed air-fuel mixture as a jet into the combustion chamber.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/581,914 filed Jun. 22, 2004, and U.S. Provisional Patent Application Ser. No. 60/616/085 filed Oct. 5, 2004, both hereby incorporated by reference.
STATEMENT REGARDING FEDERAL RIGHTS
This invention was made with government support under Contract No. W-7405-ENG-36 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates generally to hydrogen evolution and storage and more particularly to a method and system for storing and evolving hydrogen.
BACKGROUND OF THE INVENTION
Hydrogen (H 2 ) is currently the leading candidate for a fuel to replace gasoline/diesel fuel in powering the nation's transportation fleet. There are a number of difficulties and technological barriers associated with hydrogen that must be solved in order to realize this “hydrogen economy”. Inadequate storage systems for on-board transportation hydrogen are recognized as a major technological barrier (see, for example, “The Hydrogen Economy: Opportunities, Costs, Barriers, and R&D Needs,” National Academy of Engineering (NAE), Board on Energy and Environmental Systems, National Academy Press (2004).
One of the general schemes for storing hydrogen relates to using a chemical compound or system that undergoes a chemical reaction to evolve hydrogen as a reaction product. In principle, this chemical storage system is attractive, but all practical systems that have been studied to date involve either: (a) hydrolysis of high-energy inorganic compounds where the evolution of hydrogen is very exothermic (sodium borohydride/water as in the Millennium Cell's HYDROGEN ON DEMAND®, and lithium hydride as in SAFE HYDROGEN®, for example), thus making the cost of preparing the inorganic compound(s) high and life-cycle efficiency low; or (b) dehydrogenation of inorganic hydride materials (such as Na 3 AlH 6 /NaAlH 4 , for example) that release hydrogen when warmed but that typically have inadequate mass storage capacity and inadequate refueling rates.
Inorganic compounds referred to in (a), above, produce hydrogen according to the chemical reaction
MH x +XH 2 O→M(OH) x +XH 2 (1)
where MH x is a metal hydride, and M(OH) x is a metal hydroxide. This reaction is irreversible.
Inorganic hydride materials referred to in (b), above, produce hydrogen according to following chemical reaction, which is reversible with H 2 (hydrogen gas):
MH x =M+ x /2H 2 (2)
where MH x is a metal hydride, M is metal and H 2 is hydrogen gas. By contrast to the first reaction, which is irreversible with H 2 , the second reaction is reversible with H 2 .
A practical chemical system that evolves hydrogen yet does not suffer the aforementioned inadequacies would be important to the planned transportation sector of the hydrogen economy. This same practical chemical system would also be extremely valuable for non-transportation H 2 fuel cell systems, such as those employed in laptop computers and other portable electronic devices, and in small mechanical devices such as lawnmowers where current technology causes significant pollution concerns.
Any heat that must be input to evolve the hydrogen represents an energy loss at the point of use, and any heat that is evolved along with the hydrogen represents an energy loss where the chemical storage medium is regenerated. Either way, energy is lost, which diminishes the life-cycle efficiency. For most organic compounds, such as in those shown in equations 3-5 below, hydrogen evolution reactions are very endothermic, and the compounds are incompetent to evolve hydrogen at ambient temperature (i.e. thermodynamically incapable of evolving H 2 at significant pressure at ambient temperature). For temperatures less than about 250-400 degrees Celsius, the equilibrium pressure of hydrogen over most organic compounds is very small. As a consequence, most common organic compounds require heating above about 250 degrees Celsius, and the continual input of high-grade heat to maintain this temperature, in order to evolve hydrogen at a useful pressure.
CH 4 → C + 2 H 2
ΔH 0 = +18 kcal/mol
(3)
ΔG 0 = +12 kcal/mol
6 CH 4 → cyclohexane + 6 H 2
ΔH 0 = +69 kcal/mol
(4)
ΔG 0 = +78 kcal/mol
cyclohexane → benzene + 3 H 2
ΔH 0 = +49 kcal/mol
(5)
ΔG 0 = +23 kcal/mol
Most organic compounds have hydrogen evolution reactions that are endergonic (i.e. having a net positive free energy of reaction change, i.e. ΔG>0) and their ambient temperature equilibrium hydrogen pressure is very low, practically unobservable. Thus, most organic compounds are unsuitable for hydrogen storage, based on both life-cycle energy efficiency and delivery pressure considerations. Decalin, for example, evolves hydrogen to form naphthalene when heated to about 250 degrees Celsius in the presence of a catalyst (see, for example, “Catalytic Decalin Dehydrogenation/Naphthalene Hydrogenation Pair as a Hydrogen Source for Fuel-Cell Vehicle,” S. Hodoshima, H. Arai, S. Takaiwa, and Y. Saito, Int. J. Hydrogen Energy (2003) vol. 28, pp.1255-1262, incorporated by reference herein). Hodoshima et al. use a superheated “thin film” reactor that operates at a temperature of at least 280 degrees Celsius to produce hydrogen from decalin at an adequate rate. Thus, this endothermic hydrogen evolution reaction requires both a complex apparatus and high-grade heat, which diminishes the life-cycle energy efficiency for hydrogen storage.
Methods and systems that employ chemical compounds for storing and evolving hydrogen at ambient temperature with minimal heat input remain highly desirable.
Therefore, an object of the present invention is a method for evolving hydrogen that is thermodynamically more favored than previously-described systems.
Another object of the present invention is a thermodynamically favorable system for evolving hydrogen.
Another object of the present invention is a reversible system for evolving and storing hydrogen.
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.
SUMMARY OF THE INVENTION
In accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention includes a method for producing hydrogen. The method involves exposing at least one chemical compound to a catalyst under conditions suitable for dehydrogenating the at least one chemical compound to form at least one product, the at least one chemical compound having the formula
wherein X is oxygen, —N(H)—, or —N(R 3 )—; wherein X′ is oxygen, —N(H)— or —N(R 4 )—; wherein R 1 , R 2 , R 3 , and R 4 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl sulfonic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; and wherein R 1 and R 3 can be connected to each other to form a ring structure; and with the proviso that X and X′ cannot both be oxygen.
The invention also includes a method for producing hydrogen, and involves exposing at least one chemical compound to a catalyst under conditions suitable for chemical reaction that forms hydrogen. The chemical compound has the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are independently selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; wherein R 8 and R 9 may be connected to each other to form a ring structure; and with the proviso that at least one of R 5 or R 11 is hydrogen.
The invention also includes a method for producing hydrogen, comprising exposing at least one chemical compound and an acid to a catalyst under conditions suitable for chemical reaction that forms hydrogen. The chemical compound has the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—,
—(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are independently selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure. The acid may be an alcohol, a phenol, or a compound having the formula HX or the formula HTX, wherein X is selected from chloride, bromide, iodide, carboxylate, sulfonate, phosphate, phosphonate, sulfate, and hydroxide (i.e. the acid can be water); and wherein T is selected from imidazole, alkylimidazole, arylimidazole, benzimidazole, alkylbenzimidazole, oxazole, alkyloxazole, benzoxazole, pyrazole, alkylpyrazole, arylpyrazole, pyridine, alkylpyridine, arylpyridine, quinoline, ammonia, and amine.
The invention also includes a system for producing hydrogen. The system includes at least one organic compound, an acid, and a catalyst suitable for facilitating a chemical reaction between the at least one chemical compound and the acid in order to form hydrogen. The chemical compound has the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are independently selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure. The acid may be an alcohol, a phenol, or a compound having the formula HX or the formula HTX, wherein X is selected from chloride, bromide, iodide, carboxylate, sulfonate, phosphate, phosphonate, sulfate, and hydroxide (i.e. the acid can be water); and wherein T is selected from imidazole, alkylimidazole, arylimidazole, benzimidazole, alkylbenzimidazole, oxazole, alkyloxazole, benzoxazole, pyrazole, alkylpyrazole, arylpyrazole, pyridine, alkylpyridine, arylpyridine, quinoline, ammonia, and amine.
The invention also includes a system for producing hydrogen. The system includes at least one chemical compound having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )— wherein R 11 is hydrogen, alkyl, or aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are independently selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure.
The invention also includes a system for producing hydrogen. The system includes at least one chemical compound having the formula
wherein Z is selected from oxygen, sulfur, or —N(R 4 )— where R 4 is alkyl or aryl; wherein Q is selected from oxygen, —N(R 5 )—, —(C(R 5 R 6 )) n — where n is from 1 to 10, —(C(R 5 )═C(R 6 )) m — where m is from 1 to 2, and —(C(R 5 )═N) p — where p is from 1 to 2; wherein R 1 , R 2 , R 4 , R 5 , and R 6 are selected independently from alkyl, aryl; and wherein R 3 is selected from hydrogen, alkyl, aryl. The system also includes a catalyst suitable for facilitating the dehydrogenation of the chemical compound.
The invention also includes a system for producing hydrogen. The system includes a chemical compound having the formula
wherein each R is independently selected from hydrogen, alkyl, and aryl; and a catalyst suitable for facilitating the dehydrogenation of the chemical compound.
The invention also includes a system for producing hydrogen comprising a chemical compound having the formula
wherein each R is independently selected from hydrogen, alkyl, aryl and a higher fused ring group; and a catalyst suitable for facilitating the dehydrogenation of the chemical compound.
The invention also includes a system for producing hydrogen comprising a chemical compound having the formula
wherein Q is N or (C(R)); wherein each R is independently selected from hydrogen, alkyl, aryl, and a higher fused ring group; and a catalyst suitable for facilitating the dehydrogenation of said chemical compound.
The invention also includes a fuel cell having an anode and a hydrogen-generating fuel source for the anode. The hydrogen-generating fuel source includes at least one chemical compound and a catalyst suitable for dehydrogenating the chemical compound, which has the formula
wherein X is oxygen, —N(H)—, or —N(R 3 )—; wherein X′ is oxygen, —N(H)— or —N(R 4 )—;
wherein R 1 , R 2 , R 3 , and R 4 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl sulfonic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; and wherein R 1 and R 3 can be connected to each other to form a ring structure.
The invention also includes a fuel cell comprising an anode and a hydrogen-generating fuel source for the anode, the hydrogen generating fuel source including at least one chemical compound having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; wherein R 8 and R 9 may be connected to each other to form a ring structure.
The invention also includes a fuel cell having an anode and a hydrogen-generating fuel source for the anode, the hydrogen generating fuel source including at least one chemical compound having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )— wherein R 11 is hydrogen, alkyl, or aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure.
The invention also includes a fuel cell having an anode and a hydrogen-generating fuel source for the anode, the hydrogen generating fuel source including at least one chemical compound having the formula
wherein Z is selected from oxygen, sulfur, or —N(R 4 )— where R 4 is alkyl or aryl; wherein Q is selected from oxygen, —N(R 5 )—, —(C(R 5 R 6 )) n — where n is from 1 to 10, —(C(R 5 )═C(R 6 )) m — where m is from 1 to 2, and —(C(R 5 )═N) p — where p is from 1 to 2; wherein R 1 , R 2 , R 4 , R 5 , and R 6 are selected independently from alkyl and aryl; and wherein R 3 is selected from hydrogen, alkyl, aryl.
The invention also includes a method for storing hydrogen. The method involves exposing at least one chemical compound to hydrogen in the presence of a catalyst that facilitates the hydrogenation of the at least one chemical compound, which has an anion and cationic portion having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure.
The invention also includes a method for storing hydrogen, which includes exposing at least one chemical compound to a reducing agent, the chemical compound having an anion and a cationic portion having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure.
The invention also includes a method for storing hydrogen, and involves exposing at least one chemical compound to hydrogen or to a reducing agent in the presence of a catalyst that facilitates the hydrogenation of the at least one chemical compound, which has the formula
wherein X is oxygen, —N(H)—, or —N(R 3 )—; wherein X′ is oxygen, —N(H)— or —N(R 4 )—; wherein R 1 , R 2 , R 3 , and R 4 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl sulfonic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; and wherein R 1 and R 3 can be connected to each other to form a ring structure; and with the proviso that X and X′ cannot both be oxygen.
DETAILED DESCRIPTION
The present invention relates to a chemical system useful for chemical hydrogen storage. Using the chemical system of the invention, hydrogen (H 2 ) is evolved without significant input or evolution of heat.
One aspect of the present invention relates to hydrogen evolution from chemical compounds according to equation 6:
wherein X is oxygen, —N(H)—, or —N(R 3 )—; wherein X′ is oxygen, —N(H)— or —N(R 4 )—; wherein R 1 , R 2 , R 3 , and R 4 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl sulfonic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; and wherein R 1 and R 3 can be connected to each other to form a ring structure; and with the proviso that X and X′ cannot both be oxygen.
For equation 6, it is believed that the ΔH 0 varies from about +10 kcal/mole to about −2 kcal/mole, and the ΔG 0 varies from about +5 kcal/mole to about −10 kcal/mole. Thus, the chemical reaction for hydrogen evolution as shown in Equation 6 above is nearly thermoneutral, perhaps even slightly exothermic, based on the currently available thermodynamic data for these materials. Owing to the favorable entropy of hydrogen evolution, the reaction can become exergonic (having a standard free energy change, ΔG 0 , of less than zero) and the ambient temperature equilibrium pressure of hydrogen approaches or exceeds the DOE target of 3 atmospheres.
If the chemical compound is stabilized against classical functional group elimination by, for example, the presence of additional atoms that join to form a ring structure, then it is expected that the hydrogen evolution and hydrogenation will be reversible in the presence of a suitably active catalyst that selectively catalyzes the hydrogen evolution reaction and also the reverse reaction (i.e. the hydrogenation reaction). Such reversibility is advantageous because it allows the chemical compound to be regenerated simply by hydrogenation under pressure, and the energy cost of regenerating the chemical compound is likely to be minimal.
Another aspect of the invention is related to a method and chemical system for producing hydrogen. This aspect of the invention involves exposing one or more chemical compounds to a catalyst under conditions suitable for a chemical reaction that forms hydrogen. Chemical compounds that evolve hydrogen according to the present invention include those having the chemical formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are independently selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; wherein R 8 and R 9 may be connected to each other to form a ring structure; and with the proviso that at least one of R 5 or R 11 is hydrogen. When Q is —(C(R 7 R 8 )) n — where n is greater than one, and when Q is —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, the invention is meant to include structures where R 7 and R 8 in one C(R 7 R 8 ) grouping might be the same, but are not necessarily the same, as the R 7 and R 8 in another C(R 7 R 8 ) grouping. Structures such as the one shown below on the right, for example, where n is two and where R 7 and R 8 in one grouping are H and methyl, and are ethyl and phenyl in another grouping, are invention structures.
An embodiment system including a chemical compound exemplary of the above formula was used to demonstrate this aspect of the present invention, and is shown in equation 7 below.
While not intending to be bound by any particular explanation, it is believed that the compound shown on the top left of equation 7 tautomerizes to the zwitterionic form shown on the bottom left and that hydrogen evolution from either of these forms produces the species shown on the right.
The hydrogen evolution reaction is a classically “symmetry forbidden” reaction. Therefore, the hydrogen evolution reaction is typically very slow in the absence of a suitable catalyst. Examples of catalysts that may facilitate hydrogen evolution include, for example, rhodium or ruthenium-based hydrogen transfer catalysts, ruthenium-based formic acid decomposition catalysts, nickel/copper/zinc-based reformation/hydrogenation catalysts, and the like. Catalysts useful with the present invention also include various forms of palladium, such as finely divided palladium metal, palladium supported on carbon, palladium supported on alumina, palladium supported on silica, a slurry of palladium in a solvent, a fluidized bed comprising palladium, a packed bed comprising palladium, or palladium carboxylate. For the system shown in equation 7, hydrogen evolution was observed in the presence of a palladium catalyst at a reaction temperature of from room temperature to about 60-70 degrees Celsius (a temperature range of from about 20 degrees Celsius to about 250 degrees Celsius will facilitate the reaction). Interestingly, in the absence of the catalyst, the compound shown top left does not evolve hydrogen after heating at 185 degrees Celsius for 8 days (see P. Brunet and J. D. Wuest “Formal Transfers of Hydride from Carbon-Hydrogen Bonds. Attempted Generation of H 2 by Intramolecular Protonolysis of the Activated Carbon-Hydrogen Bonds of Dihydrobenzimidazoles,” Can. J. Chem. (1996) vol. 74, p. 689).
The system shown in equation 7 employs an acidic functional group. Other aspects of this invention relate to a method and system that relate to chemical compounds that may, but do not necessarily include acidic functional groups. Compounds of this type could be used with a catalyst and separate acid. This aspect of the invention relates to evolving hydrogen by exposing at least one chemical compound and an acid to a catalyst under conditions suitable for chemical reaction that forms hydrogen. Chemical compounds of this type have the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are independently selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure. The acid can be an alcohol (methyl alcohol, ethyl alcohol, trifluoromethyl alcohol, and the like), a phenol (phenol, resorcinol, catechol, naphthol, and the like), or a compound having the formula HX or the formula HTX, wherein X is selected from chloride, bromide, iodide, carboxylate, sulfonate, phosphate, phosphonate, sulfate, and hydroxide (i.e. the acid may be water); and wherein T is selected from imidazole, alkylimidazole, arylimidazole, benzimidazole, alkylbenzimidazole, oxazole, alkyloxazole, benzoxazole, pyrazole, alkylpyrazole, arylpyrazole, pyridine, alkylpyridine, arylpyridine quinoline, ammonia, and amine. Some examples of an acid HX useful with this invention include, but are not limited to, acetic acid, succinic acid, benzoic acid, and acrylic acid. Preferably, the compound and/or the acid HX or HTX is (are) chosen such that the change in the standard free energy of the chemical reaction comprises a standard free energy in the range of from about +5 kilocalories per mole to about −10 kilocalories per mole.
The compound may be dissolved in a solvent chosen to stabilize the at least one organic compound and any cationic reaction products derived therefrom, so that the change in the standard free energy of the chemical reaction comprises a standard free energy in the range of from about +5 kilocalories per mole to about −10 kilocalories per mole. Examples of solvents useful with the present invention include polar organic and inorganic solvents such as, but not limited to, water, acetonitrile, tetrahydrofuran, pyridine, dimethylsulfoxide (DMSO), dimethylformamide (DMF), acetone, methyl ethyl ketone, methanol, ethanol, isopropanol, and the like. Ionic liquid solvents, also know in the art as “molten salts,” may also be used as solvents. Ionic liquids useful with this invention have been described, for example, in PCT Patent Application WO 01/93363 to A. McEwen et al. entitled “Non-Flammable Electrolytes”; in Japanese Patent 98168028 to M. Watanabe et al. entitled “Room Temperature Molten Salts and Electrochemical Devices Using the Salts”; in U.S. Pat. No. 6,365,301 to C. Michot et al. entitled “Materials Useful as Electrolytic Solutes,” which issued on Apr. 2, 2002; in “Room Temperature Ionic Liquids of Alkylimidazolium Cations and Fluoroanions” by R. Hagiwara and Y. Ito, J. Fluorine Chem. vol.105, (2000), pp. 221-227; in “Room-Temperature Molten Salts Based on the Quaternary Ammonium Ion” by J. Sun, M. Forsyth, and D. R. MacFarlane, J. Phys. Chem. B, 1998, vol.102, pages 8858-8864; and in U.S. Pat. No. 5,827,602 to V. R. Koch et al. entitled “Hydrophobic Ionic Liquids,” which issued Oct. 27, 1998, all incorporated by reference herein.
Another aspect of this invention relates to a method and system for producing hydrogen that employs compounds having the formula
wherein Z is selected from oxygen, sulfur, or —N(R 4 )— where R 4 is alkyl or aryl; wherein Q is selected from oxygen, —N(R 5 )—, —(C(R 5 R 6 )) n — where n is from 1 to 10, —(C(R 5 )═C(R 6 )) m — where m is from 1 to 2, and —(C(R 5 )═N) p — where p is from 1 to 2; wherein R 1 , R 2 , R 4 , R 5 , and R 6 are selected independently from alkyl, aryl; and wherein R 3 is selected from hydrogen, alkyl, aryl. The system also includes a catalyst suitable for facilitating the dehydrogenation of the chemical compound.
Another aspect of the present invention is related to hydrogen storage, and involves exposing at least one chemical compound to a hydrogen in the presence of a catalyst that facilitates the hydrogenation of the at least one chemical compound, which includes anion and cationic portion having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure.
The invention also includes a method for storing hydrogen, which includes exposing at least one chemical compound to a reducing agent, the chemical compound having an anion and a cationic portion having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and −N(R 12 R 13 ) wherein R 12 and R 13 are selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure. The reducing agents may one or more of lithium borohydride, sodium borohydride, potassium borohydride, sodium hydride, potassium hydride, magnesium hydride, lithium hydride, calcium hydride, and electron plus proton where the electron can be provided by a metal reducing agent (zinc, for example).
The invention also includes a method for storing hydrogen, and involves exposing at least one chemical compound to hydrogen or to a reducing agent in the presence of a catalyst that facilitates the hydrogenation of the at least one chemical compound, which has the formula
wherein X is oxygen, —N(H)—, or —N(R 3 )—; wherein X′ is oxygen, —N(H)— or —N(R 4 )—; wherein R 1 , R 2 , R 3 , and R 4 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl sulfonic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; and wherein R 1 and R 3 can be connected to each other to form a ring structure; and with the proviso that X and X′ cannot both be oxygen.
Another example of a system for hydrogen evolution and storage is related to chemical compounds known generally as triazacyclohexanes, which are also known in the art as hexahydrotrazines. These materials evolve hydrogen and a product known more generally as a triazine. In this system, three molecules of hydrogen may be produced from one molecule of the triazacyclohexane. The amount of evolvable hydrogen for trazacyclohexane is 6.9 weight percent. The dehydrogenation reaction is slightly endothermic (ΔH=+17 kcal/mole by calculation) and exergonic (ΔG=−9 kcal/mole by calculation). Examples of these types of materials that can be used to produce a hydrogen evolving system of the invention include, for example, a compound having the formula
wherein each R is independently selected from hydrogen, alkyl, and aryl; and a compound having the formula
wherein each R is independently selected from hydrogen, alkyl, aryl and a higher fused ring group; and a compound having the formula
wherein each R is independently selected from hydrogen, alkyl, aryl and a higher fused ring group. For these compounds, a catalyst is included for facilitating the dehydrogenation of the chemical compound.
The method and system of the present invention can be used with a fuel cell to provide power to portable devices such as laptop or handheld computers, cellular phones, global positioning system receivers, CD/MP3 music players, flashlights, and the like, and vehicles. The following details relate to aspects of the invention that relate to fuel cells.
The invention also includes a fuel cell having an anode and a hydrogen-generating fuel source for the anode. The hydrogen-generating fuel source includes at least one chemical compound and a catalyst suitable for dehydrogenating the chemical compound, which has the formula
wherein X is oxygen, —N(H)—, or —N(R 3 )—; wherein X′ is oxygen, —N(H)— or —N(R 4 )—; wherein R 1 , R 2 , R 3 , and R 4 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl sulfonic acid, alkenyl phosphoric acid, and alkenyl phosphonic acid; and wherein R 1 and R 3 can be connected to each other to form a ring structure.
The invention also includes a fuel cell comprising an anode and a hydrogen-generating fuel source for the anode, the hydrogen generating fuel source including at least one chemical compound having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, or —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )—; wherein R 5 and R 11 are independently selected from hydrogen, alkyl, and aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl. phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ). wherein R 12 and R 13 are selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; wherein R 8 and R 9 may be connected to each other to form a ring structure; and with the proviso that at least one of R 5 or R 11 is hydrogen.
The invention also includes a fuel cell having an anode and a hydrogen-generating fuel source for the anode, the hydrogen generating fuel source including at least one chemical compound having the formula
wherein Q is —(C(R 7 R 8 )) n — where n is from 1 to 10, —(C(R 7 R 8 )-M-C(R 7 R 8 ))—, —(C(R 7 )═C(R 8 ))—, —(C(R 7 )═C(R 8 )—C(R 9 )═C(R 10 ))—, —(C(R 7 )═N)—, —(C(R 7 )═N—C(R 8 )═N)—; wherein M is oxygen, —NR 9 —, sulfur, or —C(═O)—; wherein Z is oxygen, sulfur, or —N(R 11 )— wherein R 11 is hydrogen, alkyl, or aryl; wherein R 7 , R 8 , R 9 , and R 10 are independently selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid; wherein R 6 is selected from hydrogen, alkyl, aryl, alkenyl, alkyl carboxylic acid, alkyl sulfonic acid, alkyl phosphoric acid, alkyl phosphonic acid, aryl carboxylic acid, aryl sulfonic acid, aryl phosphoric acid, aryl phosphonic acid, alkenyl carboxylic acid, alkenyl phosphoric acid, alkenyl phosphonic acid, —OR 12 , —N(H)(R 12 ) and —N(R 12 R 13 ) wherein R 12 and R 13 are selected from hydrogen, alkyl and aryl; wherein R 7 and R 8 may be connected to each other to form a ring structure; and wherein R 8 and R 9 may be connected to each other to form a ring structure.
The invention also includes a fuel cell having an anode and a hydrogen-generating fuel source for the anode, the hydrogen generating fuel source including at least one chemical compound having the formula
wherein Z is selected from oxygen, sulfur, or —N(R 4 )— where R 4 is alkyl or aryl; wherein Q is selected from oxygen, —N(R 5 )—, —(C(R 5 R 6 )) n — where n is from 1 to 10, —(C(R 5 )═C(R 6 )) m — where m is from 1 to 2, and —(C(R 5 )═N) p — where p is from 1 to 2; wherein R 1 , R 2 , R 4 , R 5 , and R 6 are selected independently from alkyl and aryl; and wherein R 3 is selected from hydrogen, alkyl, aryl.
With a suitable catalyst, the hydrogen reaction becomes reversible, allowing the organic compounds to function as reversible hydrogen carriers that are capable of carrying hydrogen from one region of a device to another.
The following EXAMPLES illustrate embodiments of the present invention.
EXAMPLE 1
Catalytic dehydrogenation of
A solution of compound 1 (9 mg, 0.03 mmol) in CD 3 CN (0.7 ml) was prepared in a nuclear magnetic resonance (NMR) tube. Palladium acetate (Pd(O 2 CCH 3 ) 2 , 1 mg, 0.003 mmol) was added to the tube. Upon mixing, a black precipitate formed and effervescence was observed. The reaction mixture was then heated to a temperature of about 70 degrees Celsius for about 30 minutes, resulting in a 90 percent conversion of (1) to
which was confirmed by 1 H NMR spectroscopy. 1 H NMR (1) (THF-d 8 , 25° C., 400 MHz): δ 8.08 (d, 1H, aromatic), δ 7.83 (d, 1H, aromatic), δ 7.53 (t, 1H, aromatic), δ 6.56 (m, 2H, aromatic), δ 6.31 (m, 2H, aromatic), δ 6.00 (s, 1H, RN 2 CH), δ 2.50 (s, 6H, CH 3 ). 1 H NMR (2) (CD 3 CN, 25° C., 400 MHz): δ 8.23 (d, 1H, aromatic), δ 7.77 (m, 2H, aromatic), δ 7.72 (t, 1H, aromatic), δ 7.60 (m, 3H, aromatic), δ 7.40 (d, 1H, aromatic), δ 3.52 (s, 6H, CH 3 ).
Evolution of molecular hydrogen from compound (1) was confirmed by catalytic hydrogenation of trans-stilbene with the hydrogen evolved from compound (1). In an experimental set-up, a flask was charged with compound (1) (50 mg, 0.18 mmol) and Pd(O 2 CCH 3 ) 2 (3 mg, 0.013 mmol) in acetonitrile. A separate flask was charged with trans-stilbene (34 mg, 0.18 mmol) and 10% Pd on carbon (20 mg) in benzene. The headspaces of the two flasks were immediately connected with a transfer tube. After about 12 hours, the contents of both flasks were analyzed using 1 H NMR spectroscopy. Complete conversion of compound (1) to compound (2) was observed for the first flask. Hydrogenation of the trans-stilbene in the second flask was 47% complete, confirming the evolution of hydrogen from compound (1).
EXAMPLE 2
Compound (1) was converted to compound (2) according to the procedure described in EXAMPLE 1, with the exception that Pearlman's catalyst (Pd(OH) 2 /C) was used instead of palladium acetate.
EXAMPLE 3
Compound (1) was converted to compound (2) according to the procedure described in EXAMPLE 1, with the exception that Pd/C was used instead of palladium acetate.
EXAMPLE 4
Compound (1) was converted to compound (2) according to the procedure described in EXAMPLE 1, with the exception that PdCl 2 (bipyridine) was used instead of palladium acetate.
EXAMPLE 5
Compound (1) was converted to compound (2) according to the procedure described in EXAMPLE 1, with the exception that K 2 PdCl 4 was used instead of palladium acetate.
EXAMPLE 6
Catalytic dehydrogenation of
in the presence of acid. A solution of compound (3) in CD 3 CN (0.7 ml) solvent was prepared in an NMR tube. Acetic acid (0.015 ml, 0.26 mmol) was added to the solution and the contents were mixed thoroughly. Palladium acetate (1 mg, 0.003 mmol) was then added to the mixture, after which a black precipitate formed and effervescence was observed. The NMR tube was heated to a temperature of about 70 degrees Celsius for about 30 minutes, resulting in complete conversion of compound 3 to
(X═CH 3 COO − ), which was confirmed by 1 H NMR spectroscopy. 1 H NMR (3) (CD 3 CN, 25° C., 400 MHz): δ 7.56-7.45 (m, 5H, aromatic), δ 6.66-6.44 (m, 4H, aromatic), δ 4.84 (s, 1H, N 2 RCH), δ 2.50 (s, 6H, NCH 3 ). 1 H NMR (4) (HX=acetic acid, CD 3 CN, 25° C., 300 MHz): δ 8.0-7.6 (m, 9H, aromatic), δ 3.87 (s, 6H, CH 3 N), δ 1.80 (s, 3H, CH 3 CO 2 ).
EXAMPLE 7
Catalytic dehydrogenation of
in the presence of acid and a homogeneous catalyst. A solution of compound 5 (15 mg, 0.10 mmol), acetic acid (60 mg, 1.0 mmol) and CD 3 CN (0.70 ml) was prepared in an NMR tube. The solution was mixed, after which RhCl(PPh 3 ) 3 (0.3 mg, 0.37 μmol, Ph═C 6 H 5 ) was added to the solution. The mixture was heated at a temperature of about 70 degrees Celsius for about one hour, resulting in a 43% conversion of compound (5) to
(X═CH 3 COO − ), which was confirmed by 1 H NMR spectroscopy. Turnover number (TON)=117 at 70° C. in 1 hour. 1 H NMR (5) (CD 3 CN, 25° C., 400 MHz): δ 6.65-6.45 (m, 4H, aromatic), δ 4.23 (s, 2H, CH 2 ), δ 2.68 (s, 6H, NCH 3 ). 1 H NMR (6) (HX=acetic acid, CD 3 CN, 25° C, 400 MHz): δ 10.81 (s, CH 3 CO 2 ), δ 9.07 (s, 1H, NCHN), δ 7.85-7.69 (m, 4H, aromatic), δ 4.05 (s, 6H, NCH 3 ), δ 1.96 (s, CH 3 CO 2 ).
EXAMPLE 8
Compound (5) was converted to compound (6) according to the procedure described in EXAMPLE 7 with the exception that CpRuH(PPh 3 ) 2 (Cp=cyclopentadienyl=C 5 H 5 ) was used instead of RhCl(PPh 3 ) 3 .
EXAMPLE 9
Compound (5) was converted to compound (6) according to the procedure described in EXAMPLE 7 with the exception that CpRuH(dppe) (dppe=diphenylphosphinoethane) was used instead of RhCl(PPh 3 ) 3 .
EXAMPLE 10
Compound (5) was converted to compound (6) according to the procedure described in EXAMPLE 7 with the exception that RuCl 2 (PPh 3 ) 3 was used instead of RhCl(PPh 3 ) 3 .
EXAMPLE 11
Compound (5) was converted to compound (6) according to the procedure described in EXAMPLE 7 with the exception that Pt(CH 3 ) 2 (COD) (COD=cyclooctadiene) was used instead of RhCl(PPh 3 ) 3 .
EXAMPLE 12
Compound (5) was converted to compound (6) according to the procedure described in EXAMPLE 7 with the exception that Rh(CO)Cl(PPh 3 ) 2 was used instead of RhCl(PPh 3 ) 3 .
EXAMPLE 13
Conversion of (5) to (6) in the presence of acid and a heterogeneous catalyst. A solution of compound (5) (15 mg, 0.10 mmol), acetic acid (60 mg, 1.0 mmol) and CD 3 CN (0.7 ml) was prepared in an NMR tube. The solution was mixed, and Pd(O 2 CCH 3 ) 2 (1 mg, 0.003 mmol) was added. Effervescence began immediately upon addition of the Pd(O 2 CCH 3 ) 2 . Complete conversion of compound (5) to compound (6) (X═CH 3 COO − ) was confirmed by 1 H NMR spectroscopy after 30 minutes at room temperature.
EXAMPLE 14
Catalytic dehydrogenation of compound (5) in the presence of D 2 O and a heterogeneous catalyst. A solution of compound (5) (15 mg, 0.10 mmol) in a 1:1 mixture of D 2 O:CD 3 OD (0.7 ml) solvent was prepared in an NMR tube. This solution was mixed, Pd(O 2 CCH 3 ) 2 (1 mg, 0.003 mmol) was added, and the resulting mixture was heated to a temperature of about 70 degrees Celsius for about one hour. Effervescence was observed. About a 15 percent conversion of compound (5) to compound (6) (X═OD − ) after about one hour was confirmed by 1 H NMR spectroscopy.
EXAMPLE 15
Catalytic dehydrogenation of compound (5) in the presence of D2O, sodium bicarbonate, and a heterogeneous catalyst. A solution of compound (5) (15 mg, 0.10 mmol) and NaHCO3 (0.12 mmol) in a 1:1 mixture of D 2 O:CD 3 OD (0.7 ml) solvent was prepared in an NMR tube. The solution was mixed, Pd(O 2 CCH 3 ) 2 (1 mg, 0.003 mmol) was added, and the resulting mixture was heated to a temperature of about 70 degrees Celsius for about one hour. Effervescence was observed. 1 H NMR indicated that the conversion from compound (5) to compound (6) (X=bicarbonate or carbonate) was about 15 percent after about one hour.
The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching.
The embodiment(s) were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
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A method and system for storing and evolving hydrogen employ chemical compounds that can be hydrogenated to store hydrogen and dehydrogenated to evolve hydrogen. A catalyst lowers the energy required for storing and evolving hydrogen. The method and system can provide hydrogen for devices that consume hydrogen as fuel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to the preparation of 2,5-dichlorophenol, and, more especially, to the preparation of 2,5-dichlorophenol from 1,2,4-trichlorobenzene.
2. Description of the Prior Art:
2,5-Dichlorophenol is a known valuable compound, particularly useful as an intermediate in the production of a wide variety of crop chemicals for, e.g., crop and plant protection.
SUMMARY OF THE INVENTION
It has now surprisingly been found, and which is a major object of the present invention, that a high purity (e.g., but little byproduct), high quality 2,5-dichlorophenol is readily and facilely prepared by (i) first sulfonating 1,2,4-trichlorobenzene into 2,4,5-trichlorobenzenesulfonic acid, (ii) next hydrolyzing said 2,4,5-trichlorobenzenesulfonic acid by known technique to give 2,5-dichloro-4-hydroxybenzenesulfonic acid or salt thereof, and then (iii) removing the sulfo or sulfonate moiety therefrom by treatment with constant boiling hydrobromic acid, advantageously under reflux.
DETAILED DESCRIPTION OF THE INVENTION
More particularly according to the present invention, it has now surprisingly been found that removal of the sulfo group is most readily and effectively carried out by treating the precursor sulfonic acid with an excess of constant boiling point hydrobromic acid (about 48 percent strength). Heretofore, the sulfonic acid function, or sulfo group, was typically cleaved under extreme conditions of high temperature, mandating reaction in an autoclave, the inner wall members of which were easily damaged (by sulfuric acid, phosphoric acid), or which otherwise did not produce a satisfactory result (hydrochloric acid). But by the use of constant boiling point hydrobromic acid consistent herewith, it is unexpectedly found that the sulfo group cleavage reaction need not be carried out in an autoclave, but only under reflux at a base temperature of about 140° C. (reflux temperature 126° C.). The hydrobromic acid employed, moreover, can easily be recovered, and reused or recycled.
In order to further illustrate the present invention and the advantages thereof, the following specific example is given, it being understood that same is intended only as illustrative and in nowise limitative.
EXAMPLE
(1) Preparation of 2,4,5-trichlorobenzenesulfonic acid
119 g (1.0 mol) of technical grade chlorosulfonic acid were added dropwise, under stirring, to 218 g (1.2 mol) of technical grade 90% strength 1,2,4-trichlorobenzene over a period of time of about one hour. The reaction was permitted to proceed at 150° to 160° C. for three hours. During the reaction a slow stream of dried air or dried carbon dioxide was passed through the reaction mixture. The resulting hydrogen chloride of reaction was transferred with the gas stream into a receiving flask containing water. The hydrochloric acid trapped in the receiving flask constituted about 96% of theoretical. The reaction mixture, after being cooled to 120° C., was mixed with 200 ml of water. Steam was then charged therein to remove excess trichlorobenzene. 37 g (0.2 mol) of trichlorobenzene were recovered. Water was added to the reaction mixture to provide a total volume of 700 g which was then titrated with sodium hydroxide solution.
Total acid: 1.068 mol,
Sulfuric acid: 0.066 mol (determined as barium sulfate)
The total yield consequently was 1.00 mol of 2,4,5-trichlorobenzenesulfonic acid (262 g).
(2) Preparation of the sodium salt of 2,5-dichloro-4-hydroxybenzenesulfonic acid
An iron autoclave was charged with 590 g of water, 273 g of 48% strength aqueous sodium hydroxide solution (3.3 mol) and 700 g of the 37.4% strength aqueous trichlorobenzenesulfonic acid solution obtained in (1). The mixture was heated at 180° C. for 5 hours, the pressure being 7-8 bar.
Upon completion of the reaction, the disodium salt of 2,5-dichloro-4-hydroxybenzenesulfonic acid was present, which, upon addition of dilute sulfuric acid, liberated sodium 2,5-dichloro-4-hydroxybenzenesulfonate.
The yield was about 98% of the theoretical.
(3) Preparation of the 2,5-dichlorophenol
139 g (0.5 mol) of sodium 2,5-dichloro-4-hydroxybenzenesulfonate were added to 400 ml of approximately 48% strength aqueous hydrobromic acid. The mixture was stirred under reflux for 4 hours, during which the base temperature was about 140° C. and the reflux temperature about 126° C. The solution which was still warm, about 60° C., was then stirred with 300 ml of toluene. The toluene phase was separated off, dried and evaporated to dryness. The residue consisted of 70 g of crude 2,5-dichlorophenol (86% of theoretical).
Analysis: calculated Cl, 43.5% found Cl, 43.2%
As the solution containing hydrogen bromide cooled, a slight amount of sodium bromide precipitated. The hydrogen bromide solution could be reused.
While the invention has been described in terms of various preferred embodiments, the skilled artisan will appreciate that various modifications, substitutions, omissions, and changes may be made without departing from the spirit thereof. Accordingly, it is intended that the scope of the present invention be limited solely by the scope of the following claims, including equivalents thereof.
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2,5-Dichlorophenol is readily and facilely prepared from 2,5-dichloro-4-hydroxybenzenesulfonic acid or salt thereof, said sulfonic acid/sulfonate itself being characteristically produced by hydrolysis of a precursor trichlorobenzenesulfonic acid, by cleaving the sulfo/sulfonate moiety therefrom by treatment, e.g., under reflux, with a constant boiling point hydrobromic acid.
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CROSS-REFERENCES TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 10/734,564, which was filed on Dec. 8, 2003, now abandoned. Pursuant to the provisions of 37 C.F.R. §1.304, the parent application remained pending as of the time of the filing of this continuation-in-part.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
MICROFICHE APPENDIX
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of cables and ropes. More specifically, the invention comprises a process for thoroughly infusing liquid potting compound into the strands of a rope or cable prior to affixing an anchor or for other uses.
2. Description of the Related Art
Devices for mounting a termination on the end of a rope or cable are disclosed in detail in copending U.S. Application Ser. No. 60/404,973 to Campbell, which is incorporated herein by reference. Throughout this disclosure, the term “strand” will be used to describe the constituents of synthetic cables, natural-fiber cables, and ropes. Although synthetic cables are used for the illustrations, the reader should understand that the methods and devices disclosed are equally applicable to any type of stranded cable.
It is often useful to affix a piece of hardware to the end of a cable. Examples of hardware would be threaded fasteners, hooks, and eyes. Such hardware will be generically referred to as an “anchor.” Anchors typically have an expanding internal passage or some type of interlocking features, such as ridges. The strands proximate the end of a cable are wetted with liquid potting compound. The wetted strands are then placed within the internal passage of the anchor. The potting compound then hardens to form a solid, thereby locking a length of strands into the anchor. The anchor, along with the contained strands and solid potting compound will be referred to as a “termination.”
Those skilled in the art will know that the term “potting compound” generally refers to any liquid which can be transformed into a solid (such as by air-drying, cooling, reacting with a catalyst, etc.). Examples include thermoplastics, molten metals, thermosets, and reactive compounds (such as two-part epoxies).
Two methods of infusing liquid potting compound into the strands of a cable are in common use. These are: (1) Pulling an anchor into its final position around the exposed strands and pouring the liquid potting compound into an open end of the anchor; or (2) Infusing the exposed strands with liquid potting compound, then pulling the anchor into its final position (The infusion is typically accomplished via painting on the liquid potting compound or dipping the exposed strands into a vat of liquid potting compound).
Under either approach, the potting compound may fail to fully infuse the strands. Moreover, both approaches must generally be performed manually, resulting in drastic variations from termination to termination.
FIG. 1 shows four cables 10 with exposed strands in varying configurations. The far left example shows core strands 12 exposed and ready for potting in an undisturbed state. Proceeding to the right, the next example shows the exposed strands being compressed to form fanned strands 14 . The next example shows the exposed strands being splayed to form conical strands 16 . The far right example shows the strands being splayed apart further to form radially fanned strands 44 . All these examples, as well as others, may be employed prior to infusing the exposed strands with liquid potting resin.
BRIEF SUMMARY OF THE PRESENT INVENTION
The present invention comprises a process for forcibly infusing liquid potting compound into the exposed strands of a cable prior to forming a termination. The process uses a mold that encloses the exposed strands. Potting compound is then pumped into the mold, where it runs around and through the exposed strands. A second venting passage is preferably employed, so that the liquid potting compound flows through the mold without trapping any air pockets. A portion of the mold is preferably an anchor that is to be attached to an end of the cable. The liquid potting compound is allowed to harden while the anchor remains in place, thereby locking the anchor to the end of the cable.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an isometric view, showing various cable strand configurations.
FIG. 2 is an isometric view, showing the operation of a mold.
FIG. 3 is an isometric view, showing internal passages within the mold.
FIG. 4 is an isometric section view, showing the mold base.
FIG. 5 is an isometric view, showing the installation of an anchor.
FIG. 6 is an isometric view, showing the installation of an anchor.
FIG. 7 is an isometric view, showing the mold on an assembly line.
FIG. 8 is an isometric view, showing a cable clamped within a mold.
FIG. 9 is an isometric view, showing an injector.
FIG. 9B is an isometric view, showing an alternate injector.
FIG. 10 is an isometric section view, showing the operation of an injector.
FIG. 11 is an isometric section view, showing the operation of an injector.
FIG. 12 is an isometric section view, showing the use of a holding fixture on the cable and the anchor.
FIG. 13 is a sectional elevation view, showing the operation of the cable holding fixture.
FIG. 14 is a sectional elevation view, showing the use of an O-ring to seal the anchor's lower surface.
FIG. 15 is a detailed elevation view, showing the O-ring seal in more detail.
FIG. 16 is an isometric section view, showing the use of an inflatable seal.
REFERENCE NUMERALS IN THE DRAWINGS
10 cable
12 core strands
14 fanned strands
16 conical strands
18 anchor
20 upper mold portion
22 mold base
24 strand cavity
26 separator
28 cable cavity
30 strand cavity
32 infeed runner
34 liquid coupling
36 liquid vent
38 vent coupling
40 infused strands
42 anchor fork
44 radially fanned strands
46 injector
48 needle
50 injection orifice
52 vent
54 dry strands
58 anchor end sealing surface
60 anchor holding fixture
62 cable holding fixture
67 anchor neck sealing surface
66 fixture sealing surface
68 anchor chamfer
70 fixture chamfer
72 O-ring
74 injector sealing surface
76 open end
78 neck end
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 shows one embodiment of the present invention. Anchor 18 is placed on cable 10 and pulled away from the exposed end strands to the position shown. Cable 10 is then positioned between the upper mold portions 20 (In the example shown, two mold portions are used. The upper portion of the mold can also be split into three or more portions). Each upper mold portion 20 preferably includes a cable cavity 28 and a strand cavity 30 . Mold base 22 lies beneath cable 10 . The two upper mold portions 20 clamp securely together, as indicated by the arrows. This action results in cable 10 being held tightly within the internal passages in the two upper mold portions.
Mold base 22 then moves upward to seal off the bottom of cable 10 . Those skilled in the art will realize that the type of mold shown is but one among many. The mold could split in other ways, move together in different ways, etc.
Once the mold closes, cable 10 is held securely within the internal passages. FIG. 3 is a sectional view of one of the two upper mold portions 20 . The reader will observe that infeed runner 32 connects liquid coupling 34 with strand cavity 30 . When clamped in place, preferably pressurized liquid potting compound is forced through infeed runner 32 where it emerges in and around the exposed strands of cable 10 . Cable cavity 28 is clamped securely around the rest of cable 10 , thereby preventing the liquid potting compound from diffusing upward beyond the exposed end strands. As an alternative, a fairly loose fit can be provided around cable 10 so that entrapped air can vent past cable 10 . The second upper molding portion can be equipped with a corresponding infeed runner. Additional infeed runners could also be provided in the mold base. An infeed runner could be placed at virtually any location and in any orientation within strand cavity 30 .
FIG. 4 is an isometric section view of mold base 22 . Its upper surface opens into strand cavity 24 (A flat upper surface having no recess can also be used). A conically shaped separator 26 may be provided in the middle in order to splay the exposed strands of the cable when mold base 22 is moved up into position. Mold base 22 is preferably equipped with one or more liquid vents 36 . These connect to vent coupling 38 . In operation, the mold parts are clamped together to form the enclosed strand cavity 30 . Liquid potting compound is then forced under pressure into the mold through infeed runners 32 . Liquid vents 36 allow air within the mold cavity to escape. Eventually, liquid potting compound completely fills the cavity and flows out through liquid vents 36 . A vacuum may be applied to vent coupling 38 in order to promote faster flow or more complete liquid potting compound infusion.
As an alternative, the infeed runners and liquid vents can be reversed so that the liquid potting compound flows from the bottom to the top, Vacuum and pressure can also be used interchangeably to create the desired flow. Although the runners and vents have been shown as circular, those skilled in the art will know that they could also be made with an oval cross section, a square cross section, or any other desired shape.
FIG. 5 shows cable 10 after its end strands have been infused with liquid potting compound within the mold. The end strands are now denoted as infused strands 40 . Anchor 18 is then moved down in the direction shown until it encloses the infused end strands (or otherwise mechanically interlocks). Anchor 18 is shown in its final position in FIG. 6 . It remains in this position while the liquid potting compound hardens into a solid, thereby forming a completed termination. As an alternative, anchor 18 can be slid into position from the opposite end of the cable after the liquid potting compound is applied.
FIG. 7 shows the application of the devices and processes disclosed to an assembly line. A series of cables 10 —with anchors 18 in an appropriate position, are sequentially fed along the line in the direction indicated by the arrow. The middle cable 10 is set to be clamped within the mold components. Its exposed end strands will then be infused with liquid potting compound. The cable 10 immediately to the right of the middle cable 10 has just exited the mold. Its end strands have been infused with liquid potting compound. They are thus denoted as infused strands 40 .
As cable 10 moves further down the line, anchor fork 42 (or other suitable devices, whether automatic or manual), may be employed to pull anchor 18 into the appropriate position before the liquid potting compound hardens. Similar devices can be employed to retain the anchors in the appropriate positions throughout the process.
The same process can be applied where a mold is substituted for anchor 18 . In other words, a mold can be pulled in place over the strands while they are allowed to set. This mold can then be removed and the strands placed in a separate anchor.
Those skilled in the art will realize that the internal cavities within the mold components, as well as the infeed runners and vents, can be made in virtually any shape. Multi-cavity molds can also be used to increase the feed rates. Returning to FIG. 1 , the reader will appreciate that the mold can be configured to clamp the fibers in any one of the four configurations shown (as well as others). As an example, FIG. 8 shows a mold having a strand cavity 30 shaped to deform the strands into radially fanned strands 44 (The cable is shown sectioned to aid visualization). A separator 26 is also used.
The injection process can even be modified to infuse the liquid potting compound from the center of the exposed strands outward. FIG. 9 shows injector 46 . Needle 48 extends from its lower surface. Injection orifice 50 passes through needle 48 (The orifice can assume a variety of shapes). The lower surface also opens into a pair of vents 52 . FIG. 10 shows injector 46 in a section view. Injection orifice 50 is connected to a supply of liquid potting compound (not shown). Vents 52 can be vented to the surrounding air or collection reservoir. In operation, a mold is placed around the dry exposed strands on the end of a cable. For the example shown, an anchor 18 is actually used as the mold (Split molds such as shown previously could also be used). The anchor has an expanding internal passage which serves as a strand cavity. It also has an open end. Injector 46 is moved toward the exposed strands as indicated.
FIG. 11 shows injector 46 mated to anchor 18 . The lower surface of injector 46 is actually pressed against the upper surface of anchor 18 to form a sealing surface. Needle 48 protrudes down into the exposed strands. Liquid potting compound is then infused through injection orifice 50 . It flows out through the strands toward the two vents 52 , thereby completely infusing the strands within the anchor's internal passage. Once the infusion is completed, injector 46 is withdrawn. The liquid potting compound then hardens to complete the termination.
Those skilled in the art will realize that injector 46 can take many forms, including breaking the injector into two or more pieces (like a mold). Needle 48 is optional. The injection could be accomplished via forcing the liquid potting compound through a simple hole. Such an alternate embodiment is shown in FIG. 9B . Likewise, the seal between injector 46 and anchor 18 can be achieved using many methods, including an O-ring or interlocking threads. With the anchor itself forming the mold, it may be advisable to add infeed runners or vents to the anchor. These features could take many shapes. As stated previously, a split mold can be used in the place of anchor 18 . In such a case, the anchor would be added after the infusion process is complete.
In performing the potting process whereby the cable strands are locked within the strand cavity, it is important that the cable be aligned with the anchor. The cable has a central axis and the anchor will generally have a central axis as well (assuming that it is a radially symmetric anchor). Any misalignment will result in some of the strands having a shorter overall length than others. When the cable is then placed under tension, the shorter strands will carry a disproportionally large share of the load and the termination will not perform as well as it could. Those familiar with synthetic cables will realize that ensuring the alignment of the cable and the anchor is difficult because synthetic cables have very fine strands and the cables do not tend to be very stiff. Where an older cable such as wire rope will tend to retain its position because of its inherent rigidity, a synthetic cable will deflect substantially under its own weight. Thus, the use of alignment fixturing can be a significant advantage.
FIG. 12 shows a solution to the alignment issue. This figure shows a sectioned elevation view through a cable undergoing the potting process. Dry strands 54 on the end of the cable have been placed within strand cavity 24 . In this case the strand cavity is actually an expanding passage within anchor 18 . Anchor 18 has open end 76 and neck end 78 (The “neck end” being the side where the freely flexing portion of the cable emerges from the anchor through the “neck” of the strand cavity). Strand cavity 24 passes through anchor 18 from neck end 78 to open end 76 . The strand cavity preferably has an expanding cross section.
Anchor 18 is placed within anchor holding fixture 60 . The anchor holding fixture can assume a virtually limitless variety of forms, but it should hold the anchor securely and keep it in a desired orientation during the process. One example of an anchor holding fixture is a split fixture that is clamped together.
Cable 10 is held in position by cable holding fixture 62 . The cable holding fixture is aligned with the anchor holding fixture so that the cable is held in the appropriate position with respect to the anchor. The cable holding fixture can also assume many different forms, with a split collar being one example. It may also be desirable in some applications to employ a lengthened cable holding fixture that grips a substantial length of the cable. Multiple cable holding fixtures can also be used.
Once the cable is properly referenced to the anchor using the two holding fixtures, injector 46 is mated to anchor end sealing surface 58 and the liquid potting compound is infused into the dry strands as described previously. The two holding fixtures are preferably left in position while the potting compound hardens. After the potting compound has hardened, the two holding fixtures are removed. Thus, the holding fixtures ensure alignment until the time when the potting compound has hardened and the cable is secured to the anchor.
The potting compound injection process is best carried out by retaining the liquid compound within the anchor. Unfortunately, some of the liquid potting compound often tends to leak out the neck end of the anchor. This portion will then harden in the cable strands lying outside the anchor, causing localized stress concentrations when the cable flexes, as well as other problems.
FIG. 13 shows a solution to this problem. The neck end of the anchor is provided with anchor neck sealing surface 64 . A fixture sealing surface 66 is clamped against anchor neck sealing surface 64 in order to seal the neck end of the anchor. Fixture sealing surface 64 may be located on a separate component or may actually be provided on cable holding fixture 62 .
Injector sealing surface 72 on injector 46 has been mated to anchor end sealing surface on anchor 18 —thereby sealing the open end of the anchor. Fixture sealing surface 66 has been mated to anchor neck sealing surface 64 on the neck end of the anchor—thereby sealing the anchor's neck end. The liquid potting compound is then injected by the injector and it floods the strand cavity. The air within the strand cavity is forced out—preferably through the vent or vents in the injector—and replaced with liquid potting compound.
FIGS. 14 and 15 illustrate a further refinement. It is preferable to clamp the cable strands in an inward direction near the point where the strands emerge from the neck end of the anchor. This action bunches the strands more tightly together and tends to prevent leakage of the liquid potting compound between the strands. FIG. 14 shows an embodiment in which the neck end of the anchor and the opposing surface on the cable holding fixture are provided with a sealing O-ring.
FIG. 15 shows this configuration in more detail. Anchor chamfer 68 is provided in anchor neck sealing surface 64 . An opposing fixture chamfer 70 is provided in fixture sealing surface 66 (which may or may not be part of the cable holding fixture). O-ring 72 is shown in position between the two opposing chamfers. When the anchor neck sealing surface and the fixture sealing surface are pressed toward each other, O-ring 72 is forced inward and upward, suitably compressing the cable strands. Once the potting compound is hardened, the O-ring can be removed or left in place. Although an O-ring having a round cross section is shown, other shapes could be substituted and the term “O-ring” should not be understood to be limited to round cross sections.
Other more sophisticated seals may be used in place of a passive O-ring. FIG. 16 shows another embodiment in which cable holding fixture 62 is equipped with inflatable seal 74 . The view shows one-half of a pair of cable holding fixtures which are configured to be clamped around the cable. Gas pressure is then applied to inflate the inflatable seals and seal the cable near the position where it emerges from the neck end of the boundary.
The reader will thereby appreciate how the additional components and steps described can ensure the proper alignment of the cable and the anchor as the potting compound transitions to a solid. The reader will also appreciate how the sealing features and methods help contain the potting compound within the anchor.
Throughout the preceding disclosure, terms referring to the orientation of the parts have been used (“upper”, “lower”, etc.). Those skilled in the art will realize that the orientation of the components has no significant impact on the operation of the devices. These terms referred only to the orientations shown in the views, and should not be taken as limiting the scope of the invention.
Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed solely by the language in the claims that follow.
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A process for forcibly infusing liquid potting compound into the exposed strands of a cable prior to forming a termination. The process uses a mold that encloses the exposed strands. Potting compound is then pumped into the mold, where it runs around and through the exposed strands. A second venting passage is preferably employed, so that the liquid potting compound flows through the mold without trapping any air pockets.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 09/968,083 filed Oct. 1, 2001, which application is hereby incorporated by reference in its entirety. Under 35 U.S.C. § 119, this application claims priority to Korean Application Serial No. 2000-57823 filed on Oct. 2, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a digital communication system, and more particularly, to a vestigial sideband (VSB) modulation transmission system including a TCM (Trellis-Coded Modulation) encoder and an additional ½ rate convolutional encoder having a superior state transition property when connected to the TCM encoder in the system.
2. Background of the Related Art
The TCM coded 8-VSB modulation transmission system has been selected as a standard in 1995 for the U.S. digital terrestrial television broadcasting, and the actual broadcasting incorporating the system has started since the second half of the year 1998.
In general, a digital communication system performs error correcting processes to correct the errors occurred at the communication channels. The total amount of the transmitting data is increased by such error correcting coding processes since it creates additional redundancy bits added to the information bits. Therefore, the required bandwidth is usually increased when using an identical modulation technique. Trellis-coded modulation (TCM) combines multilevel modulation and coding to achieve coding gain without bandwidth expansion. Also an improved signal to noise ratio can be achieved by using the trellis-coded modulation (TCM) technique.
FIG. 1A and FIG. 1B illustrate a typical TCM encoder used in a typical ATSC 8-VSB system and corresponding set partitions used by the TCM encoder. According to the FIG. 1A , an input bit d 0 is output as c 1 and c 0 after trellis-coded modulation, and then a subset is selected among (−7,1), (−5,3) (−3,5), and (−1,7). Thereafter, an input bit d 1 selects a signal within the selected subset. In other words, when d 1 and d 0 are inputted, one of eight signals (−7,−5,−3,−1,1,3,5,7) is selected by c 2 , c 1 , and c 0 generated by the TCM encoder. d 1 and d 0 are called an uncoded bit and a coded bit, respectively.
FIG. 1B illustrates the set partitions used by the TCM encoder used in the ATSC 8-VSB system. Eight signal levels are divided into four subsets, each of which including two signal levels. Two signals are assigned to each subset such that the signal levels of each subset are as far as possible from each other as shown in FIG. 1B .
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a VSB transmission system and a method for encoding an input signal in the VSB transmission system that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a VSB transmission system that can transmit data reliably even at a lower signal to noise ratio and can have an optimal state transition property when connected to the TCM encoder by using a ½ rate convolutional encoder as an additional error correcting encoder in the system.
Another object of the present invention is to provide a method for encoding an input signal in a VSB modulation transmission system enabling a data sender to achieve more reliable data transmission at a lower signal to noise ratio and to have an optimal state transition property of a ½ convolutional encoder, which is concatenated to the TCM encoder for error correcting in the system.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a vestigial sideband (VSB) modulation transmission system includes a convolutional encoder encoding an input signal; a trellis-coded modulation (TCM) encoder encoding the convolutionally encoded input signal; and a signal mapper mapping the trellis-coded input signal to generate a corresponding output signal.
In another aspect of the present invention, a vestigial sideband (VSB) modulation transmission system includes a ½ rate convolutional encoder encoding an input signal to generate first and second output signals; a ⅔ rate trellis-coded modulation (TCM) encoder encoding the first and second output signals to generate third, forth and fifth output signals; and a signal mapper mapping the third, forth, and fifth output signals.
There are three different types of ½ rate convolutional encoders that can be used in this aspect of the present invention. The first type includes a plurality of multipliers, each i th multiplier multiplying the input signal by a constant k i to generate an i th multiplier value; a plurality of memories, a first memory storing the previous second output value as a first memory value and each i+1 th memory storing an i+1 th memory value obtained by adding an i th memory value stored in a i th memory and the i th multiplier value; and a plurality of adders, each i th adder adding the i th memory value and the i th multiplier value, where i=1, 2, 3, . . . , n, and a n+1 th memory value stored in a n+1 th memory is the second output signal.
The second type of the ½ rate convolutional encoder includes a first memory storing the input signal as a first memory value; a second memory storing the first memory value as a second memory value; a first adder adding the input signal and the second memory value to generate the first output signal; and a second adder adding the input signal and the first and second memory values to generate the second output signal.
Finally, the third type of the ½ rate convolutional encoder includes a first memory storing the previous second output value as a first memory value; an adder adding the input signal and the first memory value; and a second memory storing a result from the adder as a second memory value, the second memory value being the second output signal.
In another aspect of the present invention, a method for encoding an input signal in a vestigial sideband (VSB) modulation transmission system includes the steps of encoding the input signal by the convolutional encoder; encoding the convolutionally encoded input signal by the TCM encoder; and generating a final output signal my mapping the trellis-coded input signal.
In a further aspect of the present invention, a method for encoding an input signal in a vestigial sideband (VSB) modulation transmission system includes the steps of generating first and second output signals by encoding the input signal using the ½ convolutional encoder; generating a third, forth, and fifth output signals by encoding the first and second output signals using the ⅔ rate TCM encoder; and generating a final output signal by mapping the third, forth, and fifth output signals.
The second output signal can be generated using three different methods in the last aspect of the present invention described above. The first method for generating the second output signal includes the steps of multiplying the input signal by a constant k i to generate an i th multiplier value for i=1, 2, 3 . . . n ; storing the previous second output value as a first memory value; and storing an i+1 th memory value obtained by adding an i th memory value and the i th multiplier value for i=1, 2, 3 . . . n, where the second output signal is an n+1 th memory value.
The second method for generating the second output signal includes the steps of storing the input signal as a first memory value; storing the first memory value as a second memory value; generating the first output signal by adding the input signal and the second memory value; and generating the second output signal by adding the input signal and the first and second memory values.
Finally, the third method for generating the second output signal includes the steps of storing the previous second output value as a first memory value; adding the input signal and the first memory value; storing the value resulted from the adding step as a second memory value; and outputting the second memory value as the second output signal.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings;
FIG. 1A illustrates a typical trellis-coded modulation (TCM) encoder used in a ATSC 8VSB transmission system according to the related art;
FIG. 1B illustrates set partitions used by a typical TCM encoder of a ATSC 8VSB transmission system according to the related art;
FIG. 2 illustrates an error correcting encoder concatenated to a ⅔ rate TCM encoder in a ATSC 8-VSB transmission system according to the present invention;
FIG. 3A illustrates a ½ rate convolutional encoder concatenated to a ⅔ TCM encoder to be used as an error correcting encoder in a ATSC 8-VSB transmission system according to the present invention;
FIG. 3B illustrates ⅔ and ⅓ rate convolutional encoders used as an error correcting encoder in a ATSC 8-VSB transmission system according to the present invention;
FIG. 4 illustrates a first type of a ½ rate convolutional encoder concatenated to a ⅔ TCM encoder in a ATSC 8-VSB transmission system according to the present invention;
FIG. 5A illustrates a second type of a ½ rate convolutional encoder used in a ATSC 8-VSB transmission system according to the present invention and its corresponding state transition diagram;
FIG. 5B illustrates a third type of ½ rate convolutional encoder used in a ATSC 8-VSB system according to the present invention and its corresponding state transition diagram;
FIG. 6 illustrates a VSB receiving system corresponding to a ATSC 8-VSB transmission system according to the present invention;
FIG. 7A illustrates Euclidean distances of a set of output signals generated from the ½ rate convolutional encoder shown in FIG. 5A ;
FIG. 7B illustrates Euclidean distances of a set of output signals generated from the ½ rate convolutional encoder shown in FIG. 5B ; and
FIG. 8 illustrates performances of ATSC 8-VSB transmission systems when each of the ½ rate convolutional encoders shown in FIG. 5A and FIG. 5B is used.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 2 illustrates a VSB transmission system in which an error correcting encoder is concatenated to a ⅔ rate TCM encoder according to the present invention. By adding an additional error correcting encoder to the ⅔ rate TCM encoder in the VSB system, it is possible to achieve a reliable data transmission even at a lower signal to noise ratio than that of the conventional ATSC TCM coded 8VSB system. In the present invention, a ½ rate convolutional encoder is used for the additional error correcting encoder. In addition, a multiplexer located between the error correcting encoder and the ⅔ rate TCM encoder classifies the data received from each of the error correcting encoder and a ATSC encoder and inputs each data to the TCM encoder. The additional error-corrected data will be regarded as an error by the ATSC receiver and will be discarded.
FIG. 3A and 3B illustrate a ½ rate encoder used as an additional error correcting encoder shown in FIG. 2 . According to FIG. 3A , an input bit u is processed in the ½ rate encoder to generate two output bits d 1 and d 0 , and these are inputted to a ⅔ rate TCN encoder. In FIG. 3B , each of ⅔ and ⅓ rate encoders is connected to a ⅔ rate TCM encoder. Since the bit error rate of uncoded bits u 1 is lower than that of a coded bit u 0 , the encoder having a higher code rate is used for u 1 , and the other encoder is used for u 0 . This will compensate the difference between two input bits u 0 and u 1 . In addition, the ⅔ and ⅓ rate encoders can be considered as being a ½ rate encoder since it has three input bits and six output bits. Thus, combining encoders having different code rates can reduce the bit error rate of the whole system. As a result, the additional encoder can be any one of the ½ rate encoder and the combination of the ⅔ rate encoder and the ⅓ rate encoder shown in FIG. 3A and FIG. 3B , respectively. By adding the additional encoder, the performance of the system can be enhanced, and this will be shown later in this section. Considering the signal mapping of the TCM encoder, the error correcting encoder must be designed so that it has the optimal state transition property when connected to the TCM encoder.
FIG. 4 illustrates a first type of a ½ rate convolutional encoder concatenated to a ⅔ TCM encoder in a VSB transmission system according to the present invention. The ½ rate convolutional encoder receives an input bit u and generates a first output bit d 1 by bypassing u. A second output bit d 0 is the value of the N+1 th memory m i+1 . The ½ rate convolutional encoder includes N mutipliers, N adders, and N+1 memories. The first memory m 1 stores a previous second output value, the first multiplier g 1 multiplies the input bit u by a first constant k 1 , and the first adder adds the outputs from g 1 and m 1 . Similarly, each i+1 th memory m i+1 stores the output from the ith adder, the i th multiplier g i multiplies the input bit u by an i th constant k i , and the i th adder adds the outputs from g i and m i , where i=2, 3, 4, . . . , N. Finally, the N+1 th memory m 1+1 stores the output from the N th adder. Then the value stored in m i+1 is output as a second output bit (current). In addition, the second output bit (current) is feedback to the first memory m 1 for calculating a next second output value. N can be greater than or equal to two and can be determined as one wishes to design the system. As shown in the FIG. 4 , the ½ rate convolutional encoder receives u and outputs d 0 and d 1 . d 0 and d 1 then become the output bits c 1 and c 2 of the TCM encoder. Therefore, when d 1 d 0 =00, c 2 c 1 =00, and the corresponding 8VSB symbol becomes 7 (c 2 c 1 c 0 =000) or −5( c 2 c 1 c 0 =001) depending on the value of c 0 . c 0 is equal to the value stored in a second memory s 1 and is obtained by adding s 0 and d 0 , where s 0 is the value stored in a first memory. The 8VSB symbols for d 1 d 0 =01, 10, 11 are (−3, −1), (1,3), and (5,7), respectively.
FIG. 5A illustrates a non-systematic ½-rate convolutional encoder used in a VSB system according to the present invention and its corresponding state transition diagram. This type of encoder is often used because of its long free-distance property. In the state transition diagram shown in FIG. 5A , a transition from the state S k at t=k to the state S k+1 at t=k+1 is denoted as a branch, and the value indicated above each branch corresponds to the output of the branch. The probability of receiving a signal r when a signal z having zero mean and variance σ 2 is sent through a AWGN channel can be obtained by using the equation:
p ( r | z ) = 1 2 π σ 2 exp ( - | r - z | 2 2 σ 2 ) [ Equation 1 ]
where z represents a branch output. A branch metric is a probability measure of receiving r when the branch output z is sent from the encoder. It is an Euclidean distance between r and z, and can be obtained by the following equation:
Branch Metric ∝Log( p ( r/z ))=| r−z| 2 . [Equation 2]
A metric corresponding to a path including S 0 , S 1 , S 2 , . . . , S k can be calculated by the equation:
Path Metric = ∑ t = 0 t = k Branch Metric . [ Equation 3 ]
The path metric is an accumulated value of the branch metrics of the branches included in a path and represents a probability of the path.
As shown in the state transition diagram of FIG. 5A , two branches are divided from each S k , and two branches are merged into each S k+1 . A viterbi decoder that decodes a convolutional code first calculates the path metrics of the two paths that are merging into each state and selects the path having a lower path metric. The path metric selected using this technique represents the lowest path metric of the paths starting from an initial state (t=0) to each S k .
When selecting a path between two paths merging into one state, the probability of the path selection becomes higher as the difference between the metrics of the two paths is larger. Since a path metric represents the sum of metrics of the branches included in a path, it is desired to have the largest difference between the branch metrics in order to maximize the performance of the encoder.
The ½ rate convolutional encoder shown in FIG. 5A includes a first memory for storing an input bit u as a first memory value s 0 ; a second memory for storing s 0 as a second memory value s 1 ; a first adder for adding u and s 1 ; and a second adder for adding u, s 0 , and s 1 . The output from the first and second adders becomes a first output bit d 1 and a second output bit d 0 .
FIG. 5B illustrates a systematic convolutional encoder used in a VSB transmission system and its corresponding state transition diagram. A first output bit d 1 is generated by bypassing an input bit u, and a second output bit d 0 is generated by adding and delaying u. The systematic ½ rate convolutional encoder includes a first memory for storing a previous second output bit value as a first memory value s 0 , an adder for adding the input bit u and s 0 , and a second memory for storing the output from the adder as a second memory value s 1 and outputting s 1 as the second output bit d 0 .
According to FIG. 5A , the combination of the branch outputs dividing from a state at t=k or merging into a state at t=k+1 is (00,11) or (01,10). According to the trellis-coded modulation fundamental, the encoder has a better performance as the difference between branch metrics of the combination is larger. A larger difference between the branch metrics means that the corresponding Euclidean distance is larger. The Euclidean distance of (00,11) is larger than that of (01,10). When the output is either 01 or 10, the error often occurs during the path selection. Therefore, it is desired to have the combination of the branch outputs of (00,10) and (01,11) so that the difference between the branch metrics is large. This is shown in FIG. 5B . Therefore, the convolutional encoder of FIG. 5B has a better encoding performance than that of FIG. 5A .
FIG. 6 illustrates a VSB receiving system corresponding to the VSB transmission system of the present invention.
FIG. 7A and FIG. 7B illustrate Euclidean distances corresponding to the output combinations generated from the encoders shown in FIG. 5A and FIG. 5B , respectively. As it can be shown from both figures, the Euclidean distances of (00,10) and (01,11) are much larger than the that of (01,10). Therefore, the convolutional encoder of FIG. 5B has a better performance when connected to the ⅔ rate TCM encoder in the VSB transmission system.
FIG. 8 illustrates performances of ATSC 8-VSB transmission systems when each of the convolutional encoders shown in FIG. 5A and FIG. 5B is used in the system. For a bit error rate of 1e−3, the signal to noise ratio is reduced by 2 dB and 4 dB when the convolutional encoders shown in FIG. 5A and FIG. 5B are used as an additional error-correcting encoder in the VSB system. Therefore, a bit error rate can be reduced by using a ½ rate convolutional encoder as an outer encoder of the TCM encoder, and the encoder shown in FIG. 5B has a better bit error rate reduction property.
In conclusion, data can be transmitted at a lower signal to noise ratio by concatenating a ½ rate convolutional encoder to the TCM encoder in a VSB transmission system according the present invention.
The forgoing embodiments are merely exemplary and are not to be construed as limiting the present invention. The present teachings can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art.
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A vestigial sideband (VSB) modulation transmission system and, a method for encoding an input signal in the system are disclosed. According to the present invention, the VSB transmission system includes a convolutional encoder for encoding an input signal, a trellis-coded modulation (TCM) encoder for encoding the convolutionally encoded signal, and a signal mapper mapping the trellis-coded signal to generate a corresponding output signal. Different types of the convolutional encoders are explored, and the experimental results showing the performances of the VSB systems incorporating each type of encoders reveals that a reliable data transmission can be achieved even at a lower input signal to noise ratio when a convolutional encoder is used as an error-correcting encoder in a VSB system.
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TECHNICAL FIELD
[0001] This invention relates to a method for forming LED (light emitting diode), and more particularly to a method for forming LED by a chemical method or a physical method.
BACKGROUND
[0002] Basically, the principle of LED is to employ a characteristic of semiconductor to emit light. This is different from the conventional lighting apparatuses that lighting by discharging or heating, so the LED is called “cold light.” Compared with the conventional the light bulb or the fluorescent tube, the LED has advantages of high durability, long life, light, low power consumption, and mercury-free.
[0003] The basic structure of LED is a PN diode structure that comprises a P-type epitaxial layer, an N-type epitaxial layer, and an active layer there between. In general, a current is input by two pads on the epitaxial layers of the LED. The pads may be formed on the same side or opposite sides according to the material selection of substrate and epitaxial layer, as shown in FIG. 1A and FIG. 1B . For example of GaN-based LED, the common substrate is an unconductive sapphire (Al 2 O 3 ) or a conductive SiC. FIG. 1A shows a structure of a GaN LED with a sapphire substrate 40 . An N-type epitaxial layer 30 , an active layer 20 , and a P-type epitaxial layer 10 are on the substrate 40 in sequence. Pads 25 and 15 are formed on an exposed region of the N-type epitaxial layer 30 and the P-type epitaxial layer 10 , respectively. FIG. 1B shows a structure of a GaN LED with a SiC substrate 50 . An N-type epitaxial layer 30 , an active layer 20 , and a P-type epitaxial layer 10 are on the substrate 50 in sequence. Pads 15 and 25 are formed on an upper surface of the P-type epitaxial layer 10 and a lower surface of the substrate 50 , respectively.
[0004] Due to the light-absorbing and light-covering problems of the pads 15 and 25 , some manufacturers produce LEDs by Flip-Chip technology for improving the illumination of LEDs. As shown in FIG. 1C , the LED structure is a reverse structure of that shown in FIG. 1A . The structure has a P-type epitaxial layer 10 , an active layer 20 , an N-type epitaxial layer 30 , and a substrate 40 in sequence from bottom to top, and light is emitted upwards from the side of substrate 40 . The substrate 40 is transparent, so it has no problem of light-absorbing or light-covering. The flip-chip LED is generally adhered to a submount 60 , and a reflecting layer is formed to reflect the downward light emitted by the LED upwards. Furthermore, the submount 60 may be made of a material (as metal) having good cooling effect to diffuse the heat of LED, so it is proper to operate under high current. Hence, the LED having flip-chip structure improves the illumination and cooling effect.
[0005] Although the illumination of flip-chip LED is substantially increased and the flip-chip LED is proper to operate under high current, the product yield thereof is not well. That is resulted from the conventional Flip-Chip technology is to connect the pads of LED with the submount by bonding, and the bonding yield is not well. Hence, the yield of flip-chip LED is not efficiently increased, and the product cost is higher.
SUMMARY
[0006] In those conventional arts, the Flip-Chip technology for LED has some drawbacks and problems. Therefore, one of objectives of the present invention is to provide a method for forming LED to increase the LED yield.
[0007] Another objective of present invention is to form a substrate of LED by chemical or physical method for increasing the conductivity and cooling effect.
[0008] Still another objective of present invention is to form a reflecting layer for increasing the illumination of LED.
[0009] As aforementioned, the present invention provides a method for forming LED comprising the following steps. First, an LED epitaxial layer is formed on a provisional substrate. Then, the LED epitaxial layer is etched to form LED chips by means of photolithography. A reflecting layer formed on the LED chips. Then, a metal layer formed on the reflecting layer by means of a chemical method or a physical method as permanent substrate. The provisional substrate is removed to expose surfaces of the LED chips. Pads are formed on the surfaces of the LED chips. Finally, the metal layer is separated to form individual LED chips by means of mechanical force.
[0010] The present invention also provides a method for forming LED comprising the following steps. First, an LED epitaxial layer is formed on a provisional substrate. Then, a reflecting layer is formed on the LED epitaxial layer. A metal layer is formed on the reflecting layer by means of a chemical method or a physical method as permanent substrate. Next, the LED epitaxial layer, the reflecting layer, and the metal layer are etched to form LED chips by means of photolithography. The provisional substrate is removed to expose surfaces of the LED chips. Finally, pads are formed on the surfaces of the LED chips.
[0011] As aforementioned, in the present invention, the conductivity and cooling effect of the substrate is increased by replacing the conventional Al 2 O 3 or SiC substrate with a metal substrate according to the present invention. Furthermore, the pads are formed on opposite sides, so only one pad need to bond in package process and the bonding yield is increased. The LED is proper to operate with high current due to the well cooling effect of the metal layer, so the present invention can make high power LED. Moreover, a reflecting layer is formed on LED chip to guide the light of LED to emit outwards at the same direction, and the illumination of the LED is raised.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A to FIG. 1C are schematic diagrams of LED structure in conventional arts;
[0013] FIG. 2A to FIG. 2D are schematic diagrams of the method for forming LED of a preferred embodiment in the present invention; and
[0014] FIG. 3A to FIG. 3D are schematic diagrams of the method for forming LED of another preferred embodiment in the present invention.
DETAILED DESCRIPTION
[0015] Some sample embodiments of the invention will now be described in greater detail. Nevertheless, it should be recognized that present invention can be practiced in a wide range of other embodiments besides those explicitly described, and the scope of the present invention is expressly not limited expect as specified in the accompanying claims.
[0016] Then, the components of the different elements are not shown to scale. Some dimensions of the related components are exaggerated and meaningless portions are not drawn to provide a more clear description and comprehension of the present invention.
[0017] The essence of the present invention is to form a metal layer by a chemical method and a physical method, and the metal layer is employed as a permanent substrate to replace the Al 2 O 3 or SiC substrate in the conventional arts. Accordingly, the conductivity and the cooling effect of substrate can be efficiently increased, and further the pads are formed on opposite side, so only one pad need to bond in package process. Moreover, the LED having the metal substrate is a high power LED due to the metal substrate has well cooling effect and the LED can operated with high current. The chemical method and physical method mentioned above comprise electroplating, electroless plating, CVD (chemical vapor deposition), (PVD) physical vapor deposition (as evaporation or sputtering deposition), and so on. These methods can control the thickness of the metal substrate and do not need the polishing and cutting process, and hence the complexity of LED process is also reduced. Furthermore, a reflecting layer is formed between the metal layer and the LED chip (or the LED epitaxial layer) to efficiently guide the light emitted by the LED chip to the same (outward) direction for increasing the illumination of the LED.
[0018] According to the aforementioned essence, the present invention discloses preferred embodiments for illustrating the method of forming the LED having the advantages mentioned above.
[0019] FIG. 2A to FIG. 2D are schematic diagrams of the method for forming LED of a preferred embodiment in the present invention. As shown in FIG. 2A , an LED epitaxial layer 105 is formed on a provisional substrate 100 . Then, LED chips 110 is formed by etching the LED epitaxial layer with photolithography, as shown in FIG. 2B . The preferable etching method is dry etching. Next, a reflecting layer 120 and a metal layer 130 are formed on the LED chips in sequence, wherein the metal layer 130 is formed by electroplating. The thickness of the metal layer between the every two LED chips is 5-30 μm for benefiting to separate the metal layer 130 , as shown in FIG. 2C .
[0020] After that, the provisional substrate is removing by polishing, etching, or laser ablation, and pads 140 are formed on the exposed surfaces of the LED chips 110 , as shown in FIG. 2D . Next, the metal layer is separated to form individual LED chips by means of mechanical force.
[0021] FIG. 3A to FIG. 3D are schematic diagrams of the method for forming LED of another preferred embodiment in the present invention. An LED epitaxial layer 105 , a reflecting layer 120 and a metal layer 130 are formed on a provisional substrate 100 in sequence, wherein the metal layer 130 is formed by electroplating, as shown in FIG. 3A . Then, LED chips 110 is formed by etching the aforementioned structure with photolithography, as shown in FIG. 3B .
[0022] Next, the aforementioned LED structure is adhered on a film 130 , and the provisional substrate is removing, as shown in FIG. 3C . Finally, pads 140 are formed on the exposed surfaces of the LED chips 110 , as shown in FIG. 3D .
[0023] In the present invention, the reflecting layer reflects the light of LED to increase the outward illumination of LED. The preferable material of the reflecting layer is Ag, Al, Rh, Pt, Pd, Ni, Ti, Co, Au, and so on. If the LED is blue LED (as GaN LED), the material of the reflecting layer is not recommended to use Au due to Au may absorb the blue light.
[0024] In addition, the preferable material of the metal layer is Cu or other metal having well cooling effect, such as Al, Ni, Mo, W, Ag, Au, Ti, Co, Pd, Pt, or Fe. Therefore, the effect of diffusing heat is increased and the stability and life are also increased. The preferable thickness of the metal layer is 30 - 100 ,pm.
[0025] As aforementioned, the present invention provides a method for forming LED comprising the following steps. First, an LED epitaxial layer is formed on a provisional substrate. Then, the LED epitaxial layer is etched to form LED chips by means of photolithography. A reflecting layer formed on the LED chips. Then, a metal layer formed on the reflecting layer by means of a chemical method or a physical method. The provisional substrate is removed to expose surfaces of the LED chips. Pads are formed on the surfaces of the LED chips. Finally, the metal layer is separated to form individual LED chips by means of mechanical force.
[0026] The present invention also provides a method for forming LED comprising the following steps. First, an LED epitaxial layer is formed on a provisional substrate. Then, a reflecting layer is formed on the LED epitaxial layer. A metal layer is formed on the reflecting layer by means of a chemical method or a physical method. Next, the LED epitaxial layer, the reflecting layer, and the metal layer are etched to form LED chips by means of photolithography. The provisional substrate is removed to expose surfaces of the LED chips. Finally, pads are formed on the surfaces of the LED chips.
[0027] As aforementioned, in the present invention, the conductivity and cooling effect of the substrate is increased by replacing the conventional Al 2 O 3 or SiC substrate with a metal substrate according to the present invention. Furthermore, the pads are formed on opposite sides, so only one pad need to bond in package process and the bonding yield is increased. The LED is proper to operate with high current due to the well cooling effect of the metal layer, so the present invention can make high power LED. Moreover, a reflecting layer is formed on LED chip to guide the light of LED to emit outwards at the same direction, and the illumination of the LED is raised.
[0028] Although specific embodiments have been illustrated and described, it will be obvious to those skilled in the art that various modifications may be made without departing from what is intended to be limited solely by the appended claims.
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The present invention relates to a method for forming LED. In the present invention, LED dies are defined by photolithography and etching processes to replace a cutting step, and a metal substrate of the LED is formed by chemical or physical method.
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This application is a continuation of U.S. application Ser. No. 07/641,273, filed Jan. 15, 1991 now abandoned.
FIELD OF INVENTION
This invention relates to polymer articles and to controlling dimensional changes in such articles, for example, ophthalmic devices act other suitable medical and non-medical devices. In particular this invention relates to polymer articles in which at least a portion of the article is formed from copolymers containing solvolyzable bulky leaving groups, which copolymers upon solvolysis and hydration yield a hydrogel with a controllable dimensional change on removal of the leaving groups. In return, this enables the minimisation of the stresses and deformations in the polymer article during, and resulting from, hydration.
In a second aspect, this invention relates to soft contact lenses and includes lenses having a relatively harder oxygen permeable center portion and a soft hydrophilic peripheral skirt Formed From the hydrogels of the present invention.
BACKGROUND OF THE INVENTION
Hydrogels are polymeric materials which are used in the manufacture of medical devices such as soft contact lenses, intraocular lenses, etc. These polymers expand considerably from their xerogel state during hydration. The change in total volume of a polymer article made from the copolymer during water absorption (hydration) depends on the nature and hydrophilicity of the monomers/polymers of the copolymer.
In the manufacture of articles requiring exact parameters, such as contact lenses and intraocular lenses, the swelling of the article during hydration can become a serious problem. This is because accurate production requires reasonably precise predictability of the dimensional swelling in order to set the manufacturing parameters. Also the swelling produces distortions and stresses in the hydrated polymer matrix, and hence the article.
In fact, substantial residual stresses and the resulting distortions can make the material unacceptable for its intended use.
In the production of contact lenses, etc., it is unusual to shape the product to its final form from the hydrated hydrogel due to production difficulties. In fact, it is simpler to machine or cast the product the xerogel state. Now, as the article is to be used in a hydrated state, the swelling during hydration of the polymer must also be accounted for in considering the dimensions of an article which is to be produced from the polymer in the non-hydrated or xerogel state.
Further if there are any variations in the degree of swelling from batch to batch or within a batch of material, the product will not be manufactured to the desired final dimensions. This may happen in the absence of changes in total water uptake if the ratio of the extent of swelling in the x, y or z directions changes in a fashion which compensates for the total volume increase.
Also at times there is a definite need to prepare materials from hydrogels that do not show any change in the volume during hydration. For example, U.S. Pat. No. 4,093,361 describes the preparation of a hydrogel with no net swelling during hydration. In this case the monomer was polymerized in the presence of a non-reactive water soluble neutral filler material. After polymerization was complete the neutral filler was washed out with a solvent, thereby leaving the final dimensions of the hydrogels articles unchanged. However, polymers made in this way suffer the disadvantage that parameters such as hardness become unsatisfactory and the mechanical properties (e.g. modulus, tear strength, max. elongation) of the resulting product are no longer optimum.
Furthermore, there can be a need to change the surface characteristics of hydrogels through surface treatments of the polymer in the xerogel state. Substantial volume changes in the hydrogel duping hydration can render these surface modifications useless due to the development of cracks and fissures in the surface.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide polymer articles constructed at least in part from a co-polymer material which contains solvolyzable bulky leaving groups, and which yields after solvolysis and hydration, hydrogels which have undergone a selected and controlled volume change.
Preferred solvolyzable polymers are made from acrylate, methacrylate and vinyl monomers incorporating large leaving groups such as trifluoroacetyl, trichloroacetyl, trimethylsilyl and the like.
The co-polymer articles of the present invention exhibit controlled dimensional changes after polymerization and hydration which enables substantial stress and distortion in articles made therefrom to be avoided.
A further objective of the present invention is to provide contact lens made in whole, or in part, from novel polymer compositions which are soft and hydrophilic in nature and which after hydration exhibit excellent properties including high strength, no deterioration with time, relatively slow release of hydrated water upon exposure to air, good optical characteristics and which can be easily formed into contact lenses.
The present invention provides a polymer article at least a portion of which comprises a hydrogel containing water in the range from 5 to 95% by weight, which hydrogel is formed from a co-polymer which can be solvolyzed and hydrated to form the hydrogel, and which during treatment undergoes a volume change of between a shrinkage off 20% and an expansion off 40% which volume change is dictated by the monomer composition of the co-polymer, the co-polymer being formed from two or more monomers of a first group I, which contains two or more monomers, said monomers each having one or more substituable leaving groups which can be removed from the co-polymer by solvolysis, and one or more monomers of a second group II, containing one or more ethylenically unsaturated monomers without such substituable leaving groups, the quantity by weight of each group present in the co-polymer being chosen so that the first group is in the range 5 to 95% by weight of the co-polymer, and the second group 5 to 95% by weight of the copolymer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 illustrate first and second types of contact lenses made using the polymer composition described herein.
DETAILED DESCRIPTION OF THE INVENTION
As used in this application "solvolyzable" means an ester linking group capable of cleaving into a carboxy containing compound for example, amide, ester or acid and an alcohol in the presence of a nucleophile, for example, water or a weak base, For example, ammonia or organic amine or the presence of a lower C 1 to C 4 alcohol.
We prefer to form the polymer articles of the invention at least partially from a co-polymer in which the monomers of the first group are selected from monomers of the general formula shown below:
CH.sub.2 ═C(R.sup.1)--Y--R.sub.x.sup.L
where
R 1 =--H, --alkyl and --substituted alkyl groups, R x L ;
Y=--(CH 2 ) k --, --(Ar)-- or --substituted (Ar)--, --COO(CP 2 ) 1 --(CR 2 R 3 ) m --(CP 2 ) n --, where Ar is an aromatic group;
P=--H, --alkyl and --substituted alkyl groups, halo (chloro, bromo, iodo) groups, --(Art) or --substituted (Ar);
R 2 R 3 =--H, --CH 2 --,
or
--OCO(CP 2 ) j --CH 3 ;
R x L =--OCOCF 3 , --OCOCCl 3 , --OCOCBr 3 , --O--Si[(CP 2 ) k --CP 3 ] 3 ,
--OSO 3 --CH 3 , --OSO 3 --Ar--CH 3 ;
k=0-16, preferred values for k are 0-6;
j, m, n are 0 or an integer between 1 and 16 with the proviso that j+m+n=2-16; preferred values for j, m, n are 0-6.
The synthesis of monomers with k, j, m, n>16 results in hydrogels with undesirable properties. Further, x is functionally dependent on Y; for example when Y is difunctional [--CH 2 --], x=1; when Y is trifunctional aromatic (At), x=2.
Other suitable monomers of the first group which can be suitably modified by solvolysis, in these cases to give alcohols or diols, include monomers which include the following groups:
Chloroacetyl, dichloroacetyl, trichloroacetyl, fluoroacetyl, methoxyacetyl, triphenylmethoxyacetyl, phenoxyacetyl, silyl ethers such as trimethysilyl, triethylsilyl, isopropyldimethylsilyl, t-butyldimethylsilyl, methyldiisopropylsilyl, tribenzylsilyl, triphenylsilyl, cyclic acetals and ketals incorporating methylene, ethyledene, 2,2,2-trichloroethyledene groups; cyclic orthoesters formed from methoxy methylene, ethoxymethylene, 1-(N,N-dimethylamino)ethyledene derivatives, 1-(N,N-dimethylamino)benzylidene derivatives, and methanesulfonate and toluenesulfonates.
The preferred monomers of the first group may be produced by the synthesis shown below by the reaction schemes: ##STR1##
The trichloroacetate ester of glyceryl methacrylate (HCE-GMA(2)), a colorless viscous liquid, is prepared by the reaction of glycidyl methacrylate (1) with an equivalent of trichloroacetic anhydride (TCAA). ##STR2##
The trifluoroacetate derivative of glyceryl methacrylate (HFE-GMA(3)) can be synthesized using trifluoroacetic anhydride. ##STR3##
Trifluoroacetate derivative of hydroxyethyl methacrylate (TFA-HEMA, (5)) or trifluoroacetate derivative of hydroxy methacrylate (7) can be synthesized by the reaction of pyridine with hydroxyethyl methacrylate (4) or methyl pyruvate (6) and trapping the corresponding anion with trifluoroacetic arthydride [TFAA].
Now, in a particular example of the present invention, the co-polymerization of HCE-GMA and/or HFE-GMA with methyl methacrylate (MMA) and a suitable cross-linking agent, for example, ethylene glycol dimethacrylate produces a co-polymer or xerogel which on removal of the leaving groups by solvolysis and subsequent hydration yields a hydrogel.
The dimensions of an article made from the hydrogel, as compared to that of an article made from the xerogel, as will be appreciated by those skilled in the art, are dependent on the ratio of components of the copolymer, as well as the material components of the copolymer of the hydrogel.
In particular, with copolymers of HFE-GMA and HCE-GMA and MMA the final dimensions of the hydrated article were found to be dependent on the weight ratio of HCE-GMA to HFE-GMA at constant MMA concentration. For example, a copolymer of a mixture of HCE-GMA/HFE-GMA in a ratio of 3:1 and MMA resulted in a hydrogel with substantially little change in dimensions from the xerogel to the hydrogel state. However, with the HCE-GMA/HFE-GMA in a ratio by weight of 1:3 (and not 3:1) the change in dimensions of the article can be up to 11%. The monomer of the second group (II) may include any one or more of the following monomer materials
Methyl Methacrylate (MMA)
Trifluoromethyl methacrylate (TFMMA)
Hydroxymethyl methacrylate (HMMA)
Trifluoroethyl methacrylate (TFEMA)
Hydroxyethyl methacrylate (HEMA)
Dimethyl acrylamide (DMA)
Contact lenses may be made by machining lens blanks made by cutting small cylinders or buttons from pods of the co-polymer before conversion from the xerogel to the hydrogel form.
The monomers may be co-polymerized with ethylene glycol dimethacrylate (EGMA) as the cross linking agent in the presence of t-butyl peroxy pivalate (TBPP) as the initiator in silylated glass tubes. After the reaction is complete, the glass tubes are broken to provide the xerogel in the form of colorless hard rods which are then cut into buttons which in turn are shaped into contact lenses on a lathe. The finished lenses are solvolyzed in 5% aqueous ammonia for 24-48 h and then allowed to equilibrate in saline solution for 24 hours.
Contact lens with a soft peripheral skirt and relatively harder center may be made by forming a rod as above with a size equal to the outside diameter of a lens and then drilling a hole through the center of the rod equal to the diameter of the central portion of the desired lens. This hole is then filled with a polymerizable material which forms a harder non-hydrophilic polymer.
By choosing a xerogel with little or no change in dimensions on hydration to form the hydrophilic skirts, any stresses or distortions which might occur if there was a substantial change in dimensions on hydration are eliminated. In other cases it may be desirable to use materials with matched expansions or shrinkage at values varying between a shrinkage of 20% and an expansion of 40%.
The present invention will be further illustrated by the examples which are provided for purposes of illustrations only and are not intended to be limiting of the present invention.
EXAMPLE 1
A mixture of (HCE-GMA:HFE-GMA) 3:1 ratio by weight and MMA with EGDMA crosslinker was prepared and the mixture was stirred for 30 min. After degassing the mixture for 30 seconds in bubbling Argon, TBPP was added. The mixture was transferred to a silylated glass tube and polymerized in a water bath maintained at 50° C. for 48 h. The partially polymerized material was transferred to an oven maintained at 70° C. and allowed to cure for 24 h. The polymer was allowed to cool slowly in the oven till it reached room temperature. The glass tubes were broken and the colorless transparent polymer was removed. Disks (0.2-0.5 mm in diameter) were cut from the material and hydrolyzed in aqueous NH 4 OH for 24 h. After equilibrating the disks in saline for another 24 h its linear expansion was measured. It was found that the disk expanded an average of 11% in diameter. The % hydration was 59%.
EXAMPLE 2
This reaction was repeated in exactly the same reaction conditions as before. However, this time (HCE-GMA:HFE-GMA 3:1) ratio by weight and MMA were polymerized at 50° C. and cured at 70° C. For 48 h in silylated glass tubes. After breaking the glass tubes, the material was isolated and disks were cut from the stress free, colorless, transparent and bubble free rods. These 0.2-0.5 mm thick disks were hydrolyzed in 5% NH 4 OH solution for 24 h. Later they were transferred to a saline solution and allowed to equilibrate for 24-28 h. Their expansions were measured upon hydration. It was found that the disk expanded an average of 1--2% in diameter. The % hydration was 8%.
EXAMPLE 3
This reaction was repeated in exactly the same reaction conditions as before. However, this time (HCE-GMA:HFE-GMA 10:1) ratio by weight and MMA/GMA were polymerized at 50° C. and cured at 70° C. for 48 h in silylated glass tubes. After breaking the glass tubes material was isolated and disks were cut from the stress free, colorless, transparent and bubble free rods. These 0.2-0.5 mm thick disks were hydrolyzed in 5% NH 4 OH solution for 24 h. Later they were transferred to a saline solution and allowed to equiliberate for 24-28 h. Their expansions were measured upon hydration. It was found that the disk expanded an average of 12-14% in diameter. The % hydration was 40%.
EXAMPLES 4-19
In the case of examples 4 to 19, the polymerization was carried out at 50° C. For 24 hours and curing at 70° C. For 48 hours. The reaction mixture contained monomer ratios shown in the accompanying table. The polymerization was carried out in silylated glass tubes, and after completion of polymerization, the tubes were broken to extract the finished rods. These were cut into disks and the solvolysis and hydration was carried out by immersing the disks in 5% NH 4 OH for 24 hours, followed by transfer to a saline solution and equilibration for 24 hours. The change in dimensions was measured upon hydration. The expansion is given in the table below:
__________________________________________________________________________Monomers (Group I) Composition Comonomer % Expansion__________________________________________________________________________ HCE--GMA/HFE--GMA 3:1 MMA 0-1% HCE--GMA/HFE--GMA 3:1 TFEMA 0-1% HCE--GMA/HFE--GMA 2:1 MMA 2-4% HCE--GMA/HFE--GMA 1:1 MMA 4-6% HCE--GMA/HFE--GMA 19:1 MMA/GMA 12-14% HCE--GMA/HFE--GMA 19:1 MMA/DMA 6%10. HCE--GMA/HFE--GMA 3:1 MMA/TFEMA 0-1% HCE--GMA/HFE--GMA 3:1 HMMA 8% HCE--GMA/HFE--GMA 3:1 TFMMA 0-1% HCE--GMA/TFA--MA 3:1 MMA 4% HCE--GMA/TFA--MA 3:1 HMMA 8% TFA--HEMA/TFAMA* 3:1 MMA 7% TFA--HEMA/TFAMA 3:1 MMA/TFEMA 6% TCA--HEMA/TFAMA 3:1 MMA/TFEMA 4% TMS--GMC**/HFE--GMA 3:1 MMA 0-1% TBDMS--GMA***/HFE--GMA 1:0 MMA -20%__________________________________________________________________________ *TFAMA = trifluoroacetyl methacrylate **TMS--GMA = trimethylsiloxy glyceryl methacrylate ***TBDMS--GMA = .sub.- tbutyldimethylsiloxy glyceryl methacrylate
Now, referring to FIG. 1 of the accompanying drawings there is shown a first type of contact lens made in accordance with the present invention. The contact lens 1 comprises a solid section of one of the compositions listed in examples 1 to 17 listed above.
Now referring to FIG. 2 of the accompanying drawings there is shown a second type of contact lens made in accordance with the present invention. The contact lens 2 comprises a central section 3 made from a standard rigid gas permeable contact lens material, for example Fluoroboro 60, and an outer section 4 which surrounds the central section 3 and is made from HCE-GMA/HFE-GMA(3:1):MMA as per 4 above.
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A polymeric composition suitable for use in ophthalmic devices such as contact lenses, intraocular lenses and other medical and non-medical devices which composition comprises a copolymer that incorporates repeating units containing a solvolyzable group and various desired hydrophilic repeating units in predetermined ratios, which copolymer is mechanically stable and upon hydration the dimensions of polymeric articles which as formed therefrom can be controlled. In particular, the hydrophilic compositions resulting from the invention are user in applications where stresses and distortions of the polymer article due to water absorption etc. must be minimized or, if possible, eliminated.
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RELATED APPLICATIONS
The present application is a non-provisional of U.S. Provisional Patent Application No. 61/089,522, filed Aug. 16, 2008, titled IMPLANTABLE MIDDLE EAR TRANSDUCER HAVING IMPROVED FREQUENCY RESPONSE, herein incorporated by reference in its entirety.
TECHNICAL FIELD
The present invention is related generally to implantable medical devices. More specifically, the present invention is related to implantable transducers, which can be used in partial middle ear implantable or total middle ear implantable hearing aid systems.
BACKGROUND
In some types of partial middle ear implantable (P-MEI) or total middle ear implantable (T-MEI) hearing aid systems, sounds produce mechanical vibrations within the ear which are converted by an electromechanical input transducer into electrical signals. These electrical signals are in turn amplified and applied to an electromechanical output transducer. The electromechanical output transducer causes an ossicular bone to vibrate in response to the applied amplified electrical signals, thereby improving hearing.
An electromechanical transducer used for the purpose of vibrating or sensing from any or all elements of the ossicular chain may be mounted in or near the middle ear. The transducer is generally contained in a housing or enclosure, forming a driver or sensor assembly that facilitates the placement of the transducer within the middle ear.
In previous designs, applicant has noticed unwanted resonances within the audible frequency range, which can be disconcerting to the person having the implant.
What would be desirable are transducers which more accurately convert the electrical signal received into vibrations which can be coupled to the ossicular chain.
SUMMARY
Some embodiments of the present invention provide an implantable transducer assembly for implanting into a middle ear region, the transducer assembly including an elongate transducer adapted to receive an electrical signal and produce a vibration in response to the electrical signal, in which the vibration occurs substantially in a first plane which extends through the transducer. The transducer can have a length, a free vibrating end, and a base region opposite the free end for operable coupling to a bone. The transducer can also have a pair of fins operably coupled to the transducer base region, the fins having a thickness dimension, and in which the fins lie substantially in a second plane which is normal to the first plane.
Some transducer assembly embodiments also have a protective layer covering the transducer, in which the fins are not directly coupled to the transducer, and in which the fins are secured to the protective layer, such that the operable coupling is made through the protective layer. Some transducer assemblies may have a base member, in which the transducer base region is coupled to the base member, and in which the fins are not directly coupled to the base member, such that the vibrating in the first plane moves the fins in a direction orthogonal to the fin thickness dimension.
Some transducer assembly embodiments have a base member, in which the transducer base region is coupled to the base member, and in which the fins each have a free edge disposed near the base member, such that the vibrating in the first plane moves the fins in a direction orthogonal to the fin thickness dimension. In some embodiments, the protective layer includes a metallic sheet, which may be formed of titanium less than about 3 mils thick. Some fins may be triangular shaped, others may have a nominal triangular shape but with convex outer edges, some others may have a nominal triangular shape but with concave outer edges, and still others may have rounded outer edges.
Some fins have a length at least about 20 percent of the length of the transducer, and some may have a length less than about 80 percent of the length of the transducer. In some embodiments, the fins have a length of less than about ½ inch. The transducer is less than about 1inch long in some embodiments. Some transducer assemblies also include a biocompatible bone mount assembly coupled to the transducer base for securing to a bone. In some embodiments, the transducer is hermitically sealed.
The present invention also includes systems for treating hearing loss, the systems comprising all the systems described herein and combinations thereof.
Methods are also provided for aiding hearing. One method includes receiving an acoustic signal near a human ear; converting the acoustic signal to an electrical signal; transmitting the electrical signal to a vibratory transducer; and vibrating the transducer in a first plane responsive to the received electrical signal. The vibration can be attenuated in a second plane orthogonal to the first plane by a pair of fins disposed substantially in the second plane where the fins are operably coupled to the vibratory transducer. In one method, the transducer is coupled to a base member, and the fins are not directly coupled to the base member, such that the vibrating in the first plane moves the fins with respect to the base member. In one embodiment method, the transducer is coupled to a base member, and the fins have free edges not coupled to the base member, such that the vibrating in the first plane moves the fins with respect to the base member, such that the fin edges near the base member are free to move in the second plane relative to the base member. In one method, the transducer is covered by a protective layer, and the fins are secured to the protective layer, such that transducer vibrations are transmitted through the protective layer.
DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a frontal section of an anatomically normal human right ear.
FIG. 2 is a cross-sectional illustration of a typical use of a bi-element transducer coupled to an auditory element in the middle ear.
FIG. 3 is a cross-sectional illustration of a bi-element transducer secured only to a vibrated auditory element.
FIG. 4 is a cross-sectional illustration of a bi-element transducer secured only to a vibrating auditory element.
FIG. 5 is a perspective view of one embodiment of the invention.
FIG. 6 is a second perspective view of an embodiment of the invention.
FIG. 7 is a perspective view of one fin according to the present invention.
FIG. 8 is a plot showing experimental results from some embodiments of the present invention.
DETAILED DESCRIPTION
The following detailed description should be read with reference to the drawings, in which like elements in different drawings are numbered identically. The drawings depict selected embodiments and are not intended to limit the scope of the invention. It will be understood that embodiments shown in the drawings and described below are merely for illustrative purposes, and are not intended to limit the scope of the invention as defined in the claims.
Some embodiments of the invention provide an electromechanical transducer which is particularly advantageous when used in a middle ear implantable hearing aid system, such as a partial middle ear implantable (P-MEI), total middle ear implantable (T-MEI), or other hearing aid system. A P-MEI or T-MEI hearing aid system assists the human auditory system in converting acoustic energy contained within sound waves into electrochemical signals delivered to the brain and interpreted as sound.
FIG. 1 illustrates, generally, the human auditory system. Sound waves are directed into an external auditory canal 20 by an outer ear (pinna) 25 . The frequency characteristics of the sound waves are slightly modified by the resonant characteristics of the external auditory canal 20 . These sound waves impinge upon the tympanic membrane (eardrum) 30 , interposed at the terminus of the external auditory canal, between it and the tympanic cavity (middle ear) 35 . Variations in the sound waves produce tympanic vibrations. The mechanical energy of the tympanic vibrations is communicated to the inner ear, comprising cochlea 60 , vestibule 61 , and semicircular canals 62 , by a sequence of articulating bones located in the middle ear 35 . This sequence of articulating bones is referred to generally as the ossicular chain 37 . Thus, the ossicular chain transforms acoustic energy at the eardrum to mechanical energy at the cochlea 60 .
The ossicular chain 37 includes three primary components: a malleus 40 , an incus 45 , and a stapes 50 . The malleus 40 includes manubrium and head portions. The manubrium of the malleus 40 attaches to the tympanic membrane 30 . The head of the malleus 40 articulates with one end of the incus 45 . The incus 45 normally couples mechanical energy from the vibrating malleus 40 to the stapes 50 . The stapes 50 includes a capitulum portion, comprising a head and a neck, connected to a footplate portion by means of a support crus comprising two crura. The stapes 50 is disposed in and against a membrane-covered opening on the cochlea 60 . This membrane-covered opening between the cochlea 60 and middle ear 35 is referred to as the oval window 55 . Oval window 55 is considered part of cochlea 60 in this patent application. The incus 45 articulates the capitulum of the stapes 50 to complete the mechanical transmission path.
Normally, prior to implantation of the hearing aid system according to some embodiments of the invention, tympanic vibrations are mechanically conducted through the malleus 40 , incus 45 , and stapes 50 , to the oval window 55 . Vibrations at the oval window 55 are conducted into the fluid filled cochlea 60 . These mechanical vibrations generate fluidic motion, thereby transmitting hydraulic energy within the cochlea 60 . Pressures generated in the cochlea 60 by fluidic motion are accommodated by a second membrane-covered opening on the cochlea 60 . This second membrane-covered opening between the cochlea 60 and middle ear 35 is referred to as the round window 65 . Round window 65 is considered part of cochlea 60 in this patent application. Receptor cells in the cochlea 60 translate the fluidic motion into neural impulses which are transmitted to the brain and perceived as sound. However, various disorders of the tympanic membrane 30 , ossicular chain 37 , and/or cochlea 60 can disrupt or impair normal hearing.
Hearing loss due to damage in the cochlea is referred to as sensorineural hearing loss. Hearing loss due to an inability to conduct mechanical vibrations through the middle ear is referred to as conductive hearing loss. Some patients have an ossicular chain 37 lacking sufficient resiliency to transmit mechanical vibrations between the tympanis membrane 30 and the oval window 55 . As a result, fluidic motion in the cochlea 60 is attenuated. Thus, receptor cells in the cochlea 60 do not receive adequate mechanical stimulation. Damaged elements of ossicular chain 37 may also interrupt transmission of mechanical vibrations between the tympanic membrane 30 and the oval window 55 .
Implantable hearing aid systems have been developed, utilizing various approaches to compensate for hearing disorders. For example, cochlear implant techniques implement an inner ear hearing aid system. Cochlear implants electrically stimulate auditory nerve fibers within the cochlea 60 . A typical cochlear implant system may include an external microphone, an external signal processor, and an external transmitter, as well as an implanted receiver and an implanted probe. A signal processor converts speech signals transduced by the microphone into electrical stimulation that is delivered to the cochlea 60 .
A particularly interesting class of hearing aid systems includes those which are configured for disposition principally within the middle ear space 35 . In middle ear implantable (MEI) hearing aids, an electrical-to-mechanical output transducer couples mechanical vibrations to the ossicular chain 37 , which is optionally interrupted to allow coupling of the mechanical vibrations to the ossicular chain 37 . Both electromagnetic and piezoelectric output transducers have been used to effect the mechanical vibrations upon the ossicular chain 37 .
One example of a partial middle ear implantable (P-MEI) hearing aid system having an electromagnetic output transducer comprises: an external microphone transducing sound into electrical signals; external amplification and modulation circuitry; and an external radio frequency (RF) transmitter for transdermal RF communication of an electrical signal. An implanted receiver detects and rectifies the transmitted signal, driving an implanted coil in constant current mode. A resulting magnetic field from the implanted drive coil vibrates an implanted magnet that is permanently affixed only to the incus. Such electromagnetic output transducers have relatively high power consumption, which limits their usefulness in total middle ear implantable (T-MEI) hearing aid systems.
A piezoelectric output transducer is also capable of effecting mechanical vibrations to the ossicular chain 37 . An example of such a device is disclosed in U.S. Pat. No. 4,729,366, issued to D. W. Schaefer on Mar. 8, 1988. In the '366 patent, a mechanical-to-electrical piezoelectric input transducer is associated with the malleus 40 , transducing mechanical energy into an electrical signal, which is amplified and further processed. A resulting electrical signal is provided to an electrical-to-mechanical piezoelectric output transducer that generates a mechanical vibration coupled to an element of the ossicular chain 37 or to the oval window 55 or round window 65 . In the '366 patent, the ossicular chain 37 is interrupted by removal of the incus 45 . Removal of the incus 45 prevents the mechanical vibrations delivered by the piezoelectric output transducer from mechanically feeding back to the piezoelectric input transducer.
Piezoelectric output transducers have several advantages over electromagnetic output transducers. The smaller size or volume of the piezoelectric output transducer advantageously eases implantation into the middle ear 35 . The lower power consumption of the piezoelectric output transducer is particularly attractive for T-MEI hearing aid systems, which may include a limited longevity implanted battery as a power source.
A piezoelectric output transducer is typically implemented as a ceramic piezoelectric bi-element transducer, which is a cantilevered double plate ceramic element in which two opposing plates are bonded together such that they amplify a piezoelectric action in a direction normal to the bonding plane. Such a bi-element transducer vibrates according to a potential difference applied between the two bonded plates. A proximal end of such a bi-element transducer is typically cantilevered from a transducer mount which is secured to a temporal bone within the middle ear. A distal end of such a bi-element transducer couples mechanical vibrations to an ossicular element such as stapes 50 .
FIG. 2 is a generalized illustration of a bi-element transducer 70 cantilevered at its proximal end from a mount 75 secured to a temporal bone within middle ear 35 . A distal end of bi-element transducer 70 is mechanically coupled to an auditory element to receive or effect mechanical vibrations when operating as an input or output transducer respectively. For example, to receive mechanical vibrations as an input transducer, bi-element transducer 70 may be coupled to an auditory element such as a tympanic membrane 30 (shown in FIG. 1 ), malleus 40 , or incus 45 . In another example, to effect vibrations as an output transducer, bi-element transducer 70 may be coupled to an auditory element such as incus 45 , stapes 50 , oval window 55 , round window 65 , vestibule 61 (shown in FIG. 1 ), or semicircular canal 62 . The transducer 70 is coupled by leads 85 and 90 to an electronics unit 95 .
FIG. 3 illustrates generally a cross-sectional view of an electromechanical output transducer. A piezoelectric element, more particularly bi-element transducer 70 , is mechanically coupled, and preferably secured, at its proximal end to middle ear 35 (shown in FIG. 1 ) through an auditory element, preferably stapes 50 , or alternatively incus 45 , stapes 50 , oval window 55 , round window 65 , vestibule 61 , or semicircular canals 62 . Bi-element transducer 70 can be secured only to stapes 50 by any known attachment technique, including biocompatible adhesives or mechanical fasteners. For example, in one embodiment, a deformable wire (not shown) secured to the proximal end of bi-element transducer 70 is looped through an inner portion of stapes 50 , for example, and crimped to secure bi-element transducer 70 to stapes 50 .
Electronics unit 95 may couple an electrical signal through lead wires 85 and 90 to any convenient respective connection points on respective opposing elements of bi-element transducer 70 .
In response to the electrical signals received from electronics unit 95 , bi-element transducer 70 bends with respect to a longitudinal plane between its opposing elements. The bending is resisted by inertial mass 80 which may be connected to bone through the use of adhesive or bone cement or a mechanical connector, for example a screw, thus mechanically coupling a force to stapes 50 through bi-element transducer 70 . This force upon stapes 50 is in turn transmitted to cochlea 60 at oval window 55 .
FIG. 4 illustrates generally a cross-sectional view of an electromechanical input transducer. A piezoelectric element, such as bi-element transducer 70 , is secured by any known attachment technique at its proximal end, such as described above, for example, to malleus 40 .
Bi-element transducer 70 may also be secured only to other auditory elements for receiving mechanical vibrations, such as incus 45 or tympanic membrane 30 . Vibrations of malleus 40 cause, at the proximal end of bi-element transducer 70 , vibratory displacements that are opposed by inertial mass 80 which may be connected to bone through the use of adhesive or bone cement or a mechanical connector, for example a screw. As a result, bi-element transducer 70 bends with respect to the longitudinal plane between its opposing elements. A resulting electrical signal is provided at any convenient connection point on respective opposing elements of bi-element transducer 70 , through respective lead wires 92 and 93 to electronics unit 95 .
FIG. 5 is a perspective view of one transducer assembly 100 having a bi-element transducer 70 contained within a sleeve 110 . The proximal end of the sleeve 110 is connected to a diaphragm 120 which is connected to a housing 130 . The diaphragm 120 allows the sleeve 110 to move with the movement of the transducer 70 as will be described in further detail hereinafter. A pin 140 may be connected, for example by welding or gluing, to the distal end of the sleeve 110 . In one embodiment, the sleeve 110 has a longitudinal body with a rectangular cross section, but it may also have a circular, trapezoidal, or triangular cross section, and its longitudinal body may be trapezoidal, triangular, or circular in shape. In one embodiment, a pair of fins 150 , also known as gussets, is located on an exterior surface of the sleeve 110 .
The elements of the transducer assembly 100 may be made of metallic or non-metallic implantable materials that can be hermetically sealed, for example, titanium, gold, platinum, platinum-iridium, stainless steel, or plastic. In one embodiment, the transducer assembly 100 is made out of a thin-walled metallic or non-metallic material that preferably can be made to minimize spring constant and mass while providing a hermetic barrier. In another embodiment, the transducer assembly 100 has a wall thickness ranging from about 0.0005 inches to 0.01 inches and may be made by die forming, hydroforming, electro deposition, or thin film deposition. Elements of the transducer assembly 100 may be connected together by gluing, soldering, brazing, or welding, for example.
The transducer assembly 100 may also be provided with one or more coatings that may enhance the mechanical and/or biological characteristics of the devices. The coatings may be organic or inorganic and may provide one or more of the following characteristics while maintaining low spring rate and mass loading: scratch and/or moisture resistance, biocompatibility, tissue adhesion resistance, microbial resistance, for example. For instance, a medical adhesive coating or a conformal coating may be applied from a point just proximal the pin 140 to the housing 130 . In one embodiment, a medical adhesive may be applied to the pin 140 .
In another embodiment, the transducer assembly 100 may be formed by coating the bi-element transducer 70 with organic or inorganic coatings. Inorganic coatings may consist of a single or multiple layers of formed or deposited metals including titanium, platinum, gold, nickel, copper, palladium cobalt, for example. Organic materials may include Teflon, silicone, parylene, polyolefin, polyurethane, for example. Coatings may be applied by several well known techniques including dipping the transducer assembling in the materials, rolling it, spraying it on, vapor depositing, electrostatic, ion beam, plasma and vacuum depositing for example. The coating or coatings may also be surface modified to incorporate desired properties.
The transducer assemblies according to the embodiments described herein can be hermetically sealed to provide a fully implantable device.
Applicant has learned that vibration in the intended/primary direction is well damped by the cochlear fluid, but that the cochlea has limited damping in the lateral direction. A resonance not in the primary direction will result in large displacements due to the low damping. The large displacements can result in poor performance or mechanical feedback.
FIG. 6 is a perspective view of one transducer assembly 100 having a bi-element transducer 70 within sleeve 110 where the bi-element transducer 70 has a fixed region within a housing 130 and is coupled to diaphragm 120 . A pin 140 , which is connected to the sleeve 110 , can be coupled to various parts of the ossicular chain, for example, stapes 210 . Stapes 210 includes a head or capitulum 214 and two crura portions 216 and 218 which in turn are joined to footplate 212 . Footplate 212 typically remains coupled to the oval window for transmitting the mechanical vibrations to the cochlea. The bi-element transducer 70 can be a piezoelectric bi-element transducer in some embodiments. The bi-element transducer 70 may generate motion in the direction shown by arrows 220 . The direction of an alternate motion that may occur in the current application is indicated by arrows 221 . A pair of fins 150 or gussets are coupled to sleeve 110 and diaphram 120 and lie generally in a plane. The vibration movement indicated at arrows 220 is substantially orthogonal or normal to the plane containing fins 150 . In the example illustrated, fins 150 have a generally triangular shape, having an outer edge 224 and an outer corner 226 . In some embodiments, the outer edge is straight, as illustrated at 224 . In other embodiments, the outer edge is curved and is either convex outward or concave inward relative to the example illustrated at 224 . The curved shapes may have elliptical, exponential, or other curves, depending on the embodiment. In other embodiments, the fins 150 may be a rectangular shape or they may have a varying saw-tooth shape.
FIG. 7 provides another view of a fin 150 , including outer edge 224 and corner 226 . In some embodiments, corner 226 is sharp, while in other embodiments the corner is slightly rounded. Fin 150 can be formed of 0.0020 inch thick titanium in some embodiments or it may have a greater thickness possibly as thick as sleeve 110 . In some embodiments fin 150 may be solid, while in other embodiments it may be hollow.
FIG. 8 illustrates comparative experimental results in a plot 600 , with and without the fins. The X axis is the swept frequency. This is the frequency of the electrical signal feeding the transducer. The Y axis is the peak to peak displacement, from 1×10 −11 meters at bottom to 1×10 −6 meters at top. There are two different experimental results shown in lines 606 and 608 . Line 606 illustrates the results without the fins, while line 608 illustrates the results with the fins in place and with a diaphragm or metallic sleeve as illustrated in FIGS. 5-6 . The results were taken in different experimental runs, and having the different sleeve in addition to the fins. The gain setting for line 608 appears to be higher than that of line 606 . For these reasons, the results are meant to be illustrative. Both lines increase up to about 1000 Hz, and then roll off. The older design, shown in line 606 , has a peak as indicated at 612 , near about 1800 Hz. This can show up as a distorted signal in the user's hearing, as the peak to peak displacement is unusually large and unnatural, given the overall downward trend of the transducer displacement above 1000 Hz. Applicant believes that this peak is near a predominate frequency in voices, which can prove to be a less than desirable attribute for conversational speech. In addition, applicant believes that this large and unnatural displacement can provide input back to a signal transducer which may be located near the eardrum in some uses of the invention. These vibrations may be transmitted through the air or through bone. The vibrations can set up a feedback loop, causing even poorer results. In some systems, the electronics may detect the distortion and/or feedback and block them out, causing a loss of signal to the user. Line 608 shows the improved results using the fins. The distortion has been significantly reduced.
Inspection of FIG. 8 shows that without the fins, there are distinct resonance peaks as indicated at 612 , near about 1800 Hz. Acoustical signals are received in this frequency range at the tympanic membrane and may be converted to electrical signals by another transducer. These electrical signals can be coupled to a transducer. Rather than reproduce this frequency faithfully, the vibratory transducer may instead produce the unwanted resonance peaks at 612 , which can be upsetting to the hearer. In some uses, the reproduction provided by the transducer is primarily or even the sole source of auditory signals, as portions of the middle ear may have been surgically removed in order to allow the device to work. The resonance in region 612 is clearly and significantly reduced in the example where the fins or gussets are present. An antiresonance valley 614 is shown on line 606 . With the addition of fins 150 and diaphragm 120 , the antiresonance valley 614 is moved to a higher frequency.
Applicant believes that the fins, wings, or gussets, allow vibration in the intended direction while reducing or controlling an apparent resonance which can be set up in a direction orthogonal to the desired direction, which distorts the desired vibratory output. Further, the combination of fins 150 and diaphragm 120 has moved the antiresonance frequency to a higher frequency thereby increasing bandwidth.
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Apparatus, systems, and methods having or using an improved implantable middle ear transducer for driving an ossicular chain bone to assist in aiding hearing. One embodiment of the present invention is a transducer assembly for converting electrical signals to mechanical vibrations which can be coupled, for example, to the stapes to provide audible frequency vibrations to the cochlea. One transducer assembly includes a pair of fins or gussets coupled to opposite sides of a transducer in the direction of unwanted movement of the transducer. The base of the transducer may be coupled to a base member while the fins have free edges that are near to but not coupled to the base member. Some fins are triangular shaped. The fins may not substantially inhibit vibration in the preferred plane, but can inhibit unwanted vibrations in a plane orthogonal to the preferred direction which can substantially include a plane containing the fins.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of Korean Application No. 2006-19431, filed Feb. 28, 2006, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Aspects of the present invention relate to a lithium ion secondary battery, and more particularly, to a lithium ion secondary battery in which a separate battery part is coupled to an upper or first part of a cap plate of a bare cell.
[0004] 2. Description of the Related Art
[0005] In general, primary batteries are not rechargeable, and secondary batteries are rechargeable. In recent years, for example, nickel-metal hydride (Ni-MH) batteries, lithium (Li) batteries, and lithium ion (Li-ion) batteries have been mainly used as the secondary batteries.
[0006] The lithium ion batteries are manufactured in various shapes. For example, the shapes of the lithium ion batteries may be classified into cylindrical, square prismatic, or pouch shapes according to the type of case used in manufacturing.
[0007] In the lithium ion battery, a carbon-based electrode is generally used as a cathode in order to reduce the risk of combustion or explosion. However, special emphasis is placed on the safety of the lithium ion battery in the manufacturing process due to the high energy density of lithium and the possibility of combustion reactions occurring with a non-aqueous electrolyte.
[0008] In order to improve the safety, the lithium ion battery generally includes a bare cell having a basic structure for charge or discharge and a protective circuit or a protective device for preventing overcharge, overdischarge, overheating, and overcurrent. The protective circuit or the protective device may be physically and electrically connected to the bare cell in the form of a printed circuit board and may be displaced on the side, the upper surface, or the lower surface of the bare cell.
[0009] In the cylindrical can battery, a cap assembly of a bare cell serves to prevent overheating and overcurrent. However, in the prismatic can battery, a cap assembly does not have such a safety feature. Therefore, in the prismatic can battery, particularly, a separate safety device should be coupled to the bare cell. In recent years, in many cases, the safety device of the prismatic can battery, such as a protective circuit board, is coupled to the upper surface of a cap plate.
[0010] Meanwhile, in a pack battery having a plurality of bare cells connected to one another, a battery part, such as a cap cover, may be coupled to an upper part of a cap plate in order for series/parallel connection of the bare cells in the pack or connection between the bare cells and a protective circuit.
[0011] An example of the cap cover will be described below. A peripheral portion or a body of the cap cover is generally formed of an insulating resin material, and forms a coupling part that is supported by a cap assembly of a bare cell while physically contacting the bare cell. A metal plate terminal that has a relatively narrow width and is connected to an electrode terminal of the bare cell is formed at the center of the lower surface of the cap cover. The narrow metal plate terminal is exposed through a hole formed in the center of the body of the cap cover. A wide metal plate terminal connected to a protective circuit terminal outside the bare cell may be provided in the vicinity of the hole on the upper surface of the cap cover. In addition, a conductive connecting part for connecting these metal plate terminals is provided.
[0012] However, in the cap assembly at the upper part of the bare cell, an electrode terminal protrudes from the surface of the cap plate and is insulated therefrom. Therefore, it is difficult to stably couple a battery part, such as a cap cover, to an upper part of the cap assembly. Further, it is difficult to stably couple the battery part to the bare cell by, for example, welding.
[0013] As a member for guiding the battery part to an accurate position with respect to the cell is not formed in the peripheral portion of the cap assembly, it is difficult to accurately couple the battery part to the upper part of the cap assembly. When the battery part is not accurately coupled to the cap assembly, it is difficult to achieve stable electrical connection between the battery part and the bare cell, which may cause defects in the electrical connection.
[0014] For example, when the cap cover is used for a pack battery, the cap cover should be fixed to the upper part of the cap plate. However, it is difficult to easily fix the cap cover to the cap plate, which may frustrate the manufacture of the pack battery.
SUMMARY OF THE INVENTION
[0015] Accordingly, aspects of the present invention have been contrived to solve the above-described drawbacks, and aspects of the present invention provide a lithium ion secondary battery having a structure capable of stably placing a battery part, such as a cap cover or a protective circuit assembly, on an upper part of a cap assembly.
[0016] According to an aspect of the invention, a lithium ion secondary battery includes: a bare cell including an electrode assembly having a first electrode, a second electrode, and a separator interposed between the first electrode and the second electrode, a can housing the electrode assembly, and a can assembly that includes a cap plate coupled to an upper open part of the can and an electrode terminal formed in a through hole of the cap plate so as to be insulated from the through hole; and a battery part coupled to an upper part of the cap assembly of the bare cell. In the lithium ion secondary battery, step portions or step structures are formed on the battery part and the cap plate so as to correspond to each other.
[0017] According to another aspect of the invention, a lithium ion secondary battery includes: an electrode assembly having a first electrode, a second electrode, and a separator interposed between the first electrode and the second electrode; a can housing the electrode assembly; and a cap assembly that includes a cap plate coupled to an upper open part of the can and an electrode terminal formed in a through hole of the cap plate so as to be insulated from the through hole. In the lithium ion secondary battery, a step portion is formed on the upper surface of the cap plate.
[0018] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0020] FIG. 1 is a cross-sectional view illustrating a cap cover, serving as a battery part, coupled to an upper part of a cap assembly of a square-shaped bare cell;
[0021] FIG. 2A is a plan view illustrating a cap plate according to another embodiment of the invention;
[0022] FIG. 2B is a cross-sectional view illustrating the cap plate of FIG. 2A ;
[0023] FIG. 3 is a perspective view schematically illustrating the coupling between a protective circuit assembly and a bare cell according to another embodiment of the invention;
[0024] FIG. 4A is a plan view illustrating a cap plate according to another embodiment of the invention;
[0025] FIG. 4B is a cross-sectional view illustrating the cap plate of FIG. 4A ;
[0026] FIG. 5 is a plan view illustrating a cap plate according to another embodiment of the invention;
[0027] FIG. 6 is a plan view illustrating a cap plate according to another embodiment of the invention; and
[0028] FIG. 7 is a plan view illustrating a cap plate according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0029] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0030] FIG. 1 is a partial cross-sectional view illustrating a square-shaped bare cell coupled to a cap cover according to aspects of the invention. Specifically, FIG. 1 is a cross-sectional view illustrating a necessary portion of the square-shaped bare cell coupled to the cap cover.
[0031] As shown in FIG. 1 , the square-shaped bare cell, which comprises at least a cap plate 110 and a can 100 , and the cap cover 440 coupled to each other may be provided in a battery pack in the same manner as cylindrical bare cells are connected in series/parallel to one another in a general battery pack and are connected to a protective circuit module.
[0032] The connection between the square-shaped bare cell and the cap cover 440 will be described in detail below with reference to FIG. 1 . As shown in FIG. 1 , a cap cover 440 , also referred to as a battery part, is generally formed of a resin mold shape by insert injection molding and includes lead plates as electrical terminals formed of nickel.
[0033] The battery part may be a protective circuit board or the cap cover 440 coupled to a plurality of prismatic can batteries to form a pack battery. In this case, the cap cover 440 can be considered as a connecting part for electrical connection. However, generally, the cap cover 440 may serve as a safety device having a protective element, such as a PTC element 446 , provided therein. The cap cover 440 may be formed in various shapes according to the type of connection among batteries.
[0034] The lead plates include a first lead plate 444 and a second lead plate 442 . The first lead plate 444 is directly connected to a cathode terminal 120 of the square-shaped bare cell, which is provided at the center of the bare cell. And, a second lead plate 442 provided on the outer surface of the cap cover 440 . After the cap cover 440 is formed, the first lead plate 444 is welded to one terminal of a positive temperature coefficient (PTC) element 446 . And, the other terminal of the PTC element 446 is welded to one end of a connecting plate 447 . The connecting plate 447 electrically connects the PCT element 446 to the second lead plate 442 on the outer surface of the cap cover 440 via a through hole 448 . Thus, the second lead plate 442 is electrically connected to the cathode terminal 120 via the connecting plate 447 , the PTC element 446 , and the first lead plate 444 .
[0035] The cap cover 440 , or battery part, is placed over a cap plate 110 of the square-shaped bare cell. The PTC element 446 is coupled to the internal surface of the cap cover 440 . In this case, a peripheral rib 4410 extending from a peripheral portion of a plate body 441 of the cap cover 440 toward the cap plate 110 is aligned with the side wall of a can 100 .
[0036] A U-shaped position fixing rib 4413 and a complementary position fixing groove 320 are provided and collectively referred to as step portions. A step portion will generally have a rib or groove shape and have a corresponding groove or rib shape with which to couple. An end of a U-shaped position fixing rib 4413 is inserted into a position fixing groove 320 formed in the upper or first surface of the cap plate 440 . The U-shaped position fixing rib 4413 may be formed closer to the cathode terminal 120 than to the peripheral rib 4410 . In FIG. 1 , a first portion 4411 is a cross section of a wall when the U-shaped position fixing rib 4413 is symmetrically cut in the vertical direction. And, a second portion 4412 is a side wall portion of the position fixing rib 4413 and is connected to the cross section of the wall.
[0037] In this way, the cap cover 440 is fixed relative to the cap plate 110 , and the connection between the cap cover 440 and the cap plate 110 is kept in a stable state. However, other configurations are possible, such as having a protrusion formed in the cap plate 110 that extends to insert into a groove formed in the cap cover 440 .
[0038] The first lead plate 444 formed on the inner surface of the cap cover 440 is welded to the cathode terminal 120 . Here, a welding rod may be inserted through a hole 445 formed in the center of the cap cover 440 .
[0039] When the welding is completed, a plurality of square-shaped bare cells coupled to the cap cover 440 are thereby connected in series or parallel to one another in a battery pack and connected to the cap cover 440 , which is a protective circuit module, through separate connecting conductors. The connection of a plurality of bare cells forms a pack-type battery.
[0040] The complementary corresponding step portions of the cap cover 440 and the cap plate 110 can be easily connected to each other, which makes it possible to easily perform a process of physically coupling the cap cover 440 to the bare cell and to easily progress a subsequent process, such as a welding process. In addition, the complementary corresponding step portions, the fixing rib 4413 and the groove 320 , make it possible to stabilize the connection between the bare cell and the cap cover 440 in the battery pack. As such, a plurality of bare cells may be stably contained in a battery pack.
[0041] As illustrated, a groove 320 is formed in the upper or first surface of the cap plate 110 , and a protruding step portion, such as the rib 4413 , is formed on the lower or first surface of the plate body 441 of the cap cover 440 . However, a protrusion may be formed on the upper or first surface of the cap plate 110 , and a groove may be formed in the plate body 441 of the cap cover 440 .
[0042] For example, when the groove 320 is formed in the upper or first surface of the cap plate 110 , a protruding portion, the fixing rib 4413 , that is inserted into the groove 320 is formed on the lower or first surface of the battery part, or the cap cover 440 . Or oppositely, when a fixing rib is formed at the center of the cap plate, a groove is formed on the lower or first surface of the battery part so as to correspond to and accept the fixing rib of the cap plate when the battery part and the cap plate are coupled. The battery part is kept at a fixed position with regard to the bare cell without being detached from the bare cell even when an external force is applied to the battery part or the bare cells. Furthermore, the cap cover 440 and the cap plate 110 need not only include grooves or ribs, but may contain a combination of both grooves and ribs.
[0043] The fixing rib 4413 may be formed in the lower or first surface of the cap cover 440 , but the shape of the step portions is not limited thereto. That is, the position and size of the step portions may vary according to the type of battery part coupled to the cap plate 110 . The height of the fixing rib 4413 or depth of the groove 320 may range from 10% to 50% of the thickness of the cap plate 110 . For example, when the thickness of the cap plate is about 0.8 mm, the height of the fixing rib 4413 and the depth of the groove 320 may be in the range of 0.1 to 0.4 mm. When the height of the fixing rib 4413 or the depth of the groove 320 is small, it is difficult for the fixing rib 4413 to maintain connection with the groove 320 . On the other hand, when the height of the fixing rib 4413 or depth of the groove 320 is large, it is difficult to form the fixing rib 4413 . Also, the larger the depth of the groove 320 , the smaller the thickness of a portion of the cap plate 110 corresponding to the groove 320 becomes, which may cause damage to or deform the cap plate 110 .
[0044] In a process of forming the cap plate 110 , the step portions, be they grooves or protrusions, may be formed, for example, by injection molding, pressing, casting, or die casting. A protrusion having a small height may be formed on only the upper or first surface of the cap plate 110 by pressing. In addition, the step portions may be formed on the upper, or first, and lower, or second, surface of the cap plate 110 in a complementary structure. For example, a protrusion may be formed on the upper or first surface of the cap plate 110 and a groove may be formed in the lower or second surface of the cap plate 110 as illustrated in FIG. 2B . As a result, the sectional structure of the step portions may be conformal.
[0045] When casting is used, a protrusion may be formed in a rib shape on only the upper or first surface of the cap plate 110 , and the lower or second surface of the cap plate 110 may be formed flat. A step portion having a rib shape may be adhered or welded to the upper or first surface of the cap plate 110 . As the height or depth of the step portions becomes larger and the edges of the step portions are vertically formed without being chamfered, the risk of the battery part, here—the cap cover 440 , being detached from the cap plate 110 is reduced.
[0046] FIG. 2A is a plan view illustrating a cap plate according to aspects of the invention, and FIG. 2B is a cross-sectional view illustrating a cross section A-A′ of the cap plate of FIG. 2A . FIG. 3 is a perspective view illustrating the coupling between a protective circuit assembly and a bare cell according to another aspect of the invention.
[0047] Referring to FIG. 2A , a cap plate 110 has a fixing rib 330 formed thereon and the fixing rib 330 is formed in a “U” shape on the outer surface of the cap plate 110 . The fixing rib 330 corresponds to the U-shaped fixing rib 4413 of FIG. 1 but is formed on the cap plate 110 . The fixing rib 330 extends to insert into a groove of the cap cover (not shown) so as to stabilize the coupling of the bare cell to the cap cover. The electrolyte injection hole 160 , the vent 190 , and a cathode through-hole 111 are formed to extend through the cap plate 110 . During the assembly of the bare cells, electrolyte is injected through the electrolyte injection hole 160 . Also, the cathode through-hole 111 allows the cathode terminal 120 to extend through the cap plate 110 . Referring to FIG. 2B , the fixing rib 330 is formed by pressing. The electrolyte injection hole 160 , the vent 190 , and the cathode through hole 111 extend through the cap plate 110 . The fixing rib 330 extends from and is an elevated portion above the outer surface of the cap plate 110 . The fixing rib 330 and the corresponding groove formed in a battery part (not shown) are step portions.
[0048] Referring to FIG. 3 , a U-shaped groove 537 is formed on the lower or first surface of a protective circuit assembly 530 , which serves as a battery part. The U-shaped groove 537 is formed to correspond to a U-shaped fixing rib 515 formed on a cap plate 520 . The U-shaped groove 537 is formed to accept the insertion of the U-shaped fixing rib 515 formed on the outer surface of the cap plate 520 . As such, the U-shaped fixing rib 515 is formed to a size slightly smaller than that of the U-shaped groove 537 , and the U-shaped fixing rib 515 is inwardly inserted to the U-shaped groove 537 . In this case, the fixing rib 515 enables a battery part, such as the protective circuit assembly 530 , to be stably coupled to the cap plate 520 . The fixing rib 515 serves to prevent the battery part from deviating from a fixed position on the protective circuit assembly 530 due to external forces. The height to which the fixing rib 515 extends above the outer surface of the cap plate 520 and the depth to which the groove 537 is formed in the plate body 531 provide a predetermined space between the plate body 531 and the cap plate 520 . The protective circuit assembly 530 may be formed of molded plastic and be formed to include an external connection electrode 533 . In the protective circuit assembly 530 , an anode terminal may be formed of the U-shaped fixing rib 515 and groove 537 . An edge skirt 535 , formed of plastic, protrudes downward from the lower or first surface of a plate body 531 , also formed of a plastic resin, to surround the protective circuit assembly 530 . The edge skirt 535 may be formed of or coated with a conductive material to be included as an element of the anode terminal.
[0049] The depth to which a cathode terminal acceptor 539 of the protective circuit assembly 530 extends, and the extent to which a cathode terminal 513 extends above the cap plate 520 of the bare cell 510 may be determined by considering the height of the U-shaped fixing rib 515 , the depth of the U-shaped groove 537 , and the length of the edge skirt 535 . For example, the cathode terminal acceptor 539 may be formed at the center of the lower or first surface of the plate body 531 of the protective circuit assembly 530 , and the height of the anode terminal composed of the U-shaped groove 537 , the U-shaped fixing rib 515 of the cap plate 520 , and the edge skirt 535 may be equal to the height to which the cathode terminal 513 extends above the cap plate 520 . The polarities of the anode terminal and the cathode terminal 513 may be switched.
[0050] The cathode terminal 513 of the bare cell, the cathode terminal acceptor 539 , contact portions of the U-shaped groove 537 and the fixing rib 515 , and the edge skirt 535 may be plated with gold or another conductive metal. Instead of a conductive metal, the cathode terminal 513 of the bare cell, the cathode terminal acceptor 539 , the contact portions of the U-shaped groove 537 and the fixing rib 515 , and the edge skirt 535 may be coated with a conductive adhesive, such as silver paste. The conductive adhesive generally reduces a contact resistance and has a high adhesive strength. Or, a medium layer structure may be formed to reduce the contact resistance between the fixing rib 515 and the groove 537 , or any of the other contact portions. Then, the protective circuit assembly 530 is coupled to the bare cell 510 through these processes, or a combination thereof, to form a simple pack battery.
[0051] A wrapping material (not shown) may be additionally provided on the assembly of the bare cells and the protective circuit, or the bare cells may be individually wrapped. Tubing may be used as a wrapping material.
[0052] FIG. 4A is a plan view illustrating a cap plate according to aspects of the invention, and FIG. 4B is a cross-sectional view illustrating a cross section B-B′ of the cap plate of FIG. 4A .
[0053] Referring to FIGS. 4A and 4B , a fixing rib 340 is formed in a “U” shape on the outer surface of the cap plate 110 , and the fixing rib 340 is adhered to an upper part of the cap plate 110 . It is possible to easily form the fixing rib 340 by fixing a member to the upper part of the cap plate 110 with an adhesive without pressing the cap plate 110 . FIGS. 4A and 4B also include the electrolyte injection hole 160 , the vent 190 , and the cathode through-hole 111 , which both extend through the cap plate 110 . The fixing rib 340 and the corresponding groove formed in a battery part (not shown) are step portions.
[0054] FIG. 5 is a plan view illustrating a cap plated according to aspects of the invention.
[0055] Referring to FIG. 5 , fixing ribs 350 are formed in U shapes on both sides of the upper or first surface of the cap plate 110 in the lateral direction. The fixing ribs 350 enable a battery part, including structures corresponding to the fixing ribs 350 on the lower or first surface thereof to be stably coupled to the upper part of a cap assembly 100 without leaning to one side. The cap plate 110 includes the electrolyte injection hole 160 , the vent 190 , and the cathode through-hole 111 . The fixing ribs 350 and the corresponding grooves formed in a battery part (not shown) are step portions.
[0056] FIG. 6 is a plan view illustrating a cap plate according to aspects of the invention.
[0057] Referring to FIG. 6 , fixing ribs 360 are formed in linear shapes along both long sides of a cap plate 110 . The fixing ribs 360 of the cap plate 110 make it possible to increase the stability of the coupling between the battery part and the cap plate 110 . The cap plate 110 includes the electrolyte injection hole 160 , the vent 190 , and the cathode through-hole 111 . The fixing ribs 360 and the corresponding grooves formed in a battery part (not shown) are step portions.
[0058] FIG. 7 is a plan view illustrating a cap plate according to aspects of the invention.
[0059] Referring to FIG. 7 , fixing ribs 370 are formed in linear shapes at the four corners of a cap plate 110 .
[0060] The fixing ribs 370 may be formed on the cap plate 110 by pressing the cap plate to form the fixing ribs 370 with a predetermined shape or by adhering a member of a predetermined shape to the cap plate 110 . The fixing ribs 370 , as described above, provide a space to be formed between a battery part and the cap plate 110 . The space above the cap plate 110 is pressurized so as to prevent an electrolyte from leaking from the electrolyte injection hole 160 . The cap plate 110 also includes the vent 190 . The fixing ribs 370 and the corresponding grooves formed in a battery part (not shown) are step portions.
[0061] According to aspects of the invention, complementary corresponding step portions are formed between a cap plate of a bare cell and a battery part provided at the upper part of the cap plate, which makes it possible to easily couple the battery part to the bare cell, or a plurality of bare cells, and thus to easily perform subsequent manufacturing processes, such as welding.
[0062] Further, according to the aspects of the invention, the coupling between the bare cell and the battery part is reliably maintained, which makes it possible to reduce defects in connection due to external impact.
[0063] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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A lithium ion secondary battery in which at least one step portion is formed on an upper surface of a cap plate, and at least one step portion is formed on a lower or first surface of a battery part opposite to the upper or first surface of the cap plate so that the at least two step portions are complementary. The complementary step portions of the cap plate of the bare cell and the battery part provided at an upper part of the cap plate result in easy coupling of the battery part to the bare cell and stable maintenance of the coupling between the battery part and the bare cell. The coupling structure results in greater ease in performing subsequent manufacturing processes and protects the bare cells coupled to the battery part from dislodging.
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RELATED APPLICATION
This is a divisional of application Ser. No. 11/028,020, filed Jan. 3, 2005, and Applicants claim priority under 35 USC § 120 from the above-identified parent application, and from U.S. Ser. No. 60/543,053 filed Feb. 9, 2004.
BACKGROUND
The present invention relates generally to fastener-driving tools used for driving fasteners into workpieces, and specifically to combustion-powered fastener-driving tools, also referred to as combustion tools.
Combustion-powered tools are known in the art for use in driving fasteners into workpieces, and examples are described in commonly assigned patents to Nikolich U.S. Pat. Re. No. 32,452, and U.S. Pat. Nos. 4,522,162; 4,483,473; 4,483,474; 4,403,722; 5,197,646; 5,263,439 and 5,713,313, all of which are incorporated by reference herein. Similar combustion-powered nail and staple driving tools are available commercially from ITW-Paslode of Vernon Hills, Ill. under the IMPULSE® and PASLODE® brands.
Such tools incorporate a generally pistol-shaped tool housing enclosing a small internal combustion engine. The engine is powered by a canister of pressurized fuel gas, also called a fuel cell. A battery-powered electronic power distribution unit produces a spark for ignition, and a fan located in a combustion chamber provides for both an efficient combustion within the chamber, while facilitating processes ancillary to the combustion operation of the device. Such ancillary processes include: inserting the fuel into the combustion chamber; mixing the fuel and air within the chamber; and removing, or scavenging, combustion by-products. The engine includes a reciprocating piston with an elongated, rigid driver blade disposed within a single cylinder body.
A valve sleeve is axially reciprocable about the cylinder and, through a linkage, moves to close the combustion chamber when a work contact element at the end of the linkage is pressed against a workpiece. This pressing action also triggers a fuel-metering valve to introduce a specified volume of fuel into the closed combustion chamber.
Upon the pulling of a trigger switch, which causes the spark to ignite a charge of gas in the combustion chamber of the engine, the combined piston and driver blade is forced downward to impact a positioned fastener and drive it into the workpiece. The piston then returns to its original or pre-firing position, through differential gas pressures within the cylinder. Fasteners are fed magazine-style into the nosepiece, where they are held in a properly positioned orientation for receiving the impact of the driver blade.
The above-identified combustion tools incorporate a fan in the combustion chamber. This fan performs many functions, one of which is cooling. The fan performs cooling by drawing air though the tool between firing cycles. This fan is driven by power supplied by an onboard battery and, to prolong battery life, it is common practice to minimizing the run time of the motor. Also, short fan run time reduces fan motor wear (bearings and brushes), limits sound emitting from the tool due to air flow, and most importantly limits dirt infiltration into the tool. To manage fan ‘on time’, combustion tools typically incorporate a control program that limits fan ‘on time’ to 10 seconds or less.
Combustion tool applications that demand high cycle rates or require the tool to operate in elevated ambient temperatures often cause tool component temperatures to rise. This leads to a number of performance issues. The most common is an overheated condition that is evidenced by the tool firing but no fastener driven. This is often referred to as a “skip” or “blank fire.” As previously discussed, the vacuum return function of a piston is dependent on the rate of cooling of the residual combustion gases. As component temperatures rise, the differential temperature between the combustion gas and the engine walls is reduced. This increases the duration for the piston return cycle to such an extent that the user can open the combustion chamber before the piston has returned, even with a lockout mechanism installed. The result is the driver blade remains in the nosepiece of the tool and prevents advancement of the fasteners. Consequently, a subsequent firing event of the tool does not drive a fastener.
Another disadvantage of high tool operating temperature is that there are heat-related stresses on tool components. Among other things, battery life is reduced, and internal lubricating oil has been found to have reduced lubricating capacity with extended high temperature tool operation.
Thus, there is a need for a combustion-powered fastener-driving tool which reduces fan on time. In addition, there is a need for a combustion-powered fastener-driving tool which manages tool operating temperatures within accepted limits to prolong performance and maintain relatively fast piston return to pre-firing position.
BRIEF SUMMARY
The above-listed needs are met or exceeded by the present combustion-powered fastener-driving tool which overcomes the limitations of the current technology. The present tool is provided with a temperature sensing system which more effectively controls running time of the fan. Fan run time may be determined by monitoring tool temperature, by comparing power source temperature against ambient temperature, or by controlling fan run time as a function of tool firing rate.
More specifically, a combustion-powered fastener-driving tool includes a combustion-powered power source, at least one fan associated with the power source, at least one temperature sensing device in operational proximity to the power source, and a control system operationally associated with the power source and connected to the at least one fan and the at least one temperature sensing device for adjusting the length of operational time of the at least one fan as a function of power source temperature sensed by the at least one temperature sensing device.
In another embodiment, a combustion-powered fastener-driving tool includes a combustion-powered power source, at least one fan associated with the power source during operation, and a control system operationally associated with the power source and connected to the at least one fan for adjusting the length of time of fan operation as a function of a rate of combustion firings by the power source.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a front perspective view of a fastener-driving tool incorporating the present temperature control system;
FIG. 2 is a fragmentary vertical cross-section of the tool of FIG. 1 shown in the rest position;
FIG. 3 is a fragmentary vertical cross-section of the tool of FIG. 2 shown in the pre-firing position;
FIGS. 4A-C are an operational flowchart illustrating a control program wherein the tool temperature is monitored for fan energization when needed; and
FIG. 4D is an operational flowchart illustrating a control program subroutine wherein tool firing rate is monitored for fan energization.
DETAILED DESCRIPTION
Referring now to FIGS. 1-3 , a combustion-powered fastener-driving tool incorporating the present control system is generally designated 10 and preferably is of the general type described in detail in the patents listed above and incorporated by reference in the present application. A housing 12 of the tool 10 encloses a self-contained internal power source 14 ( FIG. 2 ) within a housing main chamber 16 . As in conventional combustion tools, the power source 14 is powered by internal combustion and includes a combustion chamber 18 that communicates with a cylinder 20 . A piston 22 reciprocally disposed within the cylinder 20 is connected to the upper end of a driver blade 24 . As shown in FIG. 2 , an upper limit of the reciprocal travel of the piston 22 is referred to as a top dead center or pre-firing position, which occurs just prior to firing, or the ignition of the combustion gases which initiates the downward driving of the driver blade 24 to impact a fastener (not shown) to drive it into a workpiece.
Through depression of a trigger 26 associated with a trigger switch 27 (shown hidden), an operator induces combustion within the combustion chamber 18 , causing the driver blade 24 to be forcefully driven downward through a nosepiece 28 ( FIG. 1 ). The nosepiece 28 guides the driver blade 24 to strike a fastener that had been delivered into the nosepiece via a fastener magazine 30 .
Included in the nosepiece 28 is a workpiece contact element 32 , which is connected, through a linkage 34 to a reciprocating valve sleeve 36 , an upper end of which partially defines the combustion chamber 18 . Depression of the tool housing 12 against the workpiece contact element 32 in a downward direction as seen in FIG. 1 (other operational orientations are contemplated as are known in the art), causes the workpiece contact element to move from a rest position to a pre-firing position. This movement overcomes the normally downward biased orientation of the workpiece contact element 32 caused by a spring 38 (shown hidden in FIG. 1 ). Other locations for the spring 38 are contemplated.
Through the linkage 34 , the workpiece contact element 32 is connected to and reciprocally moves with, the valve sleeve 36 . In the rest position ( FIG. 2 ), the combustion chamber 18 is not sealed, since there is an annular gap 40 including an upper gap 40 U separating the valve sleeve 36 and a cylinder head 42 , which accommodates a chamber switch 44 and a spark plug 46 , and a lower gap 40 L separating the valve sleeve 36 and the cylinder 20 . In the preferred embodiment of the present tool 10 , the cylinder head 42 also is the mounting point for at least one cooling fan 48 and the associated fan motor 49 which extends into the combustion chamber 18 as is known in the art and described in the patents which have been incorporated by reference above. In addition, U.S. Pat. No. 5,713,313 also incorporated by reference, discloses the use of multiple cooling fans in a combustion-powered tool. In the rest position depicted in FIG. 2 , the tool 10 is disabled from firing because the combustion chamber 18 is not sealed at the top with the cylinder head 42 and the chamber switch 44 is open.
Firing is enabled when an operator presses the workpiece contact element 32 against a workpiece. This action overcomes the biasing force of the spring 38 , causes the valve sleeve 36 to move upward relative to the housing 12 , closing the gap 40 , sealing the combustion chamber 18 and activating the chamber switch 44 . This operation also induces a measured amount of fuel to be released into the combustion chamber 18 from a fuel canister 50 (shown in fragment).
In a mode of operation known as sequential operation, upon a pulling of the trigger 26 , the spark plug 46 is energized, igniting the fuel and air mixture in the combustion chamber 18 and sending the piston 22 and the driver blade 24 downward toward the waiting fastener for entry into the workpiece. As the piston 22 travels down the cylinder 20 , it pushes a rush of air which is exhausted through at least one petal, reed or check valve 52 and at least one vent hole 53 located beyond the piston displacement ( FIG. 2 ). At the bottom of the piston stroke or the maximum piston travel distance, the piston 22 impacts a resilient bumper 54 as is known in the art. With the piston 22 beyond the exhaust check valve 52 , high pressure gasses vent from the cylinder 20 . Due to internal pressure differentials in the cylinder 20 , the piston 22 is drawn back to the pre-firing position shown in FIG. 3 .
As described above, one of the issues confronting designers of combustion-powered tools of this type is the need for a rapid return of the piston 22 to pre-firing position prior to the next cycle. This need is especially critical if the tool is to be fired in a repetitive cycle mode, where an ignition occurs each time the workpiece contact element 32 is retracted, and during which time the trigger 26 is continually held in the pulled or squeezed position. During repetitive cycle operation, ignition of the tool is triggered upon the chamber switch 44 being closed as the valve sleeve 36 reaches its uppermost position ( FIG. 3 ). Such repetitive cycle operation often leads to elevated tool operating temperatures, which extend the piston return time.
To manage those cases where extended tool cycling and/or elevated ambient temperatures induce high tool temperature, at least one temperature sensing device 60 such as a thermistor (shown hidden in FIG. 1 ) is preferably located at a lower end of the cylinder 20 and is preferably disposed to be in or in operational relationship to, a forced-convection flow stream F of the tool 10 ( FIG. 2 ). Other types of temperature sensing devices are contemplated. Also, other locations on the tool 10 are contemplated depending on the application. The temperature sensing device 60 is connected to a control program 66 associated with a central processing unit (CPU) 67 (shown hidden in FIG. 1 ) and is configured to extend ‘on time’ of the at least one cooling fan 48 until the temperature is lowered to the preferred “normal” operating range. Alternately, the program 66 is configured to hold the fan 48 on for a fixed time, for example 90 seconds, which is long enough to assure that the combustion chamber temperature has returned to the “normal” operating range. In the preferred embodiment, the program 66 and the CPU 67 are located in a handle portion 68 of the tool 10 .
The temperature threshold is selected based upon the proximity of the temperature sensing device 60 to the components of the power source 14 , the internal forced convection flow stream, and desired cooling effects to avoid nuisance fan operation. Excessive fan run time unnecessarily draws contaminants into the tool 10 and depletes battery power. Other drawbacks of excessive fan run time include premature failure of fan components and less fan-induced operational noise of the tool 10 . For demanding high cycle rate applications and/or when elevated ambient temperatures present overheating issues, temperature controlled forced convection will yield more reliable combustion-powered nail performance and will also reduce thermal stress on the tool.
Referring now to FIG. 4A and considering a sequential firing mode, although the present program can be applied to a repetitive firing mode as well, a portion of the control program 66 associated with monitoring tool temperature is generally designated 70 . Beginning at the START prompt 71 , the program 70 determines at 72 if the chamber switch 44 (designated HEAD) is open or not. A closed HEAD signifies that the combustion chamber 18 is closed and ready for combustion. If the HEAD is closed, the program cycles. If the HEAD is open, the program 70 checks whether the trigger 26 is open at 74 . If the trigger 26 is closed with the HEAD open, the program cycles. At step 76 , once the HEAD is closed, the fan 48 is turned on at step 78 , which circulates fuel and air mixed in the combustion chamber 18 .
Next, the program 70 checks whether to activate the ignition process by determining whether the trigger 26 is closed at 80 or the HEAD is open at 82 . If the trigger 26 has not been closed, and the HEAD 44 reopened, as if the operator was interrupted in using the tool 10 or decided to put it down unused, the program 70 checks at 84 whether the 90 second fan signal is on. If not, that indicates that the tool has not been used, and the fan 48 is turned on at 86 for 5 seconds, and then is turned off. If the 90 second fan signal has been turned on, the program 70 returns to START at 71 , and the extended cooling cycle continues.
Returning to the trigger closed 80 -HEAD open 82 loop, once the trigger 26 is closed, indicating a combustion is desired, the program 70 activates a spark at 90 , which may also be performed in conjunction with the control circuit 66 . After ignition, the program 70 determines whether the HEAD 44 is open at 92 , and if not, the program cycles. If the HEAD 44 is open, the program 70 checks to see if the trigger 26 is open at 94 . If not, the program 70 cycles until the trigger does open, at which time the program goes to TEMP at 96 , or COMPARE TEMP at 98 , or to RATE at 100 , depending on which of the present embodiments is employed. The TEMP 96 subroutine uses one temperature sensor 60 to monitor tool temperature and turn on the fan 48 into extended operation, also known as “overdrive” when tool temperature exceeds a preset value. The COMPARE TEMP 98 subroutine uses a calculated value based on readings of two temperature sensors to activate the fan 48 into overdrive, and the RATE 100 subroutine monitors the firing rate of the tool 10 to activate fan overdrive.
Referring now to FIG. 4B , the TEMP subroutine 96 first determines whether the HEAD 44 is open at 102 . Once the HEAD 44 is determined to be opened, the trigger 26 is checked at 104 . If the trigger 26 is closed, indicating that the operator is actively using the tool, the program 70 cycles until the trigger is open. At that time, at step 106 , the program 70 monitors the temperature from the temperature sensor 60 . At step 108 , the program 70 determines whether the sensed temperature is greater than 60° C. If the temperature is not greater than 60° C., at 108 , the program 70 determines if the 90 second fan timer has been activated at 110 , which would also indicate that the fan 48 had been energized for that period. If not, indicating the tool 10 has not been extensively used or use has been discontinued, the fan 48 is turned on for 5 seconds at 112 and then is turned off, following which the program 70 reverts to the START routine 71 .
If the temperature is greater than 60° C. at 108 and the 90 second fan timer, as well as the fan 48 , has been turned on at 110 , then the temperature sensor 60 is checked at 114 to determine if the monitored temperature is less than or equal to 40° C. If not, indicating the tool is still at operational temperature, the program 70 begins the START routine at 71 . If the sensed tool temperature has been reduced to less than or equal to 40° C. after operation of the 90 second fan timer and the fan 48 , even if the 90 seconds has not expired, the 90 second timer reverts to a 5 second fan timer, which is turned on at 116 . After 5 seconds, the fan 48 , and an optional indicator, such as a light and/or audible alarm 115 ( FIG. 1 ) which was turned on in conjunction with the energization of the 90 second fan timer (discussed below at 118 ) is turned off. Next, the program 70 goes to START at 71 .
If the monitored tool temperature is greater than or equal to 60° C. at 108 , then the fan 48 , the fan timer, as well as the optional indicator 115 is turned on for 90 seconds at 118 , then both are turned off, following which the program 70 goes to START at 71 . It is preferred that the fan running for 90 seconds is sufficient to cool the tool 10 during operation and prevent overheating. However, it will be understood that the temperature levels and fan run times discussed herein may be modified to suit the particular application.
Referring now to FIG. 4C , the COMPARE TEMP subroutine 98 is provided. In this embodiment, the tool 10 is provided with a first temperature sensor 60 near the power source 14 , such as the cylinder 20 or the combustion chamber 18 . A second temperature sensor 120 (shown hidden in FIG. 1 ) is also located on the tool 10 , but further from the power source 14 such that it is not significantly affected by the power source 14 . One potential location is on the tool housing 12 in the handle portion 68 , however other locations are contemplated.
Initially, at step 124 , the program 70 determines the ambient, or close to ambient reference temperature value from reading the second temperature sensor 120 . Next, at step 126 , the program 70 determines the tool reference temperature from the first temperature sensor 60 located closer to the power source 14 . At step 128 , the readings from the sensors 120 and 60 are compared, obtaining a ΔT value. At step 130 , the resulting difference ΔT is compared against a predetermined value, such as a conventional “look-up” table developed to suit the application. If the resulting difference is greater than the predetermined value, then at step 132 the fan 48 is turned on for 90 seconds, then is turned off. If the resulting difference is less than the predetermined value, then at step 134 the fan 48 is turned on for 5 seconds, then off. It is also contemplated that the subroutine 98 is configurable so that the greater the difference ΔT, the longer the fan run time. At the conclusion of either activation of the fan, the program returns to START at 71 . It is also contemplated that the ΔT can be compared to the ambient reference temperature to determine fan run time.
Referring now to FIG. 4D , the RATE subroutine 100 is described. A tool cycle rate, or the number of firings per minute, or the number of combustions or ignitions of the spark plug 46 over time, is determined by the program 70 at step 136 , and then that value is compared against a predetermined rate at step 138 as in a “look-up” table. This data is preferably monitored by the CPU 67 . Depending on the application, a threshold firing rate is established and added to the program 70 which is considered sufficient to cause an excessive tool temperature, for example 60° C. The program 70 then checks at step 140 to determine whether the firing rate exceeds the predetermined rate, and if so, the tool 10 is likely overheating or has a raised operating temperature. As such, at step 142 , the fan is turned on for 90 seconds, then is turned off. If the tool 10 is so equipped, the indicator 115 is temporarily energized, as described above in relation to FIG. 4B . If the calculated firing rate is less than the predetermined rate, indicating that tool temperature is acceptable, the fan 48 is turned on for 5 seconds at step 144 , then is turned off, again optionally with periodic energization of the indicator 115 . Upon the execution of either of steps 142 or 144 , the program 70 returns to start at 71 .
Note that it is contemplated that the program 70 may be configured so that GO TO TEMP 96 , GO TO COMPARE TEMP 98 and GO TO RATE 100 may be used in combination with each other, and are not required to be exclusively used as a fan control.
While a particular embodiment of the present temperature monitoring for fan control for combustion-powered fastener-driving tool has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
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A combustion-powered fastener-driving tool includes a combustion-powered power source; at least one fan associated with the power source during operation; and a control system operationally associated with the power source and connected to the at least one fan for adjusting the length of time for energizing the at least one fan as a function of the number of combustion firings by the power source.
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This application is a division of application No. 09/591,011, filed on Jun. 9, 2000, now U.S. Pat. No. 6,445,580.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to personal computers, and more particularly to devices and methods for conductively dissipating heat generated from operational internal electronic circuitry and/or components (e.g., microprocessors) of personal computers, to an environment external to the personal computer.
2. Description of the Related Art
Consumers typically prefer to obtain personal computers (PCs) having a higher-speed processor, more compact dimension, improved portability, and/or an overall lighter weight (e.g., IBM® models 560, T20; IBM is a registered trademark of International Business Machines, Armonk, N.Y., USA). To meet demands, PC designers often strive to economically offer added computational functionality to model designs by integrating higher-speed processors and optimizing the internal platform, components, and/or operating systems to provide a consumer enhanced performance capabilities in a more compact model. Consequently, designers desire to better the overall portability and compactness of each PC model introduced.
In accordance with recent technical developments, various types of PCs, such as desktops, towers, laptops, notebooks, and portable types, have been developed and are being sold on the market. Additionally, other portable computer-based devices such as processor-based communicators and portable information terminals (PITs) (e.g., Personal Assistants, hand-held digital notepads, and Personal Digital Assistants (PDAs)) are also being developed and sold in the marketplace with similar consumer interest and demand. Critical in the design considerations for these processor-based devices is improving dimensional slimness, optimizing portability, minimizing the production cost, and reducing overall weight while integrating higher-speed processors to provide a user with additional functionality. In particular, efficiently removing heat energy generated by heat-generating components, power supplies and other sources within the device, has proved difficult but is required to ensure satisfactory operation of a higher-speed processor-based device.
As used herein, the term “personal computer” includes any electronic data processing device having a central processing unit (CPU) (e.g. microprocessor) including but not limited to devices such as: a computer, PC, computing device, communicator and PIT, wherein for the general purposes herein, it is desirable for such a device to be dimensionally portable.
As used herein, the term “eat-generating source” is any source within a personal computer which generates heat energy during its operation, including but not limited to an electrical element, electronic component, resident internal device, and power source.
However, it is known that as a processor's operating speed (i.e., frequency) increases so does the power consumption by (i.e., input power to the processor) and the surface temperature of the processor. As such, there is typically a substantial increase in the power required to operate a higher-speed processor and there is a need for additional cooling of heat generated by the processor over existing known methods to maintain the junction temperature of the processor to be within acceptable limits.
For example, an INTEL® mobile zPIII processor consumes approximately 12 Watts and has a junction temperature of 212 degrees Fahrenheit at its optimal operational frequency of 500 MHz (INTEL is a registered trademark of ITEL Corporation, Santa Clara, Calif., USA). An INTEL mobile PIII processor consumes approximately 20 Watts and has a junction temperature of 212 degrees Fahrenheit at its optimal operational frequency of 600 MHz. Analogously, it is believed that next-generation processors may operate at optimal processing speeds of about 1 Ghz and greater, and require approximately 25 Watts of power and greater, while having operational junction temperatures of about 212 degrees Fahrenheit.
To overcome the heat generated by a processor, an internal conventional cooling system (CCS) is often integrated within a personal computer to dissipate heat and cool the surface of the processor. For instance, it is known to air-cool a low-speed processor or deploy an internal heat sink apparatus such as a heat pipe to cool a mid-speed processor. With mid to high-speed processors, it is known to internally mount one or more thermoelectric cooling devices (TECs) which, as used herein, typically are solid state heat pumps based on the Peltier effect and also include but are not limited to motorized fans, fan sinks, heat sinks, spreader plates, heat pipes, Peltier devices, and other similar conventional thermodynamic dissipating device, singularly or in combination, which operate to reduce the junction temperature of the processor by removing excess beat through conductive means. It is known that a CCS may comprise one or more TEC devices in a typical arrangement for dissipating heat from a heat-generating source (e.g., operating processor) for distribution within or external to the computer housing (e.g., internal environment).
Traditionally, precise thermal contact between the heat-generating component and a CCS is required for efficient heat transfer. In a conventional application, pressure mounts are often utilized to secure a surface of the CCS contact with a surface of the processor.
FIG. 1 shows an exemplary CCS 100 in which TEC 110 is mounted on processor 120 within housing 130 of personal computer 140 ., wherein heat is dissipated across internal ambient environment 150 of personal computer 140 .
Typically, TEC 110 mounted on processor 120 collects heat generated by processor 120 and dissipates the collected heat to heat sink 160 wherein the heat sink thereafter dissipates the heated air within 150 or external to the computer 140 at 180 via a motorized fan 170 . Since the amount of heat which may be dissipated is proportional to the size and location of the TEC and to the heat generated by the internal processor, often the dimensions of the TEC are increased to improve the amount of heat dissipated.
CCSs will likely prove inadequate in satisfactorily dissipating the additional heat generated by higher-speed processors, as there is often either insufficient free-space for heat dissipation within the personal computer and/or the cooling system components are undersized with respect to the thermodynamic characteristics of the higher-speed processor. It is also foreseeable that TECs and CCSs that are improperly sized or have inadequate air flow available, may fail due to increased condensation during operation within the personal computer. As a result, utilizing a CCS in certain slim computer designs having higher-speed processors may no longer be feasible and a CCS may not therefore provide adequate cooling for future slim personal computer designs having higher-speed processors.
Similarly, since CCSs continuously consume power from their personal computer host, the CCS's power consumption in combination with the added power demands from the higher-speed processor may either exceed the available power or detrimentally reduce the utilization of a portable power source. Increasing the available power from a portable power source is typically not a preferred solution since both size and weight of the power source would typically be increased.
Therefore, designers have often been limited in their ability to economically balance the physical size and weight of a personal computer with the increased thermodynamic effects and power requirements of an integrated higher-speed processor. Consequently, designers may often attempt to resolve design issues by conducting one of the following less desirable design approaches: 1) increasing a casing's dimensions to account for increased thermodynamic effects and power requirements of a higher-speed processor; 2) minimizing changes to existing casing's dimension and portable power supply, thereby limiting the selection of an integrated higher-speed processor to reduced parameters (i.e., non-op zed processor having reduced functionality); 3) minimizing changes to existing casing dimensions by reducing functionality to reduce power (also known as “throttling”) to the integrated processor such that the processor operates at a slower speed and generates less heat than at optimal speed; 4) adding costs to the personal computer by using more expensive materials, denser electronics and similar; or 5) a combination of any of the preceding approaches.
With the advent of higher-speed processors, it is projected that the overlap between the maximum operating temperature limit of the internal processors will exceed the temperature design margins of current compact personal computer designs. Similarly, with the projected increase in power requirements needed to operate the higher-speed processors, it is expected that the weight of the personal computer will increase, due to additional equipment, and that the placement of the additional equipment will virtually eliminate or exceed the available internal free-space. Additionally, since conventional heat dissipation techniques operate continuously, it is likely that the slim personal computer designs will be unable to accommodate higher-speed processors and CCSs without sacrificing dimensional compactness and portability. As a result, given the growing consumer demands to further reduce the dimensional size and weight of the personal computer while increasing functionality, integrating higher-speed processors into more portable and compact personal computer designs remains at risk.
SUMMARY OF THE INVENTION
Accordingly, due to the increased thermodynamic effects and power requirements a higher-speed processor in a personal computer presents, there is a need to develop a portable heat-dissipating apparatus which satisfactorily removes additional heat generated by an operational processor to an environment external to the personal computer without detrimentally impacting the dimensional characteristics of the personal computer. There is a further need to develop such an apparatus portable which is operatively coupled with and removably attachable to a personal computer such that the apparatus is selectively controllable to operate and dissipate heat in a power-conservation mode in relation to the processor's operational speed and the available power source.
According to one embodiment, of the present invention is a portable cooling apparatus, operable with a personal computer having a corresponding conductive connection in thermal contact with a heat-generating source within an ambient environment of the computer, comprising an adapter housing a cooling probe in thermal contact with a powered cooling unit, wherein when the adapter is mated at a connection interface with the conductive connection, generated heat energy is thermally transferred firstly from the conductive connection across the interface to the probe, secondly from the probe to the cooling unit, and lastly from the cooling unit to an external environment apart from the ambient environment.
According to another embodiment, the present invention is a portable cooling apparatus operably connected at a conductive connection interface to a personal computer having a corresponding conductive connection in thermal contact with a heat-generating source within an ambient environment of the computer, wherein the processor selectively controls power to energize or de-energize the apparatus according to the operational speed of the processor or an available power source such that generated heat energy is thermally transferred firstly from the processor across the interface to an external environment apart from the ambient environment.
According to another embodiment of the present invention, a method for selectively optimizing operation of a portable cooling apparatus attachable to a personal computer having a corresponding conductive connection in thermal contact with a heat-generating source within an ambient environment of the computer is provided, having the following steps: (a) determining power operational mode of processor in relation to power source, available power from the power source and planned operational speed of a processor of the personal computer; (b) calculating apparatus power required for dissipating heat energy theoretically generated by the heat-generating source at the planned operational processor speed, (c) determining to provide power to apparatus when available power is greater than apparatus power required, or adjust planned operational speed of processor to operate within determined power characteristics and providing power accordingly thereafter; (d) measuring actual junction temperature of the processor and comparing actual temperature with that theoretically determined in step (b); and, (e) adjusting the power to the apparatus in response to step (d) in relation to the determined power characteristics.
Advantageous features of the present invention over conventional cooling systems include the capabilities to: (1) selectively control or supplement the cooling of a processor in a personal computer prior to overheating of a processor; (2) selectively control the processor speed of a personal computer connected with the apparatus in relation to the available power; (3) reduce overall dimensions and/or weight of personal computers without impact to performance; (4) expand the operating temperature range limits of a processor; (5) provide additional space within a personal computer for additional performance improvements without impacting heat-dissipating means; (6) provide battery conservation and optimal utilization techniques; (7) provide utilization of more powerful processors in slim-design personal computers; (8) provide utilization of more powerful cooling devices with slim-design personal computers;
and (9) provide a method for safely dissipating heat energy from within a personal computer to an environment external to the computer.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims, and the accompanying drawings in which:
FIG. 1 shows an exemplary CCS in which a TEC is mounted on a processor within a housing of a personal computer, wherein heat is dissipated across an internal ambient environment of the personal computer.
FIG. 2 is an exterior view of the apparatus in accordance with a preferred embodiment of the present invention.
FIG. 3 is a first cross-section view of the apparatus of FIG. 2 .
FIG. 4 is a diagram of an apparatus having a connection adapter and housing a slidable probe, and a personal computer having a corresponding receiving port, in accordance with a preferred embodiment of the present invention.
FIG. 5 is a diagram of the apparatus operationally coupled with a personal computer, in accordance with a preferred embodiment of the present invention.
FIG. 6 is a method for optimally controlling power to an apparatus operationally coupled with a processor of a personal computer, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION
The use of figure reference labels in the claims is intended to identify one or more possible embodiments of the claimed subject matter in order to facilitate the interpretation of the claims. Such labeling is not to be construed as necessarily limiting the scope of those claims to the embodiments shown in the corresponding figures.
FIG. 2 is an exterior view of apparatus 200 in accordance with a preferred embodiment of the present invention. Apparatus 200 has exterior housing 210 , connection adapter 220 , and houses conductive probe 230 , thermo-electric cooler (TEC) 240 , and heat sink 250 . Optionally, a venting area 260 is integrated into the housing 210 to provide a direct exhaust outlet from the internal environment of apparatus 200 to external environment 299 .
FIG. 3 is a first cross-section view of apparatus ( 200 of FIG. 2 ). Housed within apparatus 200 is conductive probe ( 230 of FIG. 2 ) thermoelectric cooler (TEC) ( 240 of FIG. 2 ) having a receiving face 360 and a conducting face 350 , heat sink ( 250 of FIG. 2 ), and connection interface 330 housing surface face 340 of probe 230 . Conductive probe 230 is comprised of a thermally-conductive material such as copper, and is fixedly mounted to expose surface face 340 at connection interface 330 for the collection and/or dissipation of heat energy from a separate heatsource (e.g. processor in a personal computer). When surface face 340 is in thermal contact with a separate heat-source, heat energy is conductively collected at the surface face 340 and is transferred from face 340 along the probe to the receiving lace 360 . When power is applied from a power source (not shown) to TEC 240 , a temperature difference (i.e., temperature gradient) is created across the TEC's two faces 350 , 360 in relation to the amount of power applied to TEC 240 . With power applied to TEC 240 , receiving face 360 will have a surface temperature less than the surface temperature of conducting face 350 . The heat energy is then thermally transferred from receiving face 360 to conducting face 350 as indicated by directional flow 380 after which the heat energy is exhausted to external environments via the heat sink 250 and optional fan 395 . As used herein the term “external environment” is defined as an environment external to the internal ambient environment having a heat-generating source (e.g. a processor within a personal computer housing) and includes environments external to the housing of the personal computer such as an internal environment within the apparatus ( 390 ) and/or an atmospheric environment external to both a personal computer and the apparatus ( 399 ).
In operation, with power applied and a heat-generating source in thermal contact with surface ace 340 , heat energy from the heat-generating source (not shown) is first conductively collected at surface face 340 and is then conductively transferred along probe 230 to receiving face 360 . Heat energy is then transferred from receiving face 360 to conducting face 350 by electron transport, and is thereafter transferred within the apparatus environment 390 . Heat energy is then transferred through an optional venting area ( 260 of FIG. 2 ) to external atmospheric environment 399 preferably by fan 395 which is fixedly mounted on housing 210 in proximity to venting area 260 to increase the rate at which heat energy is dissipated from heat sink 250 to either of the external environments 390 , 399 , although other dissipating devices are also envisioned by the inventor.
In a preferred embodiment receiving face 360 is conductively mounted with conductive probe 230 such that TEC 240 is positioned between the probe 230 and the heat sink 250 . Alternatively or if concurrently, conducting face 350 is conductively mounted with heat sink 250 such that when power is applied to TEC 240 , heat energy is conductively transferred from receiving face 360 to conducting face 350 by electron transport and is thereafter dissipated from heat sink 250 .
FIG. 4 is a diagram of personal computer 400 having a receiving port 405 corresponding to and aligned to be operably connected with connector adapter 455 of apparatus 450 which houses slidable probe 460 , in accordance with a preferred embodiment of the present invention.
Personal computer 400 comprises corresponding receiving port 405 , adapted to receive connection adapter 455 , conductive face 410 which receives heat conductively transferred from heat generating device 420 along thermal conductive path means 415 when the heat-generating device 420 is operational. By way of example and not of limitation, conductive face 410 of conductive path means 415 is preferably integral to the path means and may include one or more of the following: spreader plate, heat pipe, heat exchanger, heat sink, wire, copper bar, etched circuit path, and/or other thermally-conductive device or material.
Slidable probe 460 is comprised of a thermally-conductive material such as copper and is slidably mounted along a corresponding locking means 465 affixed or a part of housing 470 . By way of example and not of limitation, locking means 465 may include a plurality of tracks, rails, guides, edges, and similar features which provide both guidance and stability to probe 460 during positioning and placement of probe with corresponding receiving port 405 . Slidable probe 460 also has surface face 475 and is in thermal contact with TEC 480 which is in thermal contact with heat sink 485 . Slidable probe 460 is moveable along locking means 465 to provide predetermined alignment and contact pressure of surface face 475 with a receiving port 405 . Optionally, a tensioned stopping means 480 , such as a spring-backed plate, is positioned at a predetermined distance from a distal end 490 of the probe 460 to place surface face 475 in contact with a conductive face 410 conducting heat from a heat-generating source 420 .
In operation, a user securably positions connection adapter 455 with receiving port 405 . During this process, fixed conductive face 410 exerts a resistive force on slidable surface face 475 which thereby causes the slidable probe 460 to move along locking means 465 for a predetermined distance until stop spring 495 is compressed. When compressed, stop spring 495 exerts an opposing force on slidable probe 460 along distal probe end 490 until connection adapter 455 is securely positioned with receiving port 405 . Once positioned, stop spring 495 continues to exert an opposing force on slidable probe 460 which thereby causes surface face 475 to be forcedly positioned in well-aligned, thermal contact with conductive face 410 .
FIG. 5 is a diagram of apparatus ( 450 of FIG. 4 ) operationally coupled at connection interface 500 with personal computer ( 400 of FIG. 4 ), in accordance with a preferred embodiment of the present invention. Apparatus 450 is removable from the computer 400 at the connection interface 500 by utilizing a release mechanism (not shown).
FIG. 6 is a method for optimally controlling power to an apparatus operationally coupled with a processor of a personal computer, in accordance with a preferred embodiment of the present invention. It will be recognized by those skilled in the art that the sequence of operations described herein may be performed under control or by a stored program, which may reside in on-processor or resident memory, software program, or hardware configured to perform the same. In a preferred embodiment, the method is accomplished by the processor performing one or more appropriate software routines. In step 600 , the processor of the coupled personal computer determines the power utilization level of a connected apparatus and the desired operational speed of the processor.
The power utilization level (P LEVEL ) may be received from the apparatus in a message, or it may be calculated by the processor using a protocol, or it may be read from storage, or some other means. From the P LEVEL , and known characteristics of the computer's power management system (PMS) and the apparatus' heat-dissipating components, a current range (I APP ) and associated thermal dissipation results (T APP ) for the apparatus can be calculated. Alternatively a table can be used to relate P LEVEL to the power controller state providing power to the apparatus.
The desired operational speed (v DESIRE ) may be received from a user by a software command, in a message, or it may be calculated by the processor using a protocol or default value, or it may be read from storage, or some other means. From v DESIRE and known characteristics of the computer's PMS and its heat-related components, an associated heat energy value (T DESIRE ) for an operational processor can be calculated. Alternatively a table can be used to relate processor speed to the surface temperature of the processor. In step 610 , the processor determines the type of power source attached (P TYPE ) and the available power (P AVAIL ) of the attached power source.
When the P TYPE is determined the operating mode (MODE) is also determined by the processor. When P TYPE is determined to be alternating current (AC), the processor determines the MODE as power mode 620 since there is typically no reason to restrict the power to the apparatus except for testing purposes or at the discretion of the user. Preferably, when MODE is power mode, the processor signals the PMS to supply power to the connected apparatus for actively dissipating heat from a heat-generating device of the personal computer (e.g., processor) and continues to 625 . When P TYPE is determined to be direct current (DC), the processor determines the MODE as conserve mode 640 . In a preferred embodiment, the power supply detection feature within the PMS identifies whether supplied power to the computer is alternating (AC) or direct current (DC) and notifies the processor. Optionally, a power supply detector interconnected with the processor may be used to determine the power supply source type.
When MODE is power mode 620 , the current required to operate the processor to efficiently remove heat generated by heat-generating components of the computer (I REQ ) is equated to the maximum current of the apparatus (I APP ) at 625 . Power is then supplied from the PMS to the apparatus at 630 prior to increasing the operating speed of the processor to v DESIRE at 635 . In this manner, heat-dissipation techniques are implemented prior to the maximum operation of the processor of the computer.
When MODE is conserve mode 640 , the processor determines I REQ in relation to the apparatus heat-dissipation ability (T APP ) and the processor's heat-generating characteristics (T GEN ) given v DESIRE at 645 . Additionally, the available current (I AVAIL ) is determined in relation to P AVAIL at 645 . At 650 , a determination of I AVAIL in relation to I REQ and I APP is performed.
If it is determined that I AVAIL is insufficient to operate the apparatus at the necessary-rate to achieve T APP , or if the required heat-dissipation exceeds that available from the apparatus (e.g. I REQ >I APP ), then a user is notified at 655 to select a lower operational speed at 660 or to deactivate the system 665 . In an alternative embodiment, a default processing speed is determined from the determined power and current characteristics and this default frequency: is equated to v DESIRE at 665 . If it is determined that I AVAIL is sufficient to operate the apparatus at the necessary rate to achieve T APP , the process continues to step 670 .
In step 670 , the current required to operate the processor to efficiently remove heat generated by heat-generating components of the computer (I REQ ) is provided to the apparatus. It is preferred that the power be supplied by the processor controlling the PMS, however, other alternatives are envisioned by the inventor as well. The operating speed of the processor is increased to v DESIRE at 675 . In this manner, heat-dissipation techniques are implemented prior to the maximum operation of the processor of the computer. A clock count is initiated at 680 to create a timed delay for iteratively determining actual junction temperature of the processor (T JUNCT ) in step 685 .
T JUNCT is determined at 685 preferably by an analog temperature sensor coupled to an A/D converter interconnected with, the processor. The processor compares the digitally converted T JUNCT with the predetermined theoretical processor junction temperature at V DESIRE (T ROC ) at 690 . Provided T JUNCT is less than T PROC , the processor determines that the apparatus is effectively removing heat at a rate anticipated based upon the earlier determinations. In this situation ( 695 ), there is no need to after the power supplied to the apparatus and an additional temperature measurement of T JUNCT is planned for a predetermined future period based upon the clock counter at 680 . When T JUNCT is greater than T PROC at 699 , additional heat-dissipation is required and additional current may be required at the apparatus to increase the rate at which heat is dissipated. In this situation, a closed-loop control reevaluates pertinent power, current and temperature data to determine whether to increase power to the apparatus, decrease operational frequency of the processor, deactivate or another alternative approach, initiating at 645 .
In a preferred embodiment, the apparatus is integrated with a personal computer docking device having power and connection ports operatively interconnected with the apparatus of the present invention such that the apparatus is controllably operable to remove excess heat energy generated by a processor of an docked personal computer.
In another preferred embodiment, the apparatus is operably connected with a personal computer to lower the temperature in heat-generating areas of a personal computer other than a processor to eliminate hot spots and effect a better temperature distribution as necessary, such as regulating the bottom-surface temperature of an otherwise hot system to a lower temperature and improved comfort level.
In another preferred embodiment, the present invention contains one or more software systems or software components of functions. In this context, a software system is a collection of one or more executable software programs, and one or more storage areas (for example RAM, ROM, cache, disk, flash memory, PCMCIA, CD-ROM. Server's Memory, ftp accessible memory, etc.). In general terms, a software system should be understood to comprise a fully functional software embodiment of a function or collection of functions, which can be added to an existing processing system to provide new function to that processing system. Software systems generally are constructed in a layered fashion such that a lowest level software system is usually the operating system which enables the hardware to execute software instructions.
A software system is thus understood to be a software implementation of a function which can be carried out in a processor system providing new functionality. Also, in general, the interface provided by one software system to another software system is well-defined. It should be understood in the context of the present invention that delineations between software systems are representative of the preferred implementation. However, the present invention may be implemented using any combination or separation of software or hardware systems.
The present invention may be implemented as circuit-based processes, including possible implementation on a single integrated circuit. As would be apparent to one skilled in the art, various functions of circuit elements may also be implemented in the digital domain as processing steps in a software program and may alternatively be provided using discrete components. Such software may be employed in, for example, a digital signal processor, micro-controller, or general-purpose computer.
The present invention can be embodied in the form of methods and apparatuses for practicing those methods. The present invention can also be embodied in the form of program code embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other machine-readable storage medium, wherein, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. The present invention can also be embodied in the form of program code, for example, whether stored in a storage medium, loaded into and/or executed by a machine, or transmitted over some transmission medium or carrier, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. When implemented on a general-purpose processor, the program code segments combine with the processor to provide a unique device that operates analogously to specific logic circuits.
Unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word “about” or “approximately” preceded the value of the value or range.
It will be further understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated in order to explain the nature of this invention may be made by those skilled in the art without departing from the scope of the invention as expressed in the following claims.
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A cooling apparatus, method and article of manufacture are disclosed which provide for selectively providing power to an attached heat-dissipating apparatus having a cooling probe in thermal contact with a cooling unit, to remove heat generated by a heat-generating source within the computer to an external environment outside of the computer. Power may be conserved, portable battery life extended, higher-speed processors utilized, and overall dimensional characteristics of a personal computer may be slimmed and reduced by utilizing the apparatus with a personal computer. Heat energy is transferred across a thermal connection interface from the heat-generating source of the personal computer to a collection face of the apparatus, and thereafter collected heat energy is dissipated in relation to the available power of the power source and/or the planned operating speed of the processor.
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FIELD OF THE INVENTION
The invention pertains to devices which facilitate movement of housings, which might include electrical equipment, for installation or service purposes. More particularly, the invention pertains to such devices which incorporate multiple pivots whereby the housing can be moved in two directions while at the same time a particular orientation can be maintained.
BACKGROUND OF THE INVENTION
Various ways have been developed to provide access to mechanical and electrical equipment for installation or service. For example, removable panels have long been used to provide access. However, merely removing a panel or opening a door does not displace any of the equipment behind or adjacent to the panel or door to facilitate installation or service functions.
Alternately, electrical and electronic chassis have been mounted on pull-out slides which not only displace the chassis but can also provide a rotary degree of freedom. With such slides, the respective chassis can be both translated and rotated to present a bottom or a back panel for service or maintenance.
Hinges have also been used to make it possible to rotate housings, or other equipment for service. While hinges to permit the respective housings or equipment to be moved, such motion is limited to rotation through a particular angle.
Known solutions have not made it possible to conveniently and cost effectively move equipment temporarily out of the way so that other equipment in the immediate area can be serviced. This is especially a problem in installations where space is at a premium and the various devices, control systems, pumps motors and the like are assembled adjacent to an exterior housing or protective enclosure. Installation and service is always a challenge where it is necessary to work immediately next to a side wall or roof of a housing or enclosure. Where the installed equipment is bulky or heavy the problem is exacerbated.
There thus continues to be a need for devices which will conveniently and easily facilitate the movement of equipment. Preferably such devices will be able to support a wide range of weights or configurations while at the same time continuing to perform in harsher environments than in office buildings Preferably such divides will themselves be low maintenance, robust devices which can be incorporated into larger pieces of equipment without adding substantially to the cost of the associated housing or equipment being supported.
SUMMARY OF THE INVENTION
An equipment carrying device incorporates first and second spaced apart pivots. A two part support arm extends between the pivots. One part of the arm is at a selected angle relative to the other. Acceptable angles fall into a range of 35 to 135 degrees.
In one aspect, a single arm can be used. One pivot is rotatably coupled to a fixed pivot support. The other pivot is rotatably coupled to a device or housing to be supported.
As the supported device or housing is pulled or pushed, it can move in one or two directions. One direction is away from or toward the fixed pivot support. A second direction is generally perpendicular to the one direction. The relationship between the directions is set by the angle between the arms.
In one embodiment, the arms can be oriented at ninety degrees to one another. As the arms rotate about the fixed pivot support, a piece of equipment carried at the second pivot can be maintained at a fixed relationship to that support. Where the equipment is supported at a first position adjacent to a housing, it can be moved to a displaced second location. In this location, the equipment can retain the same orientation as when in the first position.
The device thus makes it possible to move equipment from an initial, operating position to a final, service position with little effort. Since the equipment is displaced in two directions, when in the final position it has been moved enough that the initial position has been vacated. An opening remains at the initial position through which maintenance personnel can access other equipment located behind the equipment which has been moved out of the way. The structure of the device provides flexibility in the orientation of the equipment when in the final position.
In another embodiment, heavier equipment can be supported for movement by using two arms. The pivot axes share a common center line.
In yet another embodiment, a hanger includes an angle bracket having first and second rigid members joined at an angle to one another. One end of the bracket is pivotably supported on a mounting post.
The housing is movable in two directions, in a horizontal plane, for access or service. The rigid members can be pivotably attached to one another. The housing can be rigidly coupled to one of the rigid members. Alternately, the housing can be pivotably coupled, at a central location to the rigid member.
Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1C taken together are perspective views of a system in accordance with the present invention;
FIG. 2A is a side elevational view of an alternate system in accordance with the present invention;
FIG. 2B is a top plan view of the system of FIG. 2A;
FIG. 2C is a side elevational view of an alternate form of a support post in accordance with the present invention;
FIG. 3 is a top plan view of another system in accordance with present invention;
FIG. 4 is a top plan view of yet another system in accordance with the present invention;
FIG. 5 is a top plan view of yet another system in accordance with the present invention;
FIG. 6 is a top plan view of yet another system in accordance with the present invention;
FIG. 7 is a top plan view of an embodiment of a different system in accordance with the present invention; and
FIG. 8 is a top plan view of yet another embodiment of a system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is susceptible of embodiment in many different forms, there are shown in the drawing and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.
FIGS. 1A-1C illustrate various views of an embodiment of a system 10 in accordance with the present invention. The system 10 can movably support the unit U from a fixed post P.
Where the post P is located adjacent to or within an opening O of a building B, the unit U can be moved linearly and/or arcuately into and away from the Opening O. When moved into the opening O, the Unit U assumes its normal operating location. The Unit U can be electrically connected via cabling and/or conductors C to other equipment located within the Building B.
The other equipment can include without limitation motors, sensors or transducers or the like, all without limitation. Also without limitation, the unit U can be a closed housing which carries control elements of various types therein.
For maintenance and service purposes, the system 10 enables the personnel to move the unit U away from the opening O to gain access to the building B. When service or maintenance work is concluded, the unit U is re-positioned, on the support system 10 , to again close off, at least in part, the opening O.
The system 10 includes at least one support element 12 which includes first and second rigid elongated sides 14 a , 14 b . Each of the sides has a free end, corresponding to free end 16 a and free end 16 b.
In the embodiment of FIG. 1 c , the sides 14 a, b of the element 12 are fixedly attached to one another at a region 18 . For stability and convenience, the system 10 can incorporate a second support element 12 ′ which is displaced from but substantially identical to the element 12 .
The first and second sides 14 a , 14 b are oriented at an angle 20 relative to one another. The angle 20 , in a preferred embodiment of the system 10 is on the order of 90°. However, the angle 20 can extend in a range from 30 to 150° without departing from the spirit and scope of the present invention.
Each of the free ends 16 b , 16 b ′ of the sides of 14 b , 14 b ′ carries a pivotable coupling, for example, a pin, a socket or any other pivotable coupling 22 b , 22 b ′. The adjacent post P carries a mating pivotable coupling element 24 b , 24 b′.
The unit U is pivotably attached to free ends 16 a , 16 a ′ of sides 14 a , 14 a ′. Each of the free ends 16 a , 16 a ′ carries a pivotable coupling which rotatable engages a respective coupling element 24 a , 24 a ′. The coupling elements 24 a , 24 a ′, which can be attached to the unit U by a bracket such as would be known to those of skill in the art, in conjunction with the coupling elements 24 b , 24 b ′ make it possible to translate and rotate the unit U out of the opening O and off to the side for service access within the building B. Motion can be both arcuate 30 a and linear 30 b.
As will be understood by those skill in the art, the elements of the system 10 can be varied without departing from the scope of the present invention. For example, FIGS. 2 a and 2 b illustrate alternate embodiment 10 ′ in accordance with the present invention. The system 10 includes first and second support elements 12 - 1 , - 2 comparable to the elements 12 , 12 ′ of the system 10 . In the system 10 ′, the unit U is supported by centrally located pivoting joints 24 a - 1 , 24 a ′- 1 . Hence, the unit U can be rotated on the two pivots illustrated in the system 10 ′ for both arcuate and linear displacement.
FIG. 2C illustrates a post P′- 1 which has a two-part telescoping structure for purposes of moving the unit U vertically in addition to the previously discussed motion in a horizontal plane.
FIGS. 3 through 6 illustrate multi-pivot support structures in accordance with the present invention with various illustrated alternative configurations. As those of skill in the art will understand, the support structures of FIGS. 3 through 6 as was the case with systems 10 , 10 ′ support the respective unit U for movement in both linear and arcuate directions simultaneously.
FIGS. 7 and 8 illustrate single-pivot systems 40 and 50 in accordance with the present invention. In each of systems 40 , 50 , at least support element having first and second sides oriented at an angle therebetween, for example 42 a , 42 b or 52 a , 52 b are movably supported by a pivotable joint carried on a respective post P- 1 , P- 2 . In the embodiments of FIGS. 7 and 8, the unit U is fixedly attached, without relative motion, to the respective side of 42 a , 52 a . Notwithstanding the presence of only a single pivoting axis, adjacent to the respective supporting post P- 1 , P- 2 , the systems 40 , 50 will move the support of unit U both arcuately and linearly relative to the support post P- 1 , P- 2 .
In all instances, the embodiments disclosed herein make it possible to translate and rotate a support of the unit such as the unit U into and out of an opening of an enclosure or building for purposes of service and maintenance. The support of the unit U remains electrically connected to equipment within the structure to facilitate maintenance and service while the unit U has been moved from its normal operating position to its service position.
From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.
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A control panel, which might be enclosed within an openable housing, can be movably supported on a pivotable support structure. The support structure which incorporates one or more pivot points facilitates movement of the control panel from a normal operational position to a displaced maintenance/service position the control panel can be moved both arcuately and linearly on the support element.
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FIELD OF THE INVENTION
This invention relates to insulated automotive exhaust pipe systems and, more particularly, to means for attaching an insulated exhaust pipe to the engine manifold or another element in the exhaust system.
BACKGROUND OF THE INVENTION
The use of catalytic converters to reduce the output of pollutants from the exhaust of vehicles powered by internal combustion engines has brought out the need to insulate the exhaust pipe leading to the converter in order to deliver gases at high temperatures. Because the catalytic converter does not begin to catalyze the reaction in the converter until its light-off temperature is reached, by reducing the heat loss of the exhaust gases delivered to the catalytic converter the period during which pollutants are released is also reduced, resulting in a lesser total amount of pollutants released to the atmosphere.
Efforts to insulate the exhaust pipe have centered on the use of high temperature insulation on the pipe, with the insulation held in place by another larger pipe concentrically spaced from the exhaust pipe. To withstand the high temperatures of the exhaust gases refractory fiber is the preferred insulating material. To reduce the thermal mass of the exhaust pipe, which also contributes to maintaining the high temperatures of the exhaust gas and thus aids in reducing the catalytic light-off period, very thin metal tubing has been proposed for use as the exhaust pipe.
Exhaust pipe structure of this type is difficult to attach to the manifold or other elements of the exhaust system. The fragile nature of the refractory fiber insulation and the thin metal tubing give the pipe little resistance to crushing or deformation by clamps designed to hold the ends of the pipe in place through high pressures. If the pipe is not securely held in place, however, the vibration to which it would be subjected in time degrades the refractory fibers, reducing them to dust-like particles and destroying their insulating value. Further, the attachment should prevent the escape of gases from the inner tube into the insulation. This can readily occur at the end of the pipe, resulting in the outer pipe being exposed to the hot gases and increasing the heat loss from the exhaust pipe.
It is thus an object of the invention to provide an exhaust pipe attachment means which does not damage the pipe or the insulation but nevertheless holds the pipe securely in place against vibration. It is also an object to prevent exhaust gases from entering the insulation at the end of the pipe.
SUMMARY OF THE INVENTION
In accordance with the invention an attachment conduit is provided which is attached at one end to an element, such as the manifold, in the exhaust system. The other end of the conduit extends into an end of the inner corrugated metallic tube of the insulated pipe. The conduit includes means extending transversely therefrom which engages at least one corrugation of the inner metallic tube to assist in holding the insulated pipe in place. Because the corrugated tube is formed from a spirally wound corrugated metal strip, the corrugations extend at an angle to the axis of the pipe. The transversely extending means on the conduit are also aligned at an angle corresponding to the angle of the corrugations, enabling the conduit to be threaded into the pipe. Preferably, the transversely extending means are lugs comprising ears stamped from the ends of the conduit.
In addition, a cap is slidably mounted on the conduit so that the end of the exhaust pipe is received between the cap and the conduit. This allows the conduit to be freely threaded onto the conduit. A stop on the exhaust pipe is provided to stop the sliding movement of the cap to allow the conduit to be tightly secured to the exhaust pipe. The end of the exhaust pipe would thus be tightly pressed against the end of the cap.
Other features and aspects of the invention, as well as other benefits thereof, will readily be ascertained from the more detailed description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of the type of insulated exhaust pipe to be attached by the attachment means of the present invention to an element of an automotive exhaust system;
FIG. 2 is a transverse sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a pictorial view of a modified insulated exhaust pipe to be attached by the attachment means of the present invention;
FIG. 4 is an exploded pictorial view of the attachment means of the invention;
FIG. 5 is an end view of the attachment means with the slidable cap shown mounted on the attachment conduit;
FIG. 6 is an enlarged partial sectional view showing the attachment means in the initial stage of being threaded into the end portion of an exhaust pipe;
FIG. 7 is an enlarged partial sectional view showing the attachment means after it has been fully threaded into the end portion of an exhaust pipe;
FIG. 8 is a transverse sectional view showing the attachment means connected to the manifold of an automotive engine;
FIG. 9 is a partial side view showing a modified mounting flange arrangement;
FIG. 10 is a pictorial view of a modified attachment tube; and
FIG. 11 is a front elevational view of the modified attachment tube of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the exhaust pipe attachment means of the present invention is designed to be used in connection with an insulated exhaust pipe of the type shown in FIGS. 1 and 2. In this exhaust pipe arrangement the annular space between the inner and outer corrugated metallic tubes 10 and 12, respectively, is filled with high temperature insulation such as refractory fiber insulation 14. The corrugated tube walls are typically very thin, in the range of 0.005 inch to 0.010 inch, in order to reduce the weight of the pipe and to reduce the thermal mass as a means of minimizing heat loss. The corrugated tubes are typically produced by introducing a corrugated strip at an angle to a forming mandrel and attaching adjacent strips to each other along a seam. This produces a tube the corrugations of which extend helically about its periphery in much the same manner as the thread of a screw. A more complete description of an insulated exhaust pipe of this type and its manufacture may be found in application Ser. No. 07/386,754 filed of even date herewith in the name of David William Bainbridge.
Because refractory fibers are very fragile, the clamping attachment to the exhaust system must hold the pipe firmly in place to prevent undue vibration that can cause the fibers to be reduced to dust-like particles. Even when using a pipe such as that shown in FIG. 3, described in more detail in the aforementioned application Ser. No. 07/386,754, wherein spacer strips 16 of higher density refractory fiber are embedded in the low density fiber layer to hold the low density fibers in place as a preventive measure against the effects of vibration, it is still essential that the pipe attachment hold the pipe solidly in place. Moreover, the clamp cannot be made so tight that the tube ends are squeezed together, as this could result in metal-to-metal contact, which is detrimental to the heat and sound insulating properties of the pipe, and in crushing the fibers, thereby destroying much of their insulating value at that location.
Referring to FIGS. 4 and 5, the exhaust pipe attachment of the invention comprises a conduit 18 welded at one end, as at 20, to a mounting flange 22. The mounting flange contains three equally spaced elongated bolt holes 24 to facilitate mounting the assembly to a manifold or other element in an automotive exhaust system. At the other end of the conduit tabs 26 have been stuck from the conduit end for a purpose to be explained hereinafter. Spaced from the tabs is a circumferential protrusion 28 which acts as a stop for cap 30. The cap 30 comprises an end wall 32 containing an opening 34 through which the conduit fits. The opening is large enough to allow the cap to slide on the conduit but is smaller than the protrusion 28. Extending axially of the conduit and spaced therefrom is a sleeve portion 36. The sleeve portion is thus concentrically arranged with respect to the conduit and forms with the conduit an annular space 38.
Turning now to FIG. 6, to install the attachment to a corrugated insulated exhaust pipe the end of the conduit containing the tabs 26 is aligned with the exhaust pipe so that the pipe fits into the annular space between the conduit 18 and the sleeve portion 36 of the cap. The conduit is then rotated in a direction corresponding to the alignment of the corrugations of the pipe. Thus the conduit 18 is rotated so that each of the tabs 26 engages a corrugation on the inside diameter of the inner tube 10. Rotation of the conduit will then cause the engagement of the tabs and corrugations to have a threading action, resulting in the exhaust pipe being drawn toward the mounting flange. Because the cap 30 is slidably mounted on the conduit 18, the drawing of the pipe toward the mounting flange results in the pipe pushing the cap to slide it along the conduit in the same direction. The initial stage of such a threading action is illustrated in FIG. 6.
Continued rotation of the conduit will cause the conduit to move into the pipe until the cap is pushed against the protrusion 28. The protrusion thus acts as a stop to the threading action. When this occurs the conduit is turned still more to apply a torque to the conduit to secure the end of the pipe tightly against the end wall 32 of the cap. This final stage of the threading action is illustrated in FIG. 7. Preferably, a coating of ceramic adhesive is first applied to the end wall 32 to act as a seal or gasket to further assure against the escape of exhaust gases into the fibrous insulation 14.
To provide for the threading action to take place it is necessary to align the tabs 26 at an angle to the axis of the attachment which corresponds to the angle of the corrugations of the inside diameter of the inner pipe 10. Obviously, the angle will be the same as the angle at which the corrugated strip used to form the corrugated tube 10 has been fed to the axis of the forming mandrel. While this may vary, an angle of 20° from a plane extending at right angles through the axis of the conduit 18 would be typical.
Although the tabs 26 have been described as being formed by striking them from the end of the conduit, this is just one way in which they may be provided. Any transversely extending lugs lying at the proper angle would perform the same function, regardless of whether they are an integral part of the conduit, as the struck tabs would be, or are separate extensions affixed, as by welding, to the conduit. Although two tabs have been disclosed as the preferred arrangement due to the ease with which the threading operation can be carried out and for the holding power they provide, the number of tabs or lugs is not limited to two. One or even three or more lugs may be used as long as the desired function is provided.
The protrusion 28 in the conduit 18 has been described as circumferential or annular. This is the preferred arrangement because it can readily be formed by stamping a groove in the inside diameter of the conduit which results in a bulge or protrusion on the outside diameter. Any form of stop means can be used, however, as long as it is strong enough to withstand the pressure of the end cap being pushed against it due to the torque applied during the attachment operation. For example, tabs could be struck up from the conduit wall at spaced peripheral locations, or separate stop members could be welded to the conduit.
Once the attachment has been permanently secured in place the mounting flange can be aligned with the mounting holes in the exhaust system element to which the exhaust pipe is to be attached, and the mounting flange can be bolted to the element. Thus in FIG. 8 the pipe attachment is shown bolted to the attachment flange 42 of the engine manifold of an automotive engine. The three bolt holes 24 provided in the mounting flange 22 make it possible for them to be aligned with the holes in the attachment flange 42 with only a small amount of rotation of the attachment means being required. The exhaust pipe can readily absorb this degree of torque or stress during installation due to its helical corrugated design. This would not be possible with the more conventional solid or welded bellows type of exhaust pipe. Because the pipe design makes it possible to use a flat mounting flange such as that shown at 22, a smaller amount of space is taken up on installation, resulting in a greater portion of the length of the exhaust pipe system being insulated.
As shown in FIG. 9, a different mounting flange arrangement can be used if it is desired to apply less torque to the pipe when attaching it to the manifold or other element in the exhaust system. The flange 44 is slidably mounted on the conduit 18 and is used in conjunction with a flared portion 46 on the end of the conduit. This enables the mounting flange to be rotated to align the mounting holes with the mounting holes in the attachment flange of the manifold or other element. While this design has the advantage of lessening the stress on the exhaust pipe during mounting, it has the disadvantage of requiring more space for maneuvering during the mounting operation, requiring the length of the conduit between the mounting flange and the annular stop to be increased, thereby resulting in less of the exhaust pipe system being insulated.
If desired a variation of the exhaust pipe attachment may be used such as that shown in FIGS. 10 and 11, wherein like reference numerals to those of FIG. 4 denote like elements. In this embodiment the tube 18' does not have a straight-cut end with tabs but is provided instead with a helical end portion 50. The side edges of a notch or cutout 52 in the end of the tube 18' allow for the end of the tube to be helically shaped, the helical end portion beginning at the short side edge 54 and ending at the long side edge 56. The helical end portion 50 is formed with a rim or flange 58 which engages with the corrugations on the inside diameter of the inner tube of an insulated exhaust pipe to thread the attachment and pipe toward the mounting flange as in the embodiment of FIG. 4. The helical end portion provides greater surface contact with the corrugations than the tabs of the embodiment of FIG. 4 and can exert more force on the tube during the mounting operation.
It should now be understood that the invention is not necessarily limited to all the specific details described in connection with the preferred embodiment but that changes which do not affect the overall basic function and concept of the invention may be made by those skilled in the art without departing from the spirit and scope of the invention, as defined in the appended claims.
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Attachment means for connecting an insulated pipe to an element, such as the manifold, in the exhaust system of a vehicle. The attachment means includes a conduit which extends into the end of the insulated pipe. A transverse lug or a helical flange on the conduit engages the spiral corrugations of the inner diameter of the pipe to allow the conduit to be threaded into the pipe. The end of the pipe is received in an end cap slidably mounted on the conduit. When the cap hits a stop on the conduit during threading of the conduit into the pipe the lug or helical flange pulls the pipe against the cap, tightening the connection to the pipe.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to ladder apparatus, and more particularly pertains to a new and improved adjustable ladder apparatus wherein the same is arranged for providing selective extension of each ladder leg to accommodate uneven underlying support surfaces.
2. Description of the Prior Art
Positioning a ladder relative to a supporting structure upon an underlying surface is a typical utilization of a ladder apparatus. Frequently, however, when a ladder is not mounted upon a level surface, accident and inadvertent associated tippage of the ladder is available. Such situations effect a dangerous condition wherein associated loss of time and individual health is effected. Ladder structure is available in the prior art to provide for relative telescoping leg structure, but have heretofore been of structure to provide such relative relationship in the prior art. Such structure is exemplified in U.S. Pat. No. 4,423,797 to Batten wherein sleeves mounted to side walls of spaced parallel ladder legs are mounted relative thereto.
U.S. Pat. No. 4,090,486 to Pears sets forth a ladder stabilizing apparatus wherein a sleeve mounted to an exterior wall of each ladder leg threadedly mounts an extension leg.
U.S. Pat. No. 4,792,017 to Grove sets forth a ladder leg extension structure utilizing locking nut means mounted thereto.
U.S. Pat. No. 4,852,689 to Erion provides for a ladder leveling apparatus utilizing aligned apertures permitting selective telescoping of an extension leg relative to each ladder leg.
As such, it may be appreciated that there continues to be a need for a new and improved adjustable ladder apparatus as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in compactness of construction and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of ladder apparatus now present in the prior art, the present invention provides an adjustable ladder apparatus wherein the same utilizes extensible legs relative to each ladder leg to accommodate uneven support surfaces mounting the ladder structure of the invention. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved adjustable ladder apparatus which has all the advantages of the prior art ladder apparatus and none of the disadvantages.
To attain this, the present invention provides a ladder apparatus including a plurality of spaced parallel ladder legs, with each ladder leg telescopingly mounting an extension leg relative to each ladder leg to accommodate uneven surface conditions. Interlocking structure is provided to secure each respective extension leg relative to a receiving cylinder relative to each ladder leg.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved adjustable ladder apparatus which has all the advantages of the prior art ladder apparatus and none of the disadvantages.
It is another object of the present invention to provide all new and improved adjustable ladder apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved adjustable ladder apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved adjustable ladder apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such adjustable ladder apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved adjustable ladder apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an orthographic view, taken in elevation, of a typical ladder extension construction of the instant invention.
FIG. 2 is the invention relative to an underlying undulating support surface.
FIG. 3 is an isometric illustration of a modification of the invention.
FIG. 4 is an isometric illustration of a further modification of the invention.
FIG. 5 is an isometric illustration of a further modification of the instant invention.
FIG. 6 is an isometric illustration of a further clamp structure utilized by the instant invention.
FIG. 7 is an isometric illustration of a yet further clamp structure utilized by the instant invention.
FIG. 8 is an orthographic view, somewhat enlarged, of section 8 as set forth in FIG. 5.
FIG. 9 is an isometric illustration of sleeve structure utilized by the clamp construction of FIG. 7.
FIG. 10 is an isometric illustration of the sleeve structure as set forth in FIG. 9 arranged in a planar configuration.
FIG. 11 is an orthographic view, taken along the lines 11--11 of FIG. 10 in the direction indicated by the arrows.
FIG. 12 is an isometric illustration of a further modification of the invention.
FIG. 13 is an isometric illustration of a yet further modification of the invention.
FIG. 14 is an orthographic view, taken along the lines 14--14 of FIG. 13 in the direction indicated by the arrows.
FIG. 15 is an isometric illustration of a modified clamp structure of a yet further modification of the invention of FIG. 13.
FIG. 16 is an orthographic view, taken along the lines 16--16 of FIG. 15 in the direction indicated by the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 16 thereof, a new and improved adjustable ladder apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the adjustable ladder apparatus 10 of the instant invention essentially includes in the construction as set forth in FIG. 1 for example, a plurality of parallel ladder legs 11 that are directed coextensively relative to one another and include spaced ladder rungs 12 directed orthogonally between the ladder legs. Each of the ladder legs 11 includes a ladder leg extension 13 reciprocatably mounted within each ladder leg, with a support foot 14 pivotally mounted at each lower terminal end of each ladder leg extension.
The construction of FIG. 3 illustrates the use of a tube member 16 mounted exteriorly and in a parallel spaced longitudinally aligned relationship relative to each ladder leg 11 to include a lock pin 17, with a lock pin eye 17a mounting a tether line 18 to the lock pin eye and to a respective tube member 16. A first plurality of apertures 19 are directed through the tube 16 adjacent a lower terminal end thereof aligned with a second aperture 20 through the respective ladder leg 16. Telescoping extension leg 21 is reciprocatably mounted within the respective tube members 16 to include a plurality of extension leg apertures 22 spaced apart at equal spacings and diametrically directed through the extension leg 21 to receive the lock pin 17 through the first apertures 19, the extension leg apertures 22, and the associated second aperture 20 simultaneously to maintain each extension leg in an extended relationship.
The organization 10b, as set forth in FIG. 4, includes a modified tube member 16a that is internally threaded to threadedly receive in an adjustable manner an associated externally threaded extension leg 23. An internally threaded lock collar 24 threadedly mounted about each respective extension leg 23 when threaded into abutment with a lower terminal end of the associated modified tube member 16a effects positioning in a fixed manner of an extension leg relative to an associated tube member 16a.
The construction of FIG. 5 set forth as the apparatus 10c utilizes the externally threaded extension leg 23 threadedly received within the telescoping extension leg 21 that is adjustably securable to the modified tube member 16, in a manner as described in reference to FIG. 3 and the apparatus 10a. The lower terminal end of the externally threaded leg 23 in the construction of FIG. 5 utilizes a support plate 26, including a ball and socket interconnection 25 between the lower terminal end of the leg 23 and the plate 26 that may also include a friction plate surface 27 formed of a polymeric type material to enhance frictional engagement with an underlying surface.
The construction of FIG. 6 utilizes an externally threaded conical lower tube end 28 mounted to the tube 16, wherein the tube end 28 includes an internally threaded cap 29 defining a collet structure to effect inter-engagement and locking of the extension leg 30 relative to the tube member 16.
The construction of FIG. 7 is a yet further modified locking arrangement of an extension leg relative to a ladder leg 11, wherein the extension leg 13 is reciprocatably mounted within an associated spring-biased split cylindrical lock sleeve 31 whose cylindrical wall is split to define a gap parallel to an axis defined by the associated lock sleeve 31. A plurality of clamps 32 are provided, wherein each clamp includes a clamp loop 34 on a first side of the gap to cooperative with a respective clamp boss 33 on an opposed side of the gap to effect locking of an extension leg 13 received within the associated sleeve 31. It should be understood that each ladder leg 11 utilizes a like construction, wherein for purposes of illustration only one such construction is illustrated. A resilient liner 35 is coextensively formed with an interior surface of the lock sleeve 31 and is formed by a series of equally spaced parallel friction ribs 36. The friction ribs 36 each include an inclined ribbed top surface 38 defining an acute angle, with a planar rib wall 40. The planar rib wall 40 of each of the ribs 36 are arranged in a parallel relationship relative to one another, wherein the planar rib walls 40 face an upper terminal end of the sleeve 31 in an opposed orientation relative to the lower terminal end of each of the legs 11, whereupon clamping of the sleeve 31 effects enhanced engagement with the associated extension leg 13. Further, each of the friction ribs 31 includes a plurality of suction cavities 37 in communication with the rib top surface 38 through a suction cavity conduit 39. Upon compression of the extension leg 13 within a split sleeve and associated resilient liner 35, expelled air due to compression of the suction cavities 37 positioned below each top surface 38 of each rib 36 effects enhanced suctioning and engagement of the extension leg 13 relative to the liner 35 and associated lock sleeve 31 in use.
The FIG. 12 illustrates the use of the outer tube 50 mounted relative to the ladder rail 11, wherein an adjusting clamp 53 includes a "T" bar screw 52 orthogonally mounted to an upper terminal end of the screw rod 54, whereupon tensioning of the clamp structure relative to a split forward end 50a of the outer tube 50 effects a tightening or loosening of the adjustable leg 55 permitting its relative telescoping to the outer tube 50. The organization of FIG. 13 includes a "T" bar adjusting screw 58 diametrically directed through the outer tube 56 to effect a loosening or tightening as required of the adjustable leg 57, wherein the adjustable leg includes a serrated pattern 57a cooperative with a "T" bar screw 58. To this end, reference to FIG. 14 illustrates the serrated clamping foot 59 cooperative with the portion 57a to effect the aforenoted clamping relative to the adjustable leg 57. The modification of FIG. 15 may include a frictional clamping foot 59 directed interiorly of the sleeve 50 to provide for selective clamping of the adjustable leg 57, in a manner as discussed relative to the organization as set forth in the FIGS. 13 and 14.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
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 ladder apparatus including a plurality of spaced parallel ladder legs, with each ladder leg telescopingly mounting an extension leg relative to each ladder leg to accommodate uneven surface conditions. Interlocking structure is provided to secure each respective extension leg relative to a receiving cylinder relative to each ladder leg.
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FIELD OF THE INVENTION
[0001] The invention relates to a safety system for detecting the presence of living beings inside a lockable, or alternatively dangerous housing area, particularly the washing housing area of a washing machine or of a clothes dryer, a stove, a microwave oven, as well as also particularly in closets and chests.
OBJECT OF THE INVENTION
[0002] The object of the invention is to provide solutions by which the presence of living beings in a the housing area is detected and dangers to the living beings, particularly small children and pets, can be reliably avoided.
SOLUTION ACCORDING TO THE INVENTION
[0003] According to a first aspect of the present invention the object at the beginning is solved by means of a safety device for detecting the presence of living beings inside a dangerous housing area with:
a first electrode device which, as such, is facing the housing area and is a component of a LC network, and a second electrode device which is also facing the housing area and is a component of a LC network, and an evaluation circuit for detecting the dynamics of electric field interactions with at least one of the two electrode devices, wherein the detected dynamics is compared with the comparison values provided for the current working condition of the housing area, so that, if the detected dynamics differs from the provided comparison values, a safety function is activated.
[0007] The safety function can consist in stopping a dangerous operation, particularly in an appliance disconnection. Moreover, it is possible to form the appliance in such a way that the safety function consists in an alarm issue. This alarm issue can particularly occur in acoustic, and/or visual ways. Moreover, it is possible to form the appliance in such a way that the safety function consists in unlocking a door device.
[0008] Preferably the safety device is formed in such a way that the safety function requires an user's activation to continue the operation. Such an user's activation for example can consist in a required opening of a door and preferably also in reaching into the housing space. This reaching into is also accomplished in advantageous way on the basis of electric field interaction effects, particularly directly through the receiving electrodes.
[0009] Preferably, first of all a starting operation with reduced dynamics is promptly started. By this it is possible first of all to shake awake a possibly asleep cat and to detect it reliably through its own movement. According to that starting operation the presence of dynamic characteristics is preferably checked.
[0010] The first electrode device is preferably operated as a transmitting electrode, for the coupling of an electric field in a section of the housing area to be observed.
[0011] The second electrode device is preferably constructed as a receiving electrode device. Both electrode devices are preferably operated in such a way that differences of the electric fields adjacent to them are detected.
[0012] Particularly in the case of a washing machine, or of a clothes dryer, the transmitting field is preferably generated by electrode devices which are connected to a housing drum. The receiving electrodes are preferably connected to a detection circuit which as such generates signals which are caused by differences between the fields adjacent to the receiving electrodes, or by bridging effects between the two receiving electrodes. A technical signal feedback of the events detected through the detection circuit to a server circuit can occur by means of the transmitting electrode system. Here the detection circuit is preferably supplied with energy by means of the electric field adjacent to the receiving electrodes. The signal feedback to the transmitting electrode system can occur particularly through impedance modulation in the area of the receiving electrodes.
[0013] According to a further aspect the invention also deals with a contact and approach detection by means of capacitive sensors.
[0014] In this respect, the invention relates to a sensor device for detecting an approach of an object in an observation area monitored by the sensor device.
[0015] The object of the invention is to show solutions by which the presence of objects, particularly of living beings, in the observation area can be reliably sensed or detected.
[0016] Therefore, according to the invention, a sensor device is provided for detecting an approach of an object in an observation area monitored by the sensor device in which the sensor device comprises a server circuit with:
a LC oscillatory circuit with a signal-generating circuit, preferably a high-quality LC oscillatory circuit, for generating an electric field, an electrode device coupled with the LC oscillatory circuit in which the capacitance of the electrode device is a component of the oscillatory circuit capacitance and in which the electric field generated by the LC oscillatory circuit can be radiated on the electrode device in the observation area, and an evaluation device, wherein the approach of an object, particularly of a living being, in the observation area of the electrode device causes a change in the capacitive environment of the electrode device, which is detectable by the evaluation device.
[0020] Preferably the signal-generating circuit is constructed as an oscillator and the LC oscillatory circuit as a LC series resonant circuit, where the electrode device is connected in parallel to the LC oscillatory circuit. The oscillator and the LC series resonant circuit can thus form a free-running LC oscillator.
[0021] The LC oscillatory circuit can also be constructed as a LC parallel resonant circuit in which the electrode device is connected in series to the LC oscillatory circuit.
[0022] Further embodiments of the LC oscillatory circuit and of the arrangement of the electrode device for the LC oscillatory circuit are possible.
[0023] The high-quality LC series resonant circuit leads to an effective increase in the voltage amplitude in the electrode device, as well as to an increased sensitivity to load modulation in this electrode device. The high quality of the LC series resonant circuit at the same time implies that it generates a very stable frequency, which depends on the inductance and capacitance values in the oscillatory circuit.
[0024] The sensor device is preferably operated in such a way that the change in the capacitive environment of the electrode device causes a change in the frequency of the (free-running) LC oscillator, where the frequency change is detectable by the evaluation device. The approach of an object in the observation area of the electrode device thus leads to a change in the capacitive environment of this electrode device, which in turn leads to a change in the oscillator frequency. Therefore, through the approach of an object the oscillator signal is frequency modulated, where this frequency modulation is detectable by the evaluation device.
[0025] The signal-generating circuit can also be constructed as a generator. Preferably the generator is then operated in resonance to the LC oscillatory circuit, which has the advantage that even particularly small capacitance changes, for example capacitance changes of 1 pF or smaller, can be detected in the electrode device. In this case the capacitance change in the electrode device is detected by the evaluation device on the basis of the signal phase shift.
[0026] The server circuit can advantageously be operated also in conjunction with at least one client circuit. To this end, the sensor device also comprises at least one client circuit, with:
[0027] a second electrode device, comprising at least one first electrode and at least one second electrode, and
[0028] a modulation device coupled with the second electrode device in which the electric field radiated by the electrode device of the server circuit can be coupled with the first electrode of the second electrode device in which the coupled electric field can be modulated through the modulation device, wherein the modulated signal can be sent back through the electrode device of the server circuit, preferably by means of load modulation, to the server circuit and in which the signal sent back can be detected and evaluated by the evaluation device.
[0029] In this way, in a particularly advantageous embodiment of the invention a sensor device is provided, which allows to detect the approach of an object to the electrode device of the server circuit in case of simultaneous modulation of the signal radiated by the electrode device of the server circuit through the client circuit, where through the evaluation device, besides the frequency modulation, the modulation through the client circuit is detectable as well.
[0030] The approach of an object to the second electrode of the second electrode device can cause a modulation of the coupled electric field through the modulation device. In this way the evaluation device, besides the approach of an object to the electrode device of the server circuit, can also detect the approach of an object to the second electrode of the client circuit. The evaluation device can also detect the presence of an object on the second electrode of the client circuit, for instance the presence of a lint filter in a clothes dryer.
[0031] The first electrode can also be formed through the electrode device of the server circuit, so that a capacitive coupling of the electric field of the first electrode of the second electrode device is not necessary. In this embodiment, too, an approach of an object to the second electrode of the second electrode device causes a modulation of the electric field generated by the electrode device of the server circuit.
[0032] The coupling of the electric field to the first electrode of the client circuit can take place through bridging, where the bridging causes a modulation of the coupled electric field through the modulation device. Because of the bridging effect, the client circuit can be arranged with respect to the server circuit in such a way that an approach of an object, particularly of a living being, in the area between the electrode device of the server circuit and the first electrode of the client circuit is detectable. In such an arrangement of the client circuit with respect to the server circuit the second electrode of the client circuit is preferably coupled to earth.
[0033] With the coupled electric field the client circuit can be also supplied with energy, so that a client circuit without internal power supply can be made, which is particularly advantageous especially in terms of size and of field of application.
[0034] The modulation device is preferably constructed in such a way that the coupled electric field is amplitude-modulated, where the change in the amplitude is detectable by the evaluation device.
[0035] Preferably an approach of an object in the observation area of the electrode device of the server circuit is detectable, whereby an approach of the object to the second electrode of the second electrode device is also detectable.
[0036] More preferably, an approach of an object in the observation area of the electrode device of the server circuit is detectable just before the approach of the object to the second electrode of the second electrode device. In this way, an approach of an object to the sensor device can be detected even before the detection of an approach of the object to the client circuit.
[0037] Moreover, the invention also deals with a sensor device for determining the amount and/or the degree of humidity of the washing in a clothes dryer.
[0038] In this context, the invention relates to a sensor device for a clothes dryer with a drum which, with the aid of an electric field radiated in the drum of the clothes dryer, determines the amount and/or the degree of humidity of the washing situated in the drum.
[0039] The optimization of the drying process in a clothes dryer with respect to the necessary time and energy consumption requires knowledge of the amount of wet washing or of the water contained in the washing.
[0040] In the prior art, it is known to determine the degree of humidity of wet washing in a clothes dryer with the aid of special water sensors in conjunction with a software analysis. In this respect, it is disadvantageous that the water sensors must be arranged inside the drum or that the water sensors are located in direct contact with the wet washing situated in the drum.
[0041] In order to ascertain the amount of wet washing in a drum, in the prior art it is known, for example, to determine the weight of the washing placed in the washing drum. From the weight it is also possible to infer the amount of water contained in the washing. In particular, this method has the disadvantage that the own weight of the washing, for example of a heavy jacket, is not considered. In order to avoid this disadvantage, in the prior art it is known to lengthen the drying time, in order to certainly guarantee the drying of the washing. This leads to the fact that in certain conditions the drying process lasts longer than necessary which, at the same time, also means a higher energy consumption.
[0042] Therefore, the object of the present invention is to provide a sensor device for a clothes dryer for determining the amount and/or the degree of humidity of the washing placed in the drum of the dryer and to avoid the disadvantages of the prior art at least partially.
[0043] According to the invention it is thus provided a sensor device for a clothes dryer, where the sensor device comprises:
[0044] a circuit for generating an electric field, which can be radiated on at least one electrode coupled to the circuit, and
[0045] a evaluation circuit for detecting electric field interactions between the at least one electrode and a counter electrode in which the electrode is arranged in the area of the drum and is insulated from the drum and in which the detected electric field interactions are characteristic of the amount and/or the degree of humidity of the washing situated in the drum.
[0046] The special advantage of the sensor device according to the invention is that, by using electric field interactions or capacitance changes between an electrode and a counter electrode, the degree of humidity of the washing which is placed in the drum of a clothes dryer can be determined particularly well. Additionally, with the sensor device according to the invention, the amount of washing can be ascertained as well. Another advantage is that the energy efficiency of a clothes dryer can be improved or that energy consumption can be considerably reduced.
[0047] Moreover, the electric field interactions detected by the evaluation circuit are also characteristic of the drum rotation. Thereby, it is possible to easily determine if the drum is moving or not.
[0048] Preferably, the circuit has a free-running LC oscillator for generating the electric field or the electrode voltage on the electrode coupled with the circuit.
[0049] Thereby, the LC oscillator can consist of a serial LC oscillatory circuit in which the electrode is part of the capacitance of the oscillatory circuit. In this way, the necessary increase in the electrode voltage in the electrode is achieved as well.
[0050] The circuit can also be used as a server circuit, whereby the electrode serves as a server electrode. In this way, other events in the washing drum can be detected as well.
[0051] The sensor device is constructed in such a way that the rotation of the drum causes a change in the capacitive environment of the electrode, which causes a frequency modulation of the oscillator frequency of the circuit. From the frequency-modulated oscillator frequency the rotation of the drum and/or the degree of humidity of the washing and/or the amount of washing in the drum can be deduced or determined.
[0052] In a preferred embodiment the electrode is arranged asymmetrically with respect to the vertical axis in the drum. In this way it is also possible to determine the drum rotation direction, provided that (wet) washing is situated in the drum.
[0053] However, the rotation direction can also be known, so that with the aid of the rotation direction from the frequency-modulated signals the amount of washing or the degree of humidity of the washing can be determined.
[0054] Two similar frequency-modulated signals with respect to both drum rotation directions are characteristic of a fully loaded drum. From this it can be deduced that the capacitive environment of the electrode during a drum rotation changes only very little or does not change at all, when the drum is fully loaded, as in the drum there is not enough space for the washing to move inside the drum.
[0055] The electrode can also be constructed in such a way that the drum rotation direction can be determined also without (wet) washing in the drum. For example the electrode itself can be asymmetrically shaped with respect to its own axis or the electrode can develop asymmetrically with respect to the drum rotation direction (cf. FIG. 2 ).
[0056] The counter electrode too can have an asymmetrical shape. The shape of the counter electrode can also develop asymmetrically with respect to the drum rotation direction.
[0057] The at least one counter electrode can be arranged on at least one of the drum lifters, whereby the counter electrode is preferably arranged on the electrode-facing side on the lifter.
[0058] In a particular embodiment of the invention the at least one counter electrode can consist of at least one drum lifter. In this embodiment it is particularly advantageous that inside the drum no additional means or instruments must be provided for the operation of the sensor device according to the invention. This allows a particularly inexpensive and low-expenditure installation of the sensor device according to the invention in a commercial clothes dryer.
[0059] In a further embodiment the counter electrode is made up of the washing itself.
[0060] In a further aspect the invention deals with a method for determining the rotation of a clothes dryer drum and/or the amount and/or the degree of humidity of the washing in a washing drum, where the method comprises at least one of the following steps:
[0061] 1) Rotating the drum clockwise;
1.1) Determining the relative changes in the signal by using the sensor device according to the invention; and/or 1.2) Determining the absolute changes in the signal with respect to a predetermined reference signal by using the sensor device according to the invention;
[0064] 2) Rotating the drum counterclockwise;
2.1) Determining the relative changes in the signal by using the sensor device according to the invention; and/or 2.2) Determining the absolute changes in the signal with respect to a predetermined reference signal by using the sensor device according to the invention; 2.3) Comparing the results obtained in steps 2.1) and/or 2.2) with the results obtained in steps 1.1) and/or 1.2);
[0068] 3) Determining the drum rotation and/or the amount of washing and/or the degree of humidity of the washing.
[0069] Moreover, the method according to the invention can present a step for defining a reference signal, which is characteristic of a drum motion in the empty state. This reference signal can be stored in the sensor device, preferably in the server circuit, more preferably in the evaluation circuit. For this purpose, the sensor device, the server circuit or the evaluation circuit can be provided with an (additional) nonvolatile storage. A reference signal can be defined and stored both for a clockwise rotation and for an counterclockwise rotation. The reference signals with respect to both rotation directions in case of an empty drum differ, particularly, if the electrode develops asymmetrically with respect to its own axis.
BRIEF DESCRIPTION OF THE FIGURES
[0070] Further details and characteristics of the invention will appear from the following description in conjunction with the drawings in which:
[0071] FIG. 1 is a schematic representation which illustrates the workings of a safety device according to the invention in a clothes dryer;
[0072] FIG. 2 is a schematic circuit diagram which illustrates the workings of a circuit according to the invention constructed including the receiving electrodes particularly for a clothes dryer or a washing machine
[0073] FIG. 3 is a schematic representation which illustrates the arrangement of the electrodes in a clothes dryer or a washing machine;
[0074] FIG. 4 is another schematic representation which illustrates the arrangement of the electrodes in a clothes dryer or a washing machine;
[0075] FIG. 5 is yet another schematic representation which illustrates the arrangement of the electrodes in a clothes dryer or a washing machine;
[0076] FIG. 6 is a schematic representation which illustrates a field line progression;
[0077] FIG. 7 is another schematic representation which illustrates a field line progression;
[0078] FIG. 8 is another schematic representation which illustrates the arrangement of the electrodes in a clothes dryer or a washing machine;
[0079] FIG. 9 is a basic set-up of a circuit diagram of a server circuit of the sensor device according to the invention which illustrates the workings of the server circuit,
[0080] FIG. 10 is a basic set-up of a circuit diagram of a sensor device according to the invention, which comprises a server circuit and a client circuit in which a first variant of approach of an object to the sensor device is shown; and
[0081] FIG. 11 is a basic set-up of a circuit diagram of a sensor device according to the invention with a server circuit and a client circuit in which another variant of an approach of an object to the sensor device is shown.
[0082] FIG. 12 is the embodiment of a sensor device and its arrangement in a washing drum of a dryer according to the present invention; and
[0083] FIG. 13 is a possible embodiment of an electrode or counter electrode.
DETAILED DESCRIPTION OF THE INVENTION
[0084] The safety device according to the invention is particularly suitable for the detection of a child or animal in the drum of a washing machine or of a clothes dryer. Through the safety device according to the invention a dryer (a washing machine) can be prevented from carrying out its function to a dangerous extent, when a child is situated in the drum. The detection takes place on the basis of capacitive, e.g. electric field interaction effects. The detection according to the invention in a drum occurs by considering the latter as a cylindrical conductive hollow space with an open side. The walls are preferably on the earth potential (GND). The detection takes place from the area on the door side.
[0085] The capacitive sensors according to the invention detect a change in the electric field through the object as compared with the undisturbed state.
[0086] In the considered system, the energy density of an electrostatic field, which has its source in the area of the opening, considerably decreases with depth.
[0087] In a such system the measuring device (sensing electrode) too must be in the area of the opening, e.g. near the field source.
[0088] A (very small) change in the measuring signal on a high level of the permanently present signal can be detected.
[0089] In addition, smaller objects lying near the opening can create greater signal changes than bigger objects at the bottom of the hollow space.
[0090] It is also possible that closer objects electrically shield the further away lying objects at least to a great extent. Preferably the drum is connected as a “transmitting electrode”.
[0091] The receiving electrodes are preferably designed and arranged in such a way that their signals can be used for a reciprocal “compensation”.
[0092] Electronics is constructed accordingly.
[0093] The detection principle preferably consists in registering the movement of the living being to be detected and in not “detecting” static and common-mode signals.
[0094] A particularly advantageous simplification, which derives from the presentation of the problem—relative results are sufficient, no absolute precision is required.
[0095] The measuring system can be constructed following the acquisition technique described in DE 10 2007 020 873.3. The complete system comprises as few spots, which have a connection to GND, as possible. On the contrary, the measuring system is supplied with an operating voltage, which itself oscillates relative to GND with the operating frequency and operating amplitude. Seen from the point of view of the internal earth of the system (from the “viewpoint of the electrodes”), the whole environment oscillates with the operating frequency and operating amplitude.
[0096] In order that all the (earthed) environment objects become “transmitters”, the field to be measured establishes between the objects and the electrode system.
[0097] In this case the ground “does not absorb the field”, but rather “supplies” the field, and the range becomes maximum. Preferably, the electrodes are symmetrically constructed and supply equal signals in a symmetric (or symmetrized) environment. As these signals are processed in 2 parts (composite signal+differential signal), the detection of small changes in the ample quasiconstant signal is possible.
[0098] The electrode system preferably consists of two electrodes, that are preferably commensurate, stripe-shaped constructed and are arranged vertically in the middle of the drum door (symmetric) parallel to each other ( FIG. 1 ). The signals of the electrodes are differentially analyzed, so that only the asymmetry in them is determined. This means that in case of empty drum and closed door the system output signal will be 0 (at least approximately). Considering the geometry, the system is sensitive to changes in the X-axis (horizontal direction) and has no sensitivity in the Y-axis (vertical direction).
[0099] The vertical direction of the electrodes is selected to minimize the influence of the wet washing (which roughly lies horizontally) on the symmetry. For the same reason the electrodes should be close to each other. Electrode measures (first proposal): width—10 mm, length—200 mm (full height of the inner part of the door), distance from each other—10 mm.
[0100] Another advantage of the use of two substantially equal electrodes arranged close to each other with differential evaluation is the effective attenuation of external disturbances (e.g. mains hum).
[0101] The exemplary basic circuit is illustrated in FIG. 2 . Operational amplifiers OP 1 , OP 2 , OP 3 constitute an instrumentation amplifier with transimpedance inputs. The electrodes EL 1 and EL 2 are located on virtual earth, that oscillates with operating frequency (in the range of about 10-100 kHz) as to GND/earth. The extracted differential signal is received at the OP 3 output. This can be further amplified, i.a. with a logarithmic characteristic, as illustrated as an example in FIG. 2 , in order to emphasize the smaller signals of further away objects relative to ample signals of the objects nearby. This signal arrives in a μC (ADC) where it is evaluated e.g. according to a synchronous detection (as in a clover).
[0102] Another possibility of analysis (schematic diagram in FIG. 3 ) is based on the approach, that the difference of the signals is analogously stabilized by both electrodes. The low-frequency controlled variable is here used to draw conclusions on possible movements in the drum.
[0103] The fact that an absolute initial value is not necessary makes it possible to construct the (nonlinear) amplifiers easily from the technical viewpoint of the system—which through the drifts caused by temperature changes have much larger time constants than the wanted movement in the drum.
[0104] The measuring process to be used would look as follows: after pushing the START button a short side sway (or rotation) of the drum is carried out. After this motion has calmed, a possible motion of electric field relevant objects in the drum is examined for a predetermined period of time. For good measure or in case of unclear results the procedure can be repeated.
[0105] Since the sensitivity of the system to the small signals strongly depends on the symmetry condition in the electrodes, when necessary the following “symmetrization” procedure could be performed: after the first side sway of the drum the output signal is controlled and if it significantly differs from 0 (too strong asymmetry) the drum is slowly driven to a continuous control of the output signal. The object is to reach the symmetry of the measuring system—to bring the output signal to 0. In this way the field changes at a greater distance from the electrodes can be better measured.
[0106] Discrimination with respect to the outside: it is advantageous to distinguish the movements in the drum from the movement outside the machine, or not to react to the outside movement or not to “see” it. This can occur on the one hand through the physical shielding of the environment from inside the drum—e.g. through an earthed electrode at the drum opening (E 3 in FIG. 1 ).
[0107] Another variant is the logic discrimination, through the limitation of the spatial measuring range of capacitive sensor systems which will be described in more detail hereinafter.
[0108] A particularly advantageous electrode arrangement is illustrated in FIG. 4 . In this variant the sensing electrodes E 1 and E 2 are situated behind the plastic drum cover (drum casing) over the door opening. In this position the electrodes are shielded from external influences by the outer wall of the machine. The electrodes are situated near the drum inside and yet sufficiently far from the wet washing—the symmetry in the measuring system is substantially undisturbed. The whole measuring assembly is situated inside the “main case”—no cables must be laid in the door.
[0109] FIG. 5 shows a possible positioning of the auxiliary electrodes (HE). These auxiliary electrodes are used for enhancing the field of the main electrode (e) in the back part of the drum. They can be realized as a metallization inside the drum ribs (e.g. as conductive varnish, conductive plastic, metal strips). Their operating principle consists in that they—as equipotentials of the electric field—bring the higher field at the drum opening inside the drum. The bigger their surfaces are and the further from the drum wall they are located, the better will be their function. Such auxiliary electrodes can be useful with any main electrons.
[0110] Furthermore, the safety system according to the invention can be realized by accomplishing an approach and change of the capacitive environment of the electrode with the aid of a ZPS-Server system. A ZPS-Server system is a system in which a transmitting electrode device is controlled through a main circuit in such a way that it radiates a modulated electric field. This field is used for generating detection events by means of a receiving electrode system. The detection events can be sent back by means of a technical signal to the ZPS-Server system, so that in the area of the electrode receiving system a data technical modulation of the input impedance occurs. This impedance change can be ascertained in the area of the ZPS-Server.
[0111] Particularly in a washing machine or a clothes dryer, or even a microwave, a receiving electrode device can be applied at the door, where the receiving electrode device is connected to a detecting circuit which is directly supplied with energy through the receiving electrodes.
[0112] The detection of approaches to the receiving electrodes can take place particularly through changes in the dielectric characteristics of the environment of the receiving electrodes. Moreover, significant amplitude variations, phase variations or frequency changes are detected inside the LC network constructed including the receiving electrodes.
[0113] Preferably the ZPS-Server with a free-running LC oscillator has at its disposal a high-quality oscillator. The main object thereof is an effective enhancement of the voltage amplitude in the electrode and also of the sensitivity to load modulation. This high quality at the same time implies that the oscillator generates a very stable frequency, which depends on the inductance and capacitance values in the oscillatory circuit.
[0114] Since the capacitance of the server electrode parallels the capacitance of the oscillatory circuit, the oscillator frequency varies with the change in the capacitive environment of the electrode. The change in the electrode capacitance is usually in the range 1-100 pF. Such a change leads to a relevant change in the oscillator frequency: about 0.1-10 kHz in currently set values.
[0115] Also a capacitance change of just 1 pF can be established within 10 ms directly in the microcontroller of the server. (For this a server with synchronization on oscillator frequency must be used, e.g. LC Server V7.3).
[0116] In case of installation of the ZPS-Client in the operating panel of an appliance: the approach of the hand to the panel is detected even before the operation of a ZPS-Client. In case of use of a ZPS sensor network in a dryer: if a part of the server electrode is in (weak) capacitive coupling with the inside of the drum, “Child Detection” and “Drum Rotation” (in case of use of conductive lifters) can take place on the basis of the measurement of the frequency change of the oscillator of the ZPS-Server. The electrode can be situated e.g. over the door in the plastic cover of the drum.
[0117] In the car: in case of an electrode of the ZPS-Server incorporated in the seat it is possible to distinguish between a real operation of the ZPS and an increased level in the wanted ZPS frequencies due to people sitting on the seat—in the second case there is a large frequency change.
[0118] For example, in case of a measuring time of 10 ms a person can be detected at a distance of about 50 cm detected, a hand at the distance of about 10 cm (in 15 cm long wire electrode). The increase in the measuring time and in the electrode surface improves sensitivity.
[0119] Moreover, the invention also deals with technical solutions for limiting the spatial measuring range of capacitive sensor systems.
[0120] The capacitive detecting sensors according to the invention are based on the measurement of the change in the electric field through a conductive object for displacement currents. Preferably, the measuring system according to the invention substantially does without field forming, thus a large field expansion is achieved. Moreover, the field amplitude is measured at additional spots, in order to “logically” limit the spatial measuring range with the obtained data during the signal analysis.
Examples
[0121] FIG. 6 . Access to a production machine is to be ensured. The area is situated between the transmitters (S) and the receivers (E), which work in absorption mode. The machine is situated on the right of transmitters and receivers, which has movable (conductive) parts, which can come near the S-E line. In order to distinguish these parts from a person (coming from left side), an auxiliary electrode can be used (auxiliary receiver).
[0122] Thanks to the system geometry the auxiliary electrode reacts much more sensitively to the machine than to the person. Thus, from the logic correlation of the signals of both receivers, it can be decided if the signal change was caused by a person or by the motion of the machine. The effective spatial measuring range of the system is reduced accordingly.
[0123] FIG. 7 . A more general embodiment of an absorption-mode measuring system with discrimination of the detection direction.
[0124] FIG. 8 . Movement detection in a washing machine/dryer drum (with respect to detection of children or animals). As an example the Loading-Mode method is displayed.
[0125] Here an object movement in the drum can be distinguished from an object movement outside the machine. Therefore, besides the real sensing electrode (E 1 ), which detects the field change in its environment, the auxiliary electrode (E 2 ) is used as well. This auxiliary electrode is shielded by the case of the machine from the drum inside. Therefore, from the logic correlation “Motion detected on E 1 ” and “Motion detected on E 2 ” it inevitably follows that this movement occurred outside.
[0126] The spatial measuring range is reduced in case of need. Some applications are possible only in this way. No particular arrangements for field forming must be met, in this way the range is maximized.
[0127] The solution of the function “Children-Detection” is obtained with the aid of a load modulation in an electric alternating field. The modulation of the electric field, which is generated through an electrode in the access area of the drum, takes place through electronic switches. The electronic switches are situated in various locations in the drum and are supplied with the necessary operational energy through the electric field. Each of these switches has its own modulation frequency, its modulation deviation represented in the total frequency image depends on the presence of a child or even on a change in the position of the latter.
[0128] FIG. 9 shows a basic circuit of a server circuit of the sensor device according to the invention. The server circuit substantially consists of a generator 10 and of a LC series resonant circuit formed by inductance 20 and capacitance 30 . In this respect, the generator 10 , the inductance 20 and the capacitance 30 can form a free-running LC oscillator. Parallel to the LC series resonant circuit lies a server electrode 50 , as well as an evaluation device 40 .
[0129] First of all the generator 10 of the server circuit generates an alternating voltage, which is fed to the LC series resonant circuit 20 , 30 , thus increasing the signal level, in order to subsequently generate an electric field with a sufficiently wide range. The generated electric field is emitted on an electrode 50 , where the electric field emitted by the electrode 50 defines the observation area to be observed by the server circuit.
[0130] The LC oscillatory circuit is preferably a high-quality oscillatory circuit. The main object thereof is an effective increase in the voltage amplitude in the electrode 50 as well as an increase in the load modulation sensitivity on this electrode.
[0131] As the capacitance of the server electrode 50 parallels the oscillatory circuit capacitance 30 , the oscillator frequency varies with the change in the capacitive environment of the server electrode 50 . The change in the electrode capacitance of the electrode 50 is usually in the range 1-100 pF. Such a change leads to a relevant change in the oscillator frequency, for example to a change between 0.1 and 10 kHz.
[0132] The evaluation device is constructed in such a way that it can detect the change in the oscillator frequency and thus it can recognize an approach of an object 60 , particularly of a living being, to the electrode 50 . The approach of a living being 60 is schematically shown with a hand in FIG. 1 , where through the approach to the server electrode 50 the field radiated by this is partially absorbed by the object 60 , which leads to a change in the capacitive environment of the server electrode 50 .
[0133] For example, the evaluation device 40 can be constructed in such a way that the frequency change of the signal generated by the LC oscillator can be compared with a reference signal, which for example is generated by a quartz stabilized oscillator. The comparison of the frequency of the oscillator signal with the frequency of the reference signal can take place with various means known in the prior art. However, the quartz stabilized oscillator can also be used as a cycle for a counter in which the counter measures the frequency of the oscillator signal within a predetermined number of cycles. With measurements following each other over time within several time intervals of equal cycle length it is possible to determine whether the frequency of the oscillator signal changes or not.
[0134] On the basis of the structure of the server circuit according to the invention with a generator and LC series resonant circuit temperature induced frequency changes in the server circuit can be efficiently detected, as the order of magnitude of a temperature induced change in the oscillator frequency on the basis of the large time constant of a temperature change is much smaller than a change, which is determined by an approach of an object to the server electrode 50 .
[0135] The inductance 20 and the capacitance 30 can also be stimulated by a generator 10 with fixed frequency, whereby the detection of an approach occurs by means of the phase shift of the signal. It is particularly advantageous if the generator 10 is operated in resonance to the LC oscillatory circuit.
[0136] The server circuit according to the invention also enables particularly small capacitance changes, for example of 1 pF or smaller, within a very short time, for example within 10 ms, to be detected directly by the server circuit or by the evaluation device. Moreover, longer measuring intervals also allow the detection of very small frequency changes caused by the capacitance change in the electrode.
[0137] FIG. 10 shows another advantageous embodiment of a sensor device according to the invention. The server circuit is constructed as shown in FIG. 1 . Furthermore, the sensor device presents a client circuit. The client circuit substantially consists of an electrode device with two electrodes 51 and 52 as well as a modulation device 70 in which the electrodes 51 , 52 are coupled with the modulation device 70 from time to time.
[0138] The electric field f c generated by the server circuit and emitted on the server electrode 50 is coupled with the first electrode 51 of the client circuit. At the same time, this coupled field can also be used to supply the client circuit with energy. The coupled electric field f c is modulated by the modulation device 70 . The modulated signal f m is sent back through the server electrode 50 , preferably by means of load modulation, to the server circuit, where it is fed to the evaluation device 40 .
[0139] The modulation of the signal carried out by the modulation device 70 of the client circuit is evaluated by the evaluation device 40 . By doing this, the electric field is amplitude-modulated by the client circuit or by the modulation device 70 .
[0140] Should an object approach the second electrode 52 , as shown in FIG. 2 , this would cause a change in the level of the modulation device, which leads to a changed amplitude of the modulated electric field. This changed amplitude is detected and evaluated by the evaluation device 40 .
[0141] At the same time, an approach of an object to the client circuit can imply that also a part of the electric field radiated by the server electrode 50 is absorbed by the object. The absorption of the electric field in turn implies, as already described above in FIG. 1 , that the frequency of the signal radiated by the server electrode 50 changes. In this case both a frequency modulated and amplitude modulated signal is fed to the evaluation device 40 . In this way, both an approach of an object to the server electrode 50 and to the electrode 52 of the client circuit can be detected.
[0142] In a corresponding arrangement of the client circuit with respect to the server electrode 50 an approach of an object to the server electrode 50 can be detected, even before the detection of the approach of the object to the client circuit.
[0143] For instance, this can be used advantageously in an operating panel of an appliance, for example for a washing machine. Should the operating panel of an appliance present several client circuits in which every client circuit can be assigned a specific action, and in which a part of the operating panel is formed as a server electrode 50 , the approach of a hand to the operating panel can be detected even before the operation or before the approach of the hand to the client circuit. The early recognition of the approach of an object to the server circuit or server electrode 50 has the particular advantage that for example necessary initialization measures can already be carried out, even before the hand reaches the electrode 52 of the client circuit.
[0144] Another example of use of the sensor device according to the invention is the use in a clothes dryer. When a part of the server electrode 50 is in (weak) capacitive coupling with the drum inside, a “Child in the Drum” detection or a “Drum Rotation” detection (with the use of conductive lifters) can occur by means of the measurement of the frequency change of the oscillator 10 of the server circuit. However, at the same time a part of the server electrode 50 can also be used to operate a client circuit as shown in FIG. 2 .
[0145] Another example of use of the sensor device according to the invention is for instance the installation of the server electrode 50 and of one or more client circuits in a car seat for the purpose of seat occupation recognition. Here the advantage of the embodiment of the sensor device according to the invention becomes particularly clear. It is possible to distinguish between a real operation of the client circuit (which leads to an amplitude modulation of the signal) and an increased level of the signal, which is caused by a person sitting on the seat. In the second case, besides the signal level change, there is also a particularly large frequency change.
[0146] FIG. 11 shows another advantageous embodiment of the sensor device according to the invention. Here, too, the server circuit is constructed as shown in FIG. 1 . The client circuit substantially also corresponds to the client circuit of FIG. 2 , with the difference that the electrode 52 is capacitively coupled to earth. The client circuit is arranged with respect to the server circuit in such a way that the electric field radiated on the electrode 50 is coupled only with the electrode 51 of the client circuit, when a conductive object, for example a hand, is situated between the electrode 50 and the electrode 51 . The signal radiated on the electrode 50 is transmitted by the object situated between the client circuit and the server circuit from the electrode 50 onto the electrode 51 (i.e. the electric field is coupled with the electrode 51 by means of the bridging effect of the conductive object).
[0147] The transmission of the signal modulated by the client circuit or the modulation device 70 by the object arranged between the two electrodes takes place in the same way. Here, too, the signal generated by the client circuit is amplitude-modulated.
[0148] As already described in FIG. 10 , also in accordance with the embodiment according to FIG. 11 an approach of an object to the server electrode 50 causes an absorption of a part of the electric field radiated by the server electrode 50 . Here, too, the absorption leads to a change in the frequency of the oscillator signal. Therefore, also in this embodiment, in an appropriate arrangement of the client circuit with respect to the server circuit, for instance as shown in FIG. 11 , the approach of an object to the server electrode 50 can be detected, even before the object causes a bridging effect for the coupling of the electric field of the server electrode 50 with the electrode 51 .
[0149] Here, too, the evaluation device 40 is constructed in such a way that it can detect and evaluate both the approach of an object to the server electrode 50 (frequency change) and the coupling of the electric field with the electrode 51 (amplitude variation).
[0150] Therefore, the server circuit of the sensor device according to the invention is constructed in such a way that the server circuit alone (i.e. without interaction with a client circuit) can be used as an approaching sensor, but at the same time a sensor network together with one or more client circuits is feasible as well in which the client circuits are supplied with energy preferably with the electric field of the server electrode 50 . For instance, the construction of a sensor network with a server circuit and several client circuits can be made in such a way that the evaluation device of the server circuit can distinguish the single client circuits.
[0151] FIG. 12 is a view from inside outwards (above) as well as a side view (below) of a washing drum of a clothes dryer. The drum 10 has in its inside one or more lifters 30 , which are used to take the washing along during the drum rotation. An electrode 40 is arranged in the upper frontal area of the drum. It is situated on the plastic cover 20 . By means of this plastic cover 20 the electrode 40 is isolated from the drum inside. At the same time the electrode 40 —because of the construction of the clothes dryer—is electrically shielded from the external environment by means of the earthed front wall 70 of the clothes dryer.
[0152] The electrode 40 , presents a certain capacitive coupling with the environment. The capacitive coupling with the environment can be amplified, for example, through additional electrode surfaces or through a larger electrode surface of the electrode 40 . In the front view of the washing drum shown in FIG. 1 an illustrated embodiment of the electrode 40 can be seen.
[0153] Other embodiments different from the ring segment shaped embodiment of the electrode shown here are possible. Particularly, an asymmetric embodiment, for instance an asymmetric embodiment with respect to the drum rotation direction, is also possible, which enables to determine the rotation direction even in case of an empty drum. Such an embodiment of an electrode is shown in FIG. 13 . Here the electrode 40 is substantially wedge-shaped. In this case the signal generated during the drum rotation in interaction with the counter electrode (see below) depends on the drum rotation direction, so that the drum rotation direction can be deduced from the signal.
[0154] In the same way, the counter electrode 50 too can be asymmetric, particularly asymmetric with respect to the drum rotation direction. Here, too, the signal generated during the drum rotation in interaction with the counter electrode depends on the drum rotation direction.
[0155] In the embodiment shown here, the electrode 40 is constructed as a server electrode and is coupled with a server circuit (ZPS-Server 80 ).
[0156] The ZPS-Server 80 substantially presents a free-running LC oscillator for generating an electric field, which is radiated on the server electrode 40 coupled with the ZPS-server 80 preferably in the drum 10 inside. An emission of an electric field of the server electrode 40 is avoided in an area outside the clothes dryer because of the earthed front wall 70 or the earthed clothes dryer case. A serial LC oscillatory circuit with the server electrode 40 as (part of the) capacitance can be designed as a LC oscillator in the oscillatory circuit, so that the necessary increase in the electrode voltage on the server electrode 40 is reached as well.
[0157] Of course the server circuit can also consist of a simple circuit, for example a LC-circuit with an oscillator, for determining the capacitance change on the electrode. From the measured capacitance change it is then possible to determine the amount, the rotation direction or the degree of humidity on the basis of the arrangement of the server electrode and of the counter electrode according to the invention.
[0158] In an embodiment of the sensor device according to the invention the lifter 30 can be constructed as electrically conductive. In the embodiment shown in FIG. 12 only the side of the lifter 30 facing the server electrode 40 is constructed as electrically conductive. For instance, this can be achieved in that, on the side of the lifter facing the server electrode, should this part of the lifter 30 not be constructed as electrically conductive, an electrically conductive electrode, for example in the form of a conductive varnish or the like, is arranged.
[0159] Through the drum rotation 10 the lifters 30 pass by the server electrode 40 . In this way the capacitive environment of the server electrode 40 , which causes a change in the frequency of the oscillator or of the oscillatory circuit of the server circuit, changes. This frequency changes is used to detect the approach of the lifter 30 or of the electrodes 50 arranged on the lifter 30 to the server electrode 40 .
[0160] The result of the evaluation of this frequency changes of the oscillator depends on the amount and on the degree of humidity of the washing situated in the drum 10 .
[0161] During a rotation of the empty drum the lifters 30 or the electrodes 50 arranged on the lifter 30 pass by the server electrode 40 . Thereby, the oscillator frequency of the server is modulated with the rotation frequency of the drum. Hence, for example, the rotational speed of the drum 10 can be ascertained.
[0162] Should the drum be loaded with wet washing (yet not fully loaded), the capacitive environment or rather the capacitance of the server electrode 40 varies not only through the lifters or through the electrode 50 arranged on the lifter 30 , but also is through the washing carried by the server electrode 40 . Here, too, the oscillator frequency is modulated with the rotation frequency of the drum. Hence, the rotational speed of the drum can be deduced again.
[0163] However, as the capacitance change or rather the change in the capacitive environment of the server electrode 40 , in the case in which wet washing is carried by the server electrode 40 , is greater than in case of an empty drum, the frequency change is accordingly greater as well. Therefore, from the frequency change the degree of humidity of the washing can be deduced as well. A frequency change, which is to be found in the range of a frequency change in case of an empty drum, implies that the washing in the drum is dry. This enables the drying process to take place with a certain dynamics and the frequency change to slowly approach the frequency change in case of an empty drum.
[0164] As shown in FIG. 12 in the view from inside outwards of the drum 10 , the server electrode 40 is not arranged symmetrically to the axis A, but it is asymmetric to it. By this arrangement of the server electrode 40 according to the invention, the signal form of the frequency modulated oscillator frequency also depends on the drum 10 rotation direction. Thus, for example during a clockwise drum rotation a small quantity of washing taken along by the lifter falls down again before it reaches or passes the server electrode 40 and therefore generates a smaller signal than in the counterclockwise drum rotation, where the washing is almost completely carried by the server electrode 40 .
[0165] As in case of a fully loaded drum no place or little place is available for the washing taken along by the lifters 30 to fall down again, the frequency modulated oscillator frequencies are very similar with respect to both rotation directions of the drum. From the similar signals for both rotation directions the evaluation unit can determine that the drum 10 is fully loaded with washing. Thereby, the amplitude of the frequency modulated oscillator frequency indicates the degree of humidity of the washing situated in the drum.
[0166] In this way a method can be provided for measuring the drum rotation direction, the amount and/or the degree of humidity of the washing in a washing machine or in a clothes dryer, which comprises at least the following steps:
[0167] 1. The drum is rotated clockwise. Thereby relative changes in the signal (of the frequency modulated oscillator frequency) and/or the absolute change in the signal as opposed to the signal in case of a not loaded drum are detected.
[0168] 2. Afterwards the drum is rotated counterclockwise. Here, too, relative changes in the signal and/or absolute changes in the signal as opposed to the signal in case of a not loaded drum are detected. Afterwards, the results of the second step are compared with the results of the first step.
[0169] Of course the order of the first two steps can be inverted, so that in a first step an counterclockwise drum rotation takes place and in the second step a clockwise drum rotation takes place.
[0170] 3. In another step the required quantities, such as the amount of the washing situated in the drum or the degree of humidity of the washing, can be determined with one or more deposited formula(s) or transformation(s). The specific formulas and/or transformations to be used substantially depend on the specific embodiment of the drum 10 . Thus, for instance, the dynamics of the frequency modulated oscillator frequency can depend on the arrangement or on the size of the lifters 30 arranged inside the drum. A lifter 30 protruding further into the drum inside implies that during a drum rotation much more washing is carried by the server electrode 40 , which leads to a different frequency modulation of the oscillator frequency. Particularly, the dynamics of the frequency modulated oscillator signal can also depend on the drum 10 size or diameter, as in case of a bigger drum the washing taken along by the lifter 30 also during an counterclockwise rotation falls down again immediately before reaching the server electrode 40 so that, in order to determine the degree of humidity of the washing, other reference values must be employed than in case of a drum with a smaller diameter.
[0171] Moreover, this method can also present a calibration step in which the required reference values for determining the degree of humidity or the amount of washing in the drum are ascertained. This calibration step is preferably carried out with an empty drum, so that the frequency modulated oscillator signal can be detected both for a clockwise drum rotation and for an counterclockwise drum rotation. The frequency modulated oscillator signals generated or detected in this way, which are characteristic of an empty drum rotation, can be stored in a suitably provided storage, such as a non-volatile storage, in the server circuit or in the evaluation circuit. The stored signals (reference signals) can be then used in the steps 1) and 2) of the method as comparison signals for determining the absolute change in the current frequency modulated oscillator signals with respect to the signals of a not loaded drum.
[0172] If required, the calibration step can be repeated at any later moment, thus compensating for example environment-related or ageing-related influences on the sensor device at least with respect to the reference signals.
[0173] The arrangement of the sensor device according to the invention shown in FIG. 12 can also be used to detect the movement of a child or of an animal situated in the drum. Furthermore, a good focusing of the measurement in the changes in capacitance or in the capacitive environment of the server electrode is given by shielding the server electrode through the earthed appliance wall or through the earthed case only inside the drum.
[0174] By using a server circuit, additional electrodes or server electrodes can be connected to this server circuit, where the additional electrodes can be used for another purpose than determining the amount or the degree of humidity of the washing.
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The invention relates to a safety system for detecting the presence of living beings inside a lockable, or alternatively dangerous housing area, particularly the washing housing area of a washing machine or of a clothes dryer, of a stove, of a microwave oven, as well as particularly also in closets and chests. According to a first aspect of the present invention the aim at the beginning is solved by means of a safety device for detecting the presence of living beings inside a dangerous housing area with a first electrode device which, as such, is facing the housing area and is a component of a LC network, and a second electrode device which is also facing the housing area and is a component of a LC network, and an evaluation circuit for detecting the dynamics of electric field interactions with at least one of the two electrode devices in which the detected dynamics is compared with the comparison values provided for the current working condition of the housing area, so that, if the detected dynamics differs from the provided comparison values, a safety function is activated.
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BACKGROUND OF INVENTION
The present invention relates to safety devices intended to prevent or inhibit access by small children to cabinets and similar storage spaces. More particularly, the present invention relates to a device which blocks a child's physical access and his or her line of sight to the interior of the storage space and further biases the door of the storage space in a closed position. However, the present invention will not substantially interfere with an adult's access to the interior of the storage space.
It is a common experience that as infant children begin to crawl or walk, they become capable of opening doors on lower level storage spaces such as cabinets under kitchen sinks and the like. Since these storage spaces often contain items or substances that may be hazardous or deadly if mishandled or ingested, it is necessary to equip such storage spaces with devices that will prevent or inhibit the child's access. Typically these devices are formed of some type of latching mechanism that prevents the storage space door from being opened or only allows the door to be opened a slight amount. In order to fully open the door, the latch mechanism must be released. For example, one type of device is designed for use on twin door cabinets having loop type door handles. The device comprises a U-shaped member that is placed through the handle of both doors and a selectively releasable latch that slides over and locks onto the arms of the U-shaped member. The U-shaped member and latch bind the door handles together and thereby prevent the doors from opening. Such a device is manufactured by Brainerd Mfg. Co. of East Rochester, N.Y. Another type of device secures the cabinet door from with a latch positioned on the interior of the door. The device has an elongated latch arm that is connected to the cabinet door and extends into the cabinet when the door is closed. The end of the latch arm has a hook which engages a catch mechanism positioned in the interior of the cabinet. When the latch arm engages the catch mechanism, the cabinet door may only open a slight amount. The intention is that the door will not open enough for a child to access the interior, but will open enough for an adult to disengage the latch arm from the catch mechanism. Such a device is produced by Safety 1st Inc. of Chestnut Hill, Mass.
However, these latch devices have numerous disadvantages. First, many children quickly perceive how the latch mechanism operates and are scarcely hindered in gaining fall access to the storage space. Second, since many allow the door to partially open even before becoming unlatched, the child is allowed to see the contents of the storage space and may be inspired to even further efforts to gain access to the storage space. Third, the latch devices are often a hindrance to adults, requiring both hands to open a storage space door. Fourth, most of the latch devices require that the adult to remember to re-secure the latch device when finished accessing the storage space.
What is needed in the art is a child access inhibiting device which overcomes these disadvantages and provides a practical and cost efficient method of reducing the risk of injury and poisoning of infant children.
OBJECTS AND SUMMARY OF INVENTION
It is therefore an object of this invention to provide a safety device for inhibiting child access to a storage space which eliminates the need for conventional latching mechanisms.
It is another object to provide a safety device which will bias the door of the storage space in a closed position.
It is still another object to provide a safety device which will block a child's view of the interior of the storage space when the door is open and therefore will not incite the child's curiosity.
Therefore the present invention provides a safety device for inhibiting child access to a storage space. The safety device has a length of flexible material with a first end. The device also has a material retainer for storing the flexible material and allowing the flexible material to be retractably withdrawn from the material retainer. A first connecting member is attachable to the material retainer and a second connecting member is attachable to the first end of the flexible material. The first and second connecting members are positioned in the doorway of the storage space such that opening the door of the storage space withdraws the flexible material from the material retainer and extends the flexible material across the doorway.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention positioned in a conventional storage space or cabinet.
FIG. 2a is a perspective view of the first connecting member of the present invention.
FIG. 2b is a perspective view of the holding cylinder of the present invention.
FIG. 2c is a partial cut-away view of the flexible material mounted on the spool of the present invention.
FIG. 2d is a perspective view of the second connecting member of the present invention.
FIG. 3 is an exploded perspective view of the of the present invention as seen from the interior of a storage space.
FIG. 4 is an assembled perspective view of the of the present invention as seen from the interior of a storage space.
FIG. 5 is an exploded perspective view illustrating an alternate embodiment of the first connecting member of the present invention.
FIG. 6 is a perspective view of an alternate manner of installing the present invention in a storage space.
DETAILED DESCRIPTION
FIG. 1 illustrates the present invention, child safety device 1, mounted in a convention storage space or cabinet 50. Storage place 50 has doors 51 which are attached to storage space 50 by hinges 54 and which close against styling 53. When doors 51 are in the open position, a doorway 52 is formed between styling 53 and the section of storage place 50 to which hinges 54 are attached. While FIG. 1 illustrates a storage space with twin doors, the present invention is equally applicable to single door storage spaces. Where the specification discusses components attached to the styling 53 of twin door storage spaces, it will be understood that these components could also be attached to any corresponding part of the framing of a single door storage space. Therefore the term "frame" or "framing" may be used interchangeably with the term "styling" to denote the part of the storage space against which the door closes.
The various components comprising child safety device 1 are better seen in FIGS. 2a-2d. As seen in FIGS. 2b and 2c, a section of flexible material 3 will be mounted on a spool 7 which in turn will be positionable in a material holding cylinder 15. In the embodiment shown, the combination of flexible material 3, spool 7 and holding cylinder 15 will form material retainer 5 (seen assembled in FIG. 4). Viewing the cut-away section of FIG. 2c, an internal rod 8 will be positioned inside spool 7 and internal rod 8 will communicate through spool cap 18 with rectangular rod end 9. Spool cap 18 will be fixed to spool 7 and will be formed such that rod end 9 and internal rod 8 may rotate relative to spool cap 18 and spool 7. A biasing device 11 will be connected at between spool 7 and internal rod 8 in such a manner that relative rotation between spool 7 and internal rod 8 will cause biasing device 11 to exert a resisting torque on spool 7. In the embodiment shown, biasing device 11 is a conventional spring 12 whose first end is connected to the lower section of internal rod 8 with a second end connected to the internal surface of spool 7. Therefore when rod end 9 is fixed and spool 7 rotated, spring 12 is place under tension and will urge spool 7 to rotate back to its original position. The significance of this operation will be explained in greater detail below. The lower end of spool 7 has a spool cap 25 to which round rod end 10 is connected. However, in the embodiment shown, spool cap 25 and round rod end 10 are fixed to spool 7. It is not necessary for rod end 10 to rotate relative to spool 7 since rod end 10 is mainly intended to secure spool 7 within material retainer 5 as discussed below.
One end of flexible material 3 is attached to spool 7 (hidden from view in the Figures) with the excess length of flexible material 3 being rolled onto spool 7. The opposite end of flexible material 3, end 13, is seen in FIG. 2c. End 13 is attached to a stiffener 14 and has attaching apertures 16 formed through both flexible material 3 and stiffener 14. End 13 may be attached to stiffener 14 in any conventional manner. In the embodiment shown, end 13 is wrapped around stiffener 14 and flexible material 3 is attached to itself by a conventional heat seal 29 formed by melting the plastic-like flexible material 3 to itself. Of course, flexible material 3 could be attached to itself by any other conventional method, such as gluing or sewing. As further explained below, stiffener 14 will assist in attaching end 13 of flexible material 3 to the proper part of storage space 50. Flexible material 3 will typically be formed of vinyl or a similar flexible but comparatively strong substance, but could be formed of any material which functions for the purposes described herein. Additionally, in a preferred embodiment, flexible material 3 will be substantially opaque in order to block a child's view of the contents of storage space 50. Where the child cannot view the contents of the storage space, he or she will not be encouraged to gain access to the storage space. In order to block the child's view, it is preferred that the width of flexible material 3 be approximate to the height of doorway 52 of storage space 50. The standard height of a cabinet typically found in the home is 23 inches; therefore a preferred embodiment comprises a flexible material 3 that is from approximately 17 to 19 inches in width. Furthermore, the length of flexible material 3 stored on spool 7 may be approximately 66 inches in the embodiment shown. However, it is not strictly necessary that the width of flexible material 3 be in this range and any width that will sufficiently block the child's view of the interior of storage space 50 may be employed. Likewise, any length of flexible material 3 may used as long as it allows child safety device 1 to operate as intended.
As mentioned above, flexible material 3 is attached to spool 7 and will be positionable in material retainer 5. As seen in FIG. 2b, material retainer 5 comprises holding cylinder 15 with a section of the cylinder wall removed in order that flexible material 3 may extend out of holding cylinder 15 when spool 7 is positioned therein. Holding cylinder 15 will further have mounting lugs 17 whose function is to connect material retainer 5 to storage space 50 as is explained below. Holding cylinder 15 will also have end caps 19 and 20 which maintain spool 7 in holding cylinder 15. As illustrated, end cap 20 will have a round aperture 22 to receive round rod end 10 while end cap 19 will have a rectangular aperture 21 to receive rectangular rod end 9. End cap 19 will further have tightening knob 23 and threaded section 24. Since end rod end 9 engages aperture 21, rotation of end cap 19 will rotate end rod end 9 and place increased tension on spring 12, urging flexible material 3 to be winded onto spool 7 with greater force. It will be readily apparent that the greater the number of turns placed on rectangular rod end 9 and internal rod 8, the greater the tension on spring 12 since one end of spring 12 is attached to internal rod 8 and the other end to spool 7 as described above. In order to limit the tension placed on spring 12, end cap 19 will be given a limited number of threads on threaded section 24 such that only a given number of turns will be imparted to end cap 19 before it is secure on holding cylinder 15 and will turn no further. Therefore a preset number of threads on end cap 19 will allow a proper amount of tension to be placed on spring 12. This amount of tension will be sufficient to firmly close door 51, but not so great that door 51 will close with a high velocity which would injure a hand or other body part if the door should close thereon. When spool 7 is placed within holding cylinder 15, end 13 of flexible material 3 may extend through the opening in holding cylinder 15 as seen in FIG. 4. Since aperture 21 on end cap 19 engages rectangular rod end 9, rod end 9 is held stationary during operation when flexible material 3 is drawn out causing spool 7 to rotate. On the other hand, rod end 10 is free to rotate in aperture 22 and will rotate with spool 7 when torque is applied to spool 7. In the embodiment shown, end cap 20 threadedly engages holding cylinder 15. However, it is not strictly necessary that end cap 20 be removable from holding cylinder 15. It is an acceptable alternative for end cap 20 to be fixedly attached on holding cylinder 15 or to be formed as an integral part of holding cylinder 15.
FIG. 2a illustrates the means by which material retainer 5 will be positioned in storage space 50. First connecting member 30 comprises a half cylindrical body 31 with the concave inner surface 37 facing the viewer of FIG. 2a. A footing 35 is formed on the bottom end of the body 31. Footing 35 will have at least one footing aperture 34 (with two shown in the Figures) formed therein. Footing 35 and footing apertures 34 will allow first connecting member 30 to be secured to the floor of storage space 50 when nails, screws, or similar attachment means are passed through apertures 34 into the floor 57 of storage space 50 as seen in FIG. 5 and explained below. Adjacent to the upper end of body 31, a plurality of apertures 36 will be formed through the wall of body 31. Apertures 36 will allow first connecting member 30 to be attached to either styling 53 (see FIG. 4) or an upper horizontal member 56 (see FIG. 5). When attached to an upper horizontal member 56, the multiple apertures 36 spaced at varying heights will allow first connecting member 30 to accommodate variations in the height of upper horizontal member 56 which may occur among nonstandard storage spaces 50. An aperture 32 will also be formed approximate the lower end of first connecting member 30 and will operate to secure first connecting member 30 to styling 53. Generally, aperture 32 will be used in place of footing aperture 34 when the storage space 50 has a styling 53 to which first connecting member 30 may be attached. Returning to FIG. 2a, body 31 will also comprise a plurality of lug receiving slots 33 which are adapted to receive attaching lugs 17. In the embodiment seen in FIG. 2a, body 31 includes four lug receiving slots 33 in order for first connecting member 30 to hold two material retainers 5 as seen in FIG. 4. Those skilled in the art will readily recognize that when attaching lugs 17 pass through receiving slots 33, a downward movement of cylinder body 15 will lock attaching lugs into first connecting member 30 as shown by the dashed lines in FIG. 4.
FIG. 2d illustrates a second connecting member 40 which will attach to the inner surface 58 of storage space door 51 as seen in FIGS. 3 and 4. This embodiment of second connecting member 40 includes a planar body section 41 having a plurality of apertures 43. While this embodiment will generally employ screws passing through apertures 43 to secure body section 41 to door 51, the scope of the invention includes any and all alternate means of securing body section 41 to door 51. A plurality of connecting hooks 42 will extend from body section 41 in order to attach end 13 of flexible material 3 to door 51 as suggested in FIG. 1. Again, hooks 42 are only illustrative of one device for attaching end 13 to second connecting member 40. While the illustrated embodiments of first connecting member 1 utilizes lug receiving slots 33 to grip material retainer 5 and second connecting member 40 uses hooks 42 to grip end 13 of flexible material 3, the present invention includes all alternate ways of attaching end 13 of material retainer 5 and attaching flexible material 3 in the doorway 52 of storage space 50. Although not as preferred, material retainer 5 could be semi-permanently fixed to styling 53 by nails, screws, glue or any other conventional attachment means. Similarly, end 13 of flexible material 3 could be fixed to door 51 by like means.
In operation, child safety device 1 will be mounted to the storage space 50 as illustrated in FIG. 1 (an exterior view of storage space 50) and in FIGS. 3-6 (interior views of storage space 50). The purpose for first connecting member 30 comprising a half cylinder is best understood by viewing FIG. 4. The curved outer surface 38 of connecting member 30 allows two material retainers 5 to be connected thereto. If first connecting member 30 provided a flat or planar outer surface, first connecting member 30 would have to be much wider to accommodate two material retainers 5 and could not be hidden behind the styling 53 of many conventional storage spaces 50. Still viewing FIG. 4, material retainer 5 is first secured to storage space 50 by first connecting member 30. With spool 7 positioned in cylinder 15, first end 13 of flexible material 3 will be drawn away from cylinder 15 and extended to doors 51. Thereafter apertures 16 will be connected to hooks 42 on second connecting member 40. As previously described, second connecting member 40 will be attached to an inner surface 58 of door 51.
When door 51 is opened, flexible material 3 will be withdrawn from material retainer 5 and extend across the doorway 52 as seen in FIG. 1 from the exterior of storage space 50 and as seen in FIG. 4 from the interior of storage space 50. This does not inhibit adults from reaching over and behind flexible material 3 in order to retrieve containers in storage space 50. To begin with, the open space formed between the top edge of door 51 and the top edge of flexible material 3 is the space through which a stooping adult typically removes objects from a lower level storage space 50. Secondly, if the existing opening between flexible material 3 and doorway 52 is not large enough to accommodate an oversized object being removed, the object can be moved against flexible material 3 and more flexible material 3 will easily be withdrawn from material retainer 5, thereby increasing the opening through which the oversized object may be withdrawn. After retrieving the object sought, the adult need not remember to close door 51. Since biasing device 11 is applying torque to spool 7 and urging flexible material 3 to be drawn into material retainer 5, flexible material 3 applies a force on door 51 which moves door 51 to a closed position.
However, when a small child opens door 51, the child from his or her eye-level only sees flexible material 3. Since flexible material 3 will generally be substantially opaque, the child's line of sight to the storage space contents is blocked. Therefore the present invention tends to prevent the child's curiosity from exciting further exploration of the storage space. However, should the child persist, pressing against flexible material 3 will only tend to further bias door 51 to the closed position. At any point when the child is not blocking door 51 open, door 51 will completely close under the tension of flexible material 3, thereby further frustrating the child's efforts to open the storage space doors. Thus safety device 1 presents a substantial deterrence to the child's desire to access the contents of the storage space 50.
On the other hand, when an adult needs to access the full doorway 52 of storage space 50, such as a plumber making repairs to piping under the sink, safety device 1 can be readily removed. It is only necessary to unhook apertures 16 on end 13 of flexible material 3 from hooks 42 and allow flexible material 3 to be retracted into material retainer 5. If material retainer 5 is itself considered to be a hindrance, it may removed simple by disengaging attaching lugs 17 from lug receiving slots 33. When the work is completed, safety device 1 may be easily and quickly repositioned in storage space 50.
It will be understood that the embodiment seen in FIG. 1 discloses only one preferred apparatus for carrying out the present invention and innumerable variations come within the scope of the present invention. For example, material retainer 5 need not be attached to a styling 53 as shown in FIG. 1. Many cabinets will not have a styling or other vertical member between two doors 51. FIG. 5 illustrates how in such cases, first connecting member 30 will be fixed in an upright position in storage space 50. The lower section of first connecting member 30 will be fixed to the floor 57 of storage space 50 by screws engaging apertures 36 of footing 35. Similarly, the upper section of first connecting member 30 will be fixed to horizontal member 56 framing door 51 by screws engaging apertures 36. Naturally, attaching means other than screws could be utilized.
Another alternate embodiment can be seen in FIG. 6. In this embodiment, first connecting member 30 and material retainer 5 are fixed directly on door 51. The second connecting member 46 will be positioned in storage space 50 adjacent to the frame against which door 51 closes. The illustrated embodiment of connecting member 46 comprises an main rod 60 and a telescoping lower rod 61 which slidingly engages the tubular lower end of main rod 60. Main rod 60 is shown attached to horizontal member 56 of storage space 50 by way of a brace 63. Brace 63 has apertures 64 through which screws, nails or similar attaching means will pass in order to secure brace 63 to horizontal member 56. In the embodiment shown, main rod 60 will have an aperture 66 formed therein and brace 63 will have a pinning device or hook 67 which will pass through this aperture 66 in order to secure main rod 60 to brace 62. The same pinning method is employed to attach lower rod 61 to its respective brace 63. The aperture 66 and pinning device 67 allow second connecting member 46 to be removably attached to storage space 50 such that second connecting member 46 may be easily removed when it is necessary to create the largest possible open space in the doorway 52. FIG. 6 further illustrates how this embodiment will utilize a single continuous length of flexible material 3 extending between the two material retainers 5. In this embodiment, the length of flexible material 3 will be attached to second connecting member 46 by simply folding or wrapping flexible material 3 around second connecting member 46 and attaching flexible material 3 to itself by any convention means, including heat sealing or sewing. The seam of this attachment is represented by dashed line 68 in FIG. 6. It is envisioned that an appropriate length of flexible material 3 in this embodiment will be approximately 21 inches of flexible material 3 stored in each material retainer 5. However, any length of flexible material 3 which allows child safety device 1 to function as intended comes within the scope of this invention.
Nor are first and second connecting members 30 and 40 limited to the embodiments shown. First connecting member 30 could comprise any means of attaching retaining device 5 to storage space 50 or door 51. For example, screws, bolts or other devices attaching retaining device 5 directly to the framing of storage space 50 or door 51 are considered first connecting members 50 for the purposes of this invention. Similarly, any means of fixing end 13 of flexible material 3 to the framing of storage space 50 or door 51, whether the means be screws, nails, or adhesive materials, such means should be considered within the definition of second connecting member 40.
Of course, the foregoing disclosure and description of the invention are only illustrative and explanatory thereof, and various changes in the size, shape and materials as well as in the details of the illustrated construction may be made without departing from the intended scope and spirit of the invention. All such variations are considered within the scope of the present invention as defined by the following claims.
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The invention disclosed herein provides a safety device for inhibiting child access to a storage space. The safety device has a length of flexible material with a first end. The device also has a material retainer for storing the flexible material and allowing the flexible material to be retractably withdrawn from the material retainer. A first connecting member is attachable to the material retainer and a second connecting member is attachable to the first end of the flexible material. The first and second connecting members are positioned in the doorway of the storage space such that opening the door of the storage space withdraws the flexible material from the material retainer and extends the flexible material across the doorway. When a small child opens a storage space door on which the invention has been installed, the length of flexible material is drawn across the doorway of the storage space. The child's view of the interior of the storage space is blocked and the child's pressing against the flexible material results in the door tending to close, thereby further discouraging the child's access to the storage space.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an over speed control circuit for optimizing the power output of a wind turbine generator and more particularly to a circuit for optimizing the operational time and thus power output over time of a wind turbine generator which coordinates with known over speed relay lockout protection circuitry and incorporates closed feedback control that periodically measures the output voltage of the generator to regulate its speed by electronically controlling the load on the generator to minimize activation of the over speed relay lockout protection circuitry.
2. Description of the Prior Art
Wind turbine generator systems are generally known in the art. Examples of such systems are disclosed in U.S. Pat. Nos. 4,565,929; 5,506,453; 5,907,192; 6,265,785; and 6,541,877. Such wind turbine generator systems are also described in U.S. Patent Application Publication Nos. US2002/0117861; 2005/0034937; 2005/0230979; 2005/0236839; 2006/0006658; and 2006/0012182. Due to the ever-increasing demand and increasing cost for electrical power, renewable energy sources, such as wind turbine generator systems, are becoming more and more popular for generating electrical power. Such wind turbine generator systems are known to be used individually to generate supplemental or excess power for individual, residential or light industrial users to generate electrical power in the range of 1-2 kw. Such wind turbine generator systems are also known to be aggregated together, forming a wind turbine generator farm, to produce aggregate amounts of electrical power. It is also known that unconsumed electrical power generated by wind turbine generators is connected to the utility power grid.
Such wind turbine generators are known to include a wind turbine, which includes a plurality of turbine blades connected to a rotatable shaft. The rotatable shaft is rigidly connected to a direct current (DC) generator. Wind causes rotation of the wind turbine which acts as the prime mover for a DC generator. The generator, for example, a self-excited generator, generates DC electrical power.
One problem with such systems is that wind speeds are not constant. As is known in the art, the voltage output of the generator is a cubic function of the speed of rotation of the turbine blades and the direct connected generator. As such, the effect of wind gusts on the wind turbine generator must be controlled to prevent damage to the wind turbine generator.
Some wind turbine generator systems are known to use some type of mechanical braking to protect the wind turbine generator from an over speed condition. For example, U.S. Pat. No. 5,506,453 utilizes the pitch of the wind turbine blades to protect the wind turbine from over speed. In particular, the blades of the wind turbine are mechanically coupled to a rotatable mechanical hub. The blades are configured so as to be rotatable about their longitudinal axis relative to the hub allowing the pitch of the turbine blades to be varied. The pitch of the blades is turned in such a way as to create braking of the wind turbine.
Other known systems utilize mechanical brakes, such as disclosed in U.S. Patent Application Publication No. US 2005/0034937. Yet other systems disclose the use of aerodynamic-type brakes as well as mechanical brakes, for example, as disclosed in U.S. Pat. No. 6,265,785, to protect the wind turbine from over speed.
While mechanical brakes do an adequate job of protecting the wind turbine generator from over speed, mechanical braking systems do little to optimize the operational time and thus power output of the wind turbine generator. Moreover, such mechanical braking systems are mechanically complex and are, thus, relatively expensive.
As such, electrical braking systems have been developed to control over speed of wind turbine generator systems. For example, Japanese Patent Publication JP2000-179446 discloses an electrical braking system for a wind turbine generator. The system disclosed in the Japanese patent publication includes a relay whose contacts are connected across the output terminals of the generator. When an over speed condition is detected, the relay is energized which, in turn, shorts out the output terminals of the generator, which loads the generator and causes it to slow down and stop.
In many countries, for example, in Europe, such relay protection is dictated by industrial standards, for example, the Energy Networks Association, an engineering association in the UK, promulgated Engineering Recommendation G83/1, September 2003, Recommendations For the Connection of Small-Scale Embedded Generators (Up to 16 A Per Phase) In Parallel With Low Voltage Distribution Networks”, specifies an over speed lockout relay connected across the generator terminals. Upon detection of an over speed condition, the lock out relay shorts out the generator terminals, which causes the generator to slow down and stop. The standard specifies a three-minute wait period before the relay can be de-energized so that the wind turbine generator can be restarted.
Although the electrical brake is effective in preventing damage to the wind turbine generator due to over speed, such outages frustrate the practicality of using such wind turbine generator and connecting them to a utility power grid. Thus, there is a need for a control circuit for a wind turbine generator that not only protects the wind turbine generator from over speed, but also optimizes the time that the wind turbine generator is operational and thus maximizes the output power from the generator.
SUMMARY OF THE INVENTION
The present invention relates to an over speed control circuit for a wind turbine generator which optimizes the time that the wind turbine generator is operational and thus maximizes the power output over time. The over speed control circuit forms a closed feedback loop which periodically measures the output voltage of the wind turbine generator in order to regulate its speed by electronically controlling the load on the generator. The over speed control circuit in accordance with the present invention is adapted to work in conjunction with known over speed protection lock out relays. More particularly, the over speed control circuit causes a short circuit to be placed the generator terminals when the generator voltage reaches a threshold value, relatively less than the threshold value used to trigger the over speed lockout relay. As such, the over speed control circuit minimizes the operation of the lockout relay, thereby maximizing the power output of the generator over time making such wind turbine generator systems much more practical as a renewable energy source.
DESCRIPTION OF THE DRAWING
These and other advantages of the present invention will be readily understood with reference to the following specification and attached drawing wherein:
FIG. 1 is a block diagram of a known control circuit for a wind turbine generator. Illustrating a lockout relay across the generator terminals.
FIG. 2 is a block diagram as illustrated in FIG. 1 , further illustrating the over speed control circuit in accordance with the present invention.
FIG. 3 is a schematic diagram of an analog embodiment of the over speed control circuit in accordance with the present invention.
FIG. 4 is a schematic diagram of an alternative digital embodiment of the over speed control circuit in accordance with the present invention.
FIG. 5 is a flow chart for the embodiment illustrated in FIG. 4
FIG. 6A is a graphical illustration of wind speed and power output of a wind turbine generator as a function of time for a wind turbine generator system that utilizes an over speed lock out relay as illustrated in FIG. 1 .
FIG. 6B is similar to FIG. 6A but illustrates the power output of the generator over time for a wind turbine generator control system which includes the over speed control circuit in accordance with the present invention.
DETAILED DESCRIPTION
The present invention relates to an over speed control circuit for a wind turbine generator that is configured to co-ordinate with a conventional over speed lock-out relay to optimize the operating time and thus the power exported by the generator over time in an environment of varying wind conditions. More particularly, available electrical power for export from a wind turbine generator is approximately equal to the cube of the generator speed. Since the generator is rigidly coupled to the wind turbine, the generator rotational speed (i.e. revolutions per minute or RPM) is directly proportional to the wind speed. With a wind speed of, for example, 10 meters/second a conventional generator can support a 1.0 kWatt output, for example. Because the generator voltage output curve is a cube function, a relatively small change in wind speed can create a large change in the generator output voltage. Such changes in the wind speed can cause damage to the turbine as well as the generator attached to the turbine and the circuitry connected to the generator terminals. In known wind turbine generator systems, a electromechanical braking system is applied during an over speed condition which stops the turbine, reducing the DC output of the generator to zero. Unfortunately, some known systems utilize a lockout relay which, as discussed above, locks out the wind turbine generator system for a nominal period, such as 3 minutes, any time the generator voltage exceeds a threshold indicative of an over speed condition. Thus, during conditions when high wind speeds exist and the opportunity to export maximum power, the generator must be shut down. The over speed control circuit in accordance with the present invention solves this problem by applying electronic braking to the generator when the output voltage at the generator terminals exceeds a first predetermined threshold indicative of an over speed condition. In accordance with an important aspect of the invention, the first threshold is relatively lower than a second predetermined threshold, used to trigger the over speed lock out relay. As such, the over speed control circuit in accordance with the present invention minimizes the operation of the over speed lockout relay, thereby maximizing the power output of the generator over time making such wind turbine generator systems much more practical as a renewable energy source.
FIG. 1 illustrates a conventional wind turbine generator system, generally identified with the reference numeral 20 . The wind generator system 20 includes a generator 22 , such as, a self-excited DC generator. A wind turbine (not shown) functions as a prime-mover for the generator 22 . The generator 22 generates a DC voltage across its output terminals 24 , 26 as a cubic function of the rotational speed of the generator 22 . In as much as the generator 22 is directly coupled to the wind turbine, the rotational speed of the turbine and generator is directly proportional to the wind speed. As such, the output voltage at the generator terminals 24 and 26 is a cubic function of the wind speed.
The output terminals 24 , 26 of the generator 22 are coupled to an inverter, shown within the block 28 . The inverter 28 converts the DC output voltage, available at the output terminals 24 , 26 of the generator 22 , to an AC voltage suitable for connection to a utility AC power grid, generally identified with the reference numeral 30 . The AC power grid 30 may be a phase to phase 230/240 Volts AC, suitable for residential, commercial and industrial application. In the exemplary embodiment shown, shown, the inverter 28 generates a phase to phase voltage across two output phases L 1 and L 2 , for example, 230/240 Volts AC.
Depending on the configuration of the utility AC power grid 30 , the inverter 28 may also include a ground conductor for use with utility AC power grids which are 230/240 Volts AC with a center tap ground, for providing 230/240 Volts AC phase to phase and 115/120 Volts AC phase to ground. In such a system, the inverter ground conductor (not shown) would be electrically coupled to the utility center tap ground. The principles of the present invention are applicable to wind turbine generator systems 20 configured to be connected to various configurations of the utility AC power grid 30 .
The phase to phase output L 1 and L 2 of the inverter 28 is connected to the utility AC power grid 30 by way of a grid relay 32 . The grid relay 32 ensures that the output of the inverter 28 is in phase with the utility AC power grid before enabling any connection between the two. The grid relay 32 is under the control of an AC Relay Control Circuit 34 . The AC Relay Control Circuit 34 monitors the phase of the output of the inverter 28 and the phase of the utility AC power grid 30 . When the phase of the inverter output is synchronized with the phase of the utility AC power grid 30 , the AC Relay Control Circuit 34 causes the grid relay 32 to connect the two together.
In order to protect the wind turbine generator system 20 from damage from over speed resulting from wind gusts, some wind turbine generator systems 20 include a brake relay 36 , as mentioned above. The brake relay 36 is connected across the output terminals 24 , 26 of the generator 22 . The brake relay 36 may be an electromechanical relay, for example, as specified by G83/1, that shorts the terminals 24 , 26 of the generator 22 together when the relay is activated. Shorting the terminals 24 , 26 of the generator 22 together creates a load on the generator 22 and slows down and eventually stops the generator 22 , thus acting as an electronic brake. Due to the variability of the wind speed, many known wind turbine generator systems 20 , such as those systems designed to the Engineering Recommendation G83/1, discussed above, continuously monitor the output voltage of the generator 22 at a DC Measurement Point. When the output voltage of the generator 22 exceeds the lockout threshold voltage, for example, 310 Volts DC, indicative of an over speed condition, a Brake Relay Control Circuit 38 activates the brake relay 36 , which shorts the terminals 24 , 26 of the generator 22 and maintains the short circuit condition, thus locking out the generator 22 , for a time period of 3 minutes, for example. This lock out condition causes the wind turbine generator system 20 to be off-line during a wind condition in which the system could be delivering maximum power to the utility AC power grid 30 . The lock out condition also makes wind turbine energy systems 20 less desirable as a renewable energy source.
These problems are solved by the over speed control circuit in accordance with the present invention. With reference to FIG. 2 , the over speed control circuit in accordance with the present invention includes a pulse width modulated (PWM) Brake switch 40 that is under the control of a PWM brake control circuit 42 . The PWM Brake switch 40 is connected across the output terminals 24 , 26 of the generator 22 and is thus in parallel with the brake relay 24 . The PWM Brake control circuit 42 continuously monitors the generator output voltage at the DC Measurement Point and compares the generator output voltage with an over speed threshold voltage, for example 300 Volts DC, relatively less than the lock out threshold voltage used to trigger the brake relay 36 . As will be described in more detail below, the over speed control circuit in accordance with the present invention minimizes operation of the brake relay 36 , thus optimizing the operation of the wind turbine generator system 20 and maximizing the power exported to the utility AC power grid 30 .
The DC output voltage of the generator 22 may be measured by a DC Measurement Circuit 58 or a sensor. In particular, the DC Measurement Circuit 58 may include a diode 44 and a capacitor 46 . With such a configuration, the DC Measurement Point (i.e. cathode of the diode 44 ) is separated from the generator 22 by way of the diode 44 . The measurement side of the diode 44 may be coupled to relatively large metal film hold up capacitor 46 , for example, 1000 microfarads, which holds the generator output voltage relatively constant during measurement once the capacitor 46 is fully charged defining the DC Measurement Point. When the generator output voltage at the DC Measurement Point reaches the maximum rated design voltage (i.e. over speed threshold), the PWM Relay Control Circuit 42 generates a drive signal to actuate the PWM Brake 40 . As will be discussed in more detail below, the PWM Brake 40 may be configured as an n-channel MOSFET, coupled across the output terminals 24 , 26 of the generator 22 . In such a configuration, the drive signal from the PWM Brake Control circuit 42 is applied to the gate terminal of the n-channel MOSFET. When the drive signal is pulled high, the MOSFET is turned on. This condition looks like a short to the generator 22 . The short across the generator 22 slows the turbine down with a corresponding decrease in the generator output voltage. At this point, the voltage from the generator 22 falls below the voltage of the DC Measurement Point (i.e. the voltage on the capacitor 46 ). This condition back biases the series diode 44 , effectively isolating the generator 22 from the DC Measurement Point. The hold up capacitor 46 , coupled to the DC measurement point, is used to supply current to a flyback section of the inverter 28 during a flyback mode. While the capacitor 46 supplies current to the inverter 28 , the voltage at the DC measurement point (i.e. voltage on the capacitor 46 ) will decrease to a point below the over speed threshold voltage. When the voltage on the capacitor 46 drops below the over speed threshold value, the PWM Brake Control circuit 42 generates a low signal that is applied to the gate of the MOSFET causing the MOSFET to turn off. Once the MOSFET is turned off, the turbine can now spin freely and the DC input voltage from the generator will change according to the available wind speed.
The ramp-up voltage of the generator 22 is moderated by the load presented to the generator 22 through recharge of the holdup capacitor 46 . The recharge time of the capacitor 46 allows ample time for the MOSFET to turn off. The effect is to set up a PWM regulator whose duty cycle is inversely proportional to the DC voltage. The controlled voltage allows for the generator 22 to operate under a much wider band of wind speed than would normally be possible with the electromechanical method.
FIG. 3 illustrates an exemplary analog embodiment of the over speed control circuit in accordance with the present invention, generally identified with the reference numeral 50 . The over speed control circuit 50 includes the PWM Brake 40 , for example, a MOSFET, coupled across the output terminals 24 , 26 ( FIG. 2 ) of the generator 22 and the PWM Relay Control Circuit 42 A ( FIG. 3 ), shown within the dashed box. The PWM Brake Control Circuit 42 A is an analog circuit and includes a comparator 52 and a driver circuit, generally identified with the reference numeral 54 . The over speed threshold signal or reference 56 is applied to an inverting input of the comparator 52 . The generator output (i.e cathode of the diode 44 ), identified in FIG. 3 as the DC Measurement Point, is applied to a non-inverting input of the comparator 52 .
The generator output voltage may alternatively be sensed by a sensor or virtually any means for providing a signal representative of the generator output voltage. For example, the sensors may include a step down transformer.
When the output voltage of the generator 22 at the DC Measurement Point exceeds the Over Speed Threshold Reference 56 , the output of the comparator 52 goes high, thus actuating the PWM Brake 40 to effectively short the output terminals 24 , 26 of the generator 22 . As mentioned above, the output of the comparator 52 will remain high until the voltage on the capacitor 46 ( FIG. 2 ) drops below the Over Speed Threshold Reference 56 . At that point, the output of the comparator 52 will go low, thus providing PWM control of the PWM Brake 40 .
The output of the comparator 52 may be applied to a driver circuit 54 . The driver circuit 54 illustrated in FIG. 3 is merely exemplary and includes a pair of serially coupled resistors 60 and 62 . The output of the comparator 52 is applied to a node defined between the serially coupled resistors 60 , 62 . One resistor is coupled to a voltage source V 1 . The resistors 60 and 62 act as a voltage divider to pull up the output of the comparator 52 to a predetermined value. The driver circuit 54 also includes a pair of complementary bipolar junction transistors 64 and 66 connected in a push-pull configuration. More particularly, the transistor 64 is a NPN transistor while the transistor 66 is a PNP. The bases and emitters of the transistors 64 and 66 are coupled together. The collector of the transistor 64 is pulled high by way of a pull up resistor 68 . The collector of the transistor 66 is pulled low and is connected to ground. The emitters of the transistors 64 and 66 are coupled to the PWM Brake 40 .
In operation, when the output of the comparator 52 is low, the PNP transistor 66 is turned on, connecting the PWM Brake 40 to ground, in which case n-channel MOSFETS used as the PWM Brake 40 , remain off. When the output of the comparator 52 goes high, the PNP transistor 66 turns off and the NPN transistor 64 turns on. This causes the PWM Brake to be pulled high, thus causing the n-channel MOSFET, used for the PWM Brake 40 to be turned on, effectively shorting the generator 22 .
An exemplary alternate digital embodiment of the over speed control circuit in accordance with the present invention is illustrated in FIG. 4 and generally identified with the reference numeral 70 . The over speed control circuit 70 includes the PWM Brake 40 and the PWM Brake Control Circuit 42 D. The PWM Brake Control Circuit 42 D includes a microprocessor 72 and a driver circuit 74 . A flow diagram for the microprocessor is illustrated in FIG. 5 . The voltage at the DC Measurement Point (i.e. voltage at the cathode of the diode 44 , as illustrated in FIG. 2 ) is monitored by the microprocessor 72 .
Referring to FIG. 5 , monitoring of the voltage at the DC Measurement Point may be interrupt driven, as indicated by step 76 . Upon an interrupt, the analog DC voltage from the DC Measurement Circuit 58 is converted to a digital value by an on-board analog to digital converter (not shown), as indicated in step 78 . The system then checks in step 80 if the value of the voltage at the DC Measurement Point is greater than a PWM upper limit (i.e. over speed threshold plus a constant). If so, the PWM Brake 40 is actuated in step 82 and the n-channel MOSFET is turned on to short the generator 22 . The system then continues its processing in step 84 after servicing the interrupt.
If the system determines in step 80 that the voltage at the DC Measurement Point is not greater than the PWM upper limit (i.e. over speed threshold plus a constant), the system checks in step 86 whether the voltage at the DC Measurement Point is less than or equal to a PWM lower limit (i.e. over speed threshold minus a constant) in step 86 . If not, the system returns to step 84 and continues its processing. If it is determined in step 86 that the voltage at the DC Measurement Point is less than the PWM lower limit, for example, due to a voltage on the capacitor 46 , the PWM Brake 40 is turned off in step 88 . The upper and lower PWM limits are used to set the duty cycle of the PWM.
The driver circuit 74 ( FIG. 4 ) includes a current limiting resistor 76 , a pair of BJTs 78 , 80 , configured as a voltage enhancement circuit, a pair of load resistors 82 , 84 coupled to the collector terminals of the transistors 78 and 80 and a pair of complementary BJTs, 86 , 88 , connected in a push-pull configuration. The base and emitter terminals of the transistors 86 and 88 are coupled together. The base terminals of the transistors 86 and 88 are coupled to the collector of the NPN transistor 80 . The emitter terminals of the transistors 86 and 88 are tied to the PWM Brake 40 . The emitter terminals of the NPN transistors 78 and 80 are connected to ground.
In operation, whenever the microprocessor 74 outputs a high signal on its I/O port, the NPN transistor 78 is turned on, the NPN transistor 80 is turned off, connecting the base terminal of the PNP transistor 88 and the base terminal of the PNP transistor 86 to the high DC rail by way of the resistor 84 , thus turning off the PNP transistor 88 and turning on the NPN transistor 86 . As mentioned above, the PWM Brake 40 may be configured as an n-channel MOSFET. As such when the PNP transistor 86 is turned on, the MOSFET will be turned on. Thus allowing it to turn on and connect the positive voltage DC voltage rail to the DC Brake 40 . This causes the n-channel MOSFET, used as the PWM Brake 40 , to turn on. Alternatively, when the I/O port of the microprocessor 72 is forced low, the NPN transistor 78 is turned off, the NPN transistor 80 is turned on. During this condition, the base of the transistor 86 goes to ground, the transistor 88 is turned on and the MOSFET will be turned off.
Referring to FIG. 2 , a wind turbine generator system 20 in accordance with the present invention includes a Brake Relay 36 , a Brake Relay Control Circuit 38 , a PWM Brake 40 , a PWM Brake Control Circuit 42 , a DC Measurement circuit 58 , for example, the diode 44 and the capacitor 46 , an inverter 28 , a grid relay 32 and a AC Relay Control Circuit 34 . Inverters are extremely well known in the art and are used to convert DC electrical power to AC electrical power. Various inverters 28 may be used with the present invention. Exemplary inverters which may be used with the present invention are disclosed in U.S. Pat. Nos. 5,552,712; 5,907,192 and 6,256,212 and US Patent Application Publication No. US 2005/0012339 A1, all hereby incorporated by reference.
FIG. 6A illustrates the power exported by a conventional wind turbine generator system as illustrated in FIG. 1 . FIG. 6B illustrates the power exported by a wind turbine generator system in accordance with the present invention. Referring first to FIG. 6A , the curve 90 is an exemplary curve of the wind speed as a function time. The line 92 represents the lockout threshold value, for example, 10 meters per second. As shown, as the wind speed increases above the lockout threshold, the Brake Relay 36 locks out the generator 22 resulting in no power being exported to the utility AC power grid 30 for the lockout period of 3 minutes. After the lockout period expires, as the wind speed drops below the lockout threshold 92 , the wind turbine generator system exports power, as indicated by the curve 94 , until the wind speed goes above the lockout threshold 92 . As shown in FIG. 6A , this occurs at about 12 minutes. The wind turbine generator system is again locked out for 3 minutes. After the second lockout period, as the wind speed drops below the lockout threshold, the wind turbine generator system again begins exporting power at about 21 minutes, as indicated by the curve 96 . Thus for the 24 minute time period illustrated in FIG. 6A , the total power exported to the utility AC power grid 30 is the sum of the areas under the curves 94 and 96 . For the exemplary data indicated in FIG. 6A , the total power exported is 91 watts-hours.
FIG. 6B illustrates the power exported by a wind turbine generator system in accordance with the present invention. For the same wind speed curve 90 illustrated in FIG. 6A . In this case, the dotted line 96 represents the over speed threshold, for example 10 meters per sec. The over speed threshold is selected to be lower than the lockout threshold. As shown, any time the wind speed exceeds the over speed threshold 96 , the PWM Brake 40 electronically brakes the generator 22 to allow maximum power, for example, 1000 watts, to be exported by the generator from about 0.5 minutes to about 6 minutes, as indicated by the segment 98 of the curve 100 . With the conventional system, as illustrated in FIG. 6A , the wind turbine generator system was locked during this same time period and exported no power. As the wind speed drops off during the time period from about 6 minutes to 12 minutes, the power exported drops below the maximum as a function of the wind speed. From 14 minutes to 18 minutes, the system exports maximum power, as indicated by the line segment 102 . During this same time period, the conventional wind turbine generator system was locked out because the wind speeds exceeded the lockout threshold and thus exported no power during this period. From 18 minutes to 24 minutes, the wind turbine generator system exported power to the utility AC power grid 30 as a function of the wind speed, which remained below the lockout threshold and the over speed threshold. The total power exported by the wind turbine generator in accordance with the present invention is 350 Watt-hours, significantly higher than the conventional system illustrated in FIGS. 1 and 6A .
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. Thus, it is to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above.
What is claimed and desired to be secured by a Letters Patent of the United States is:
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An over speed control circuit for a wind turbine generator is disclosed which optimizes the time that the wind turbine generator is operational and thus maximizes the power output over time. The over speed control circuit forms a closed feedback loop which periodically measures the output voltage of the wind turbine generator in order to regulate its speed by electronically controlling the load on the generator. The over speed control circuit in accordance with the present invention is adapted to work in conjunction with known over speed protection lock out relays. More particularly, the over speed control circuit causes a short circuit to be placed the generator terminals when the generator voltage reaches a threshold value, relatively less than the threshold value used to trigger the over speed lockout relay. As such, the over speed control circuit minimizes the operation of the lockout relay, thereby maximizing the power output of the generator over time making such wind turbine generator systems much more practical as a renewable energy source.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is structural members, and the invention relates more particularly to underground vaults.
Typically, the cover of an underground vault is sealed over the vault by a cementitious grout. The major problem with the cementitious grout is that it is slow to cure. When the vault is located under a roadway, traffic must be diverted for about one day to provide sufficient time for the cement to completely cure.
One technique which does not use cementitious grout is shown in the Landers U.S. Pat. No. 4,773,792, which utilizes a plurality of porous bags placed along the upper surface of the vault wall. The bags contain an expandable epoxy resin of the type described in the Skiff U.S. Pat. No. 4,092,296 which is incorporated by reference herein. It has been found that because of the bond between the vault and vault lid, when removal of the vault lid occurs the vault itself suffers structural damage. This new process prevents that bond and saves the vault from damage.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process for sealing a cover over a vault, which process provides a rapidly cured seal.
The present invention is for an improved process for sealing a cover over a vault of the type having a vault with a wall with an upper surface and a cover which mates with the upper surface of the vault. The process comprises the steps of forming at least one porous tube having a wall having a porosity sufficiently large to permit the flow of gas therethrough, but sufficiently fine to permit only a small amount of passage of uncured epoxy resin therethrough. The porous tube is covered with a sheet of plastic film, thus forming a plastic film covered porous tube. Next, the interior of the porous tube is filled with an epoxy resin prefoam of the type which expands prior to curing and which cures with an exothermic reaction and which prefoam further has a cure delay of at least three minutes at room temperature, due to a time delay between mixing of the epoxy resin and its exotherm, filled plastic film covered porous tube. Next, the prefoam filled film plastic covered porous tube is placed between the top of the vault and the bottom of the vault cover, and the epoxy resin prefoam is allowed to expand, thereby expanding the plastic film covered porous tube into intimate contact with the cover and the vault. Preferably, the plastic film is a polyethylene bag.
BRIEF DESCRIPTION OF THE DRAWINGS
With the foregoing offered by way of background and environment, a preferred embodiment of the invention herein is depicted in the several views of the drawing wherein:
FIG. 1 is a perspective view of a vault sealed with the process of the present invention;
FIG. 2 is a cross-sectional view taking along line 202 of FIG. 1;
FIG. 3 is an enlarged cross-sectional view showing the intersection of the cover and vault of FIG. 1:
FIG. 4 is a cross-sectional view taking along line 4--4 of FIG. 3;
FIG. 5 is an exploded perspective view showing the cover, cover support member, plastic film covered porous tube and vault of FIG. 1;
FIG. 6 is a perspective view of the plastic film covered porous tube useful with the process of the present invention;
FIG. 7 shows a length of plastic film covered porous tube tied at one end and partially filled with a epoxy resin prefoam;
FIG. 8 is a perspective view of the partially filled plastic film covered porous tube FIG. 7 tied at both ends;
FIG. 9 is a perspective view of the tied plastic film covered porous tube placed between the lid and the top of the vault:
FIG. 10 is an enlarged view of the wall of the porous tube and the plastic film of FIG. 6; and
FIG. 11 is a cross-sectional view showing the epoxy resin beginning to expand with the final expanded view being shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A vault of the type used for holding electrical, or communication, or other utility connections, is shown in perspective view in FIG. 1 and indicated by reference character 10. Vault 10 has a base with four walls 11, 12, 13 and 14. A cover 15 is sealed to the top surface of the walls, and prior to expansion of the epoxy resin within the elongated tube, was held over the walls by four spacers 16, 17, 18 and 19.
The assembly of FIG. 1 is shown in cross-sectional view in FIG. 2 where it can be seen that cover 15 is sealed to the walls by an porous tube generally indicated by reference character 21. Bottom 20 is also shown in FIG. 2.
The details of the intersection between the cover 15 and wall 12 is shown in FIG. 3 where a porous tube 22 is filled with epoxy resin prefoam 23 and is covered with a plastic film 24. The details of spacer 16 are also shown where it can be seen that the space 16 has vertical legs 25, upper horizontal legs 26 and lower horizontal legs 27. It straddles the vault wall 12, as well as the downwardly depending portion of cover 15 to provide a secure support for the cover before the elongated tube 21 is placed therein.
The cross-sectional view taken along line 4--4 of FIG. 3 is shown in FIG. 4. There it is particularly clear that the plastic film 24 prevents any contact between the porous tube 22 and either the vault wall 12 or the cover 15.
Turning to FIG. 5, the elements of the assembly of FIG. 1 are shown in exploded perspective view. There it can be seen that the tube may be bent at corner 28 to accommodate corner 29 between walls 11 and 12. Thus, a single tube could actually be used to seal cover 15 to vault walls 11, 12, 13 and 14.
The details of the process are shown best in FIGS. 6 through 10. In FIG. 6, a roll of canvas tubing 30 is unrolled sufficiently to cut off a length of porous tubing. A similar length of plastic tubing is cut from roll 31 of plastic tubing. Plastic tubing 31 is preferably a six mils polyethylene tubing which provides excellent lubricity to prevent the foam from adhering to the concrete wall or cover. Next, the porous tube is inserted within a length of plastic film or tubing, and one end is tied with a tie 32, as shown in FIG. 7. The plastic film covered porous tube is indicated by reference character 33. It should be noted that while a plastic tube is shown in the drawings, it is possible that the porous tube could merely be wrapped with a plastic film. Tie 32 is preferably a conventional cable tie type tie. Next, the length of elongated tube tied at one end, as shown in FIG. 7, is partially filled with a plastic epoxy resin material of the type described in Skiff U.S. Pat. No. 4,092,296. The formulation shown in example 242 has been found to be particularly effective and its compressive strength may be dramatically increased by the addition of 0.75 parts per hundred of resin of powdered iron oxide. This resin prefoam material is mixed in a conventional manner with an inline mixture where the resin and hardener are passed through a mixing head and extruded through a nozzle into the interior of the porous tube 22.
After the porous tube 22 has been partially filled, the second end is tied, as shown in FIG. 8, with a second tie 35. The filled and tied length of elongated tube is then placed between the cover and the walls of the vault, as shown in FIG. 9. The epoxy resin prefoam has a substantial time delay between mixing and its exotherm, and it is during this time that the elongated tube is placed between the cover and the vault. Because of the plastic tubing, the assembly is particularly clean and easy to handle. If spacers, such as spacers 16 through 19, are used, the elongated tube is placed through the center of the spacing as shown best in FIG. 11.
After about eight minutes at 70° Fahrenheit, the formulation begins to cure and the foam begins to rise. As it rises, the elongated tube expands with the gas formed during the expansion step passing readily through the walls of porous tube 22 and into the interior of plastic film 24. It will be appreciated that the expanded foam enhances the overall structural strength and integrity of the vault and cover.
The fully expanded elongated tube usually causes the cover to rise above the spacers 16 through 19 so that a very tight contact is made between the expanded elongated tube and the cover and walls of the vault.
An enlarged view of the porous bag and the plastic film 24 is shown in FIG. 10, and the plastic film 24 is typically slightly larger than the expanded porous bag 22 so that it does not interfere with the full expansion of the porous bag 22.
While a single elongated tube may be used to seal the joint between the cover, it is often easier that a series of smaller elongated tubes be used, and this can easily be done since the porous tubes and plastic films or tubes can be cut on site. The material of construction of the porous tube is not critical, but it has been found that a heavy canvas tube having a 76 strand length by 28 strand with per inch weave was very satisfactory. As stated above, a polyethylene bag of six mils thickness proved very satisfactory.
The present embodiments of this invention are, thus, to be considered in all respects as illustrative and not restrictive; the scope of the invention being indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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A process and resulting structure providing a utility vault with a foam-filled tube sealing the space between the vault walls and the vault cover. Preferably the tube includes an inner tube that is sufficiently porous to permit gas to flow therethrough but only a small amount of uncured foam to flow therethrough, and a plastic outer tube that prevents the foam from bonding to the vault structure.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to the manufacturing of paper and board products and in particular to novel techniques of evaluating the condition of machine clothing and the integration of clothing performance into the production planning and execution of customer orders for such products.
BACKGROUND OF THE INVENTION
[0002] In the manufacture of paper on continuous papermaking machines, a web of paper is formed from an aqueous suspension of fibers on a traveling mesh wire or fabric and water drains by gravity and vacuum suction through the fabric. The web is then transferred to the pressing section where more water is removed by dry felt and pressure. The web next enters the dryer section where steam heated dryers and hot air completes the drying process. The wire or fabric and felt are commonly referred to as papermaking clothing which is conditioned (or cleaned) periodically and replaced as required. Substandard clothing leads to poor web formation on the machine which ultimately results in lower quality paper products exhibiting streaks, pinholes and poor mechanical and optical properties.
[0003] Techniques for regulating papermaking by monitoring the condition of the felt and/or affecting the moisture level of the felt are known. For example, EP 2198278 describes infrared measurement of the paper machine clothing condition to control paper production. U.S. Pat. No. 7,811,417 describes a cross-direction actuator system for maintaining the moisture level on press felt in order to affect the moisture content in the sheet of paper produced. EP 1342839 describes measuring the hardness or compactness of clothing to determine its condition and performance. EP 1329551 describes monitoring the cross-direction dewatering profile in the wet section to determine when replacement of the felt was necessary.
[0004] The average felt life is approximately 40 to 45 days and the average wire life is approximately 90 to 100 days, with both being dependent on the type of paper machine and nature of raw material processed. To avoid interruptions and downtime caused by unexpected clothing breakage during production, papermakers often replace the felt and wire more frequently than is required. In addition, papermakers will change the grades of paper being produced in order to reduce the likelihood of breakage. For instance, a changeover from a lower basis weight paper to a higher basis weight paper can be implemented as the wire fabric becomes impregnated with fiber and debris. The basis weight is the paper's weight per area and is typically designated in the industry by grams per square meter (gsm). Unscheduled changeovers generate excess inventory of unplanned paper grades.
SUMMARY OF THE INVENTION
[0005] The present invention is based in part on the recognition that considering clothing performance as a strong input during production planning significantly improves the operations of individual papermaking machines. Integration of the clothing performance (ageing of machine clothing) reduces the frequency of clothing breakages and attendant shutdowns, maximizes the use of the clothing, and produces consistently better paper and paperboard products. Furthermore, papermaking machine operators will be able to deliver paper product orders on time, with less waste and at lower costs. With prior art practice, clothing performance was not considered during production planning and, as a result, the frequent unplanned shutdowns of the papermaking machines required re-planning of many orders which caused inevitable delays and related problems.
[0006] In one aspect, the invention is directed to a method of operating a papermaking machine with enhanced clothing life wherein a sheet of wet stock comprising fibers is initially formed on a water permeable moving wire of a forming section of a de-watering machine and thereafter a sheet of partially de-watered web stock is transferred to a press section of the de-watering machine, wherein the press section comprises at least one continuously circulating press felt, the method including the steps of:
[0007] (a) operating the machine to produce a selected quantity of first grade paper product;
[0008] (b) monitoring the condition of the wire and generating wire data;
[0009] (c) monitoring the conditions of the felt and generating felt data;
[0010] (d) calculating the remaining useful life of the wire;
[0011] (e) calculating the remaining useful life of the felt;
[0012] (f) operating the papermaking machine to produce a selected subsequent quantity of subsequent grade of paper product, wherein the subsequent grade of paper produced could be the same as the grade of previously made paper product, with the proviso that the amount of selected subsequent quantity of subsequent grade paper product produced does not cause the papermaking machine to exceed either the remaining useful life of the wire or the remaining useful life of the felt; and
[0013] (g) repeating steps (b) through (f) until the useful life of either the wire or felt is reached with the provision that neither the wire nor felt breaks upon termination of operations of the papermaking machine.
[0014] The present invention allows for robust optimized production planning of customer orders that require manufacturing multiple grades of paper and/or paperboard products with different delivery schedules where the planner can select from a plurality of papermaking machines which are located at different mills to make the products and complete the orders. The papermaking machines include machines of various designs. The only limitation being that the machine is capable of producing one or more grades of paper product in the customer order.
[0015] In another aspect, the invention is directed to a method of manufacturing paper products that includes the steps of:
[0016] (a) monitoring the condition of the clothing on a plurality of papermaking machines and estimating the life of the clothing for each papermaking machine;
[0017] (b) obtaining customer orders for paper products;
[0018] (c) assigning one or more of the plurality of papermaking machines to produce the paper products with the objective of limiting costs;
[0019] (d) identifying the warehousing requirements for the paper products; and
[0020] (e) identifying the delivery date for each customer order.
[0021] The present invention which links the selection and operation of one or more papermaking machines to their respective clothing performance will improve clothing life cycle. It is expected that the wire life and the felt life will both be raised to at least 90% of normal. Moreover, the paper products produced will have a consistently better quality resulting in fewer production rejections and excess inventory. Furthermore, with the attendant improved production and delivery times, there will be significantly reduced warehousing requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 depicts a papermaking machine;
[0023] FIG. 2 illustrates the press arrangement of the papermaking machine; and
[0024] FIG. 3 is a production model that integrates clothing performance in customer order planning scheduling.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] The integration of clothing performance in dynamic planning optimization will be illustrated by implementing the technique in a sheet or web making system 10 that includes papermaking machine 2 , control system 4 and network 6 as illustrated in FIG. 1 . The papermaking machine 2 produces a continuous sheet or web of paper material 12 that is collected in take-up reel 14 . The paper material 12 , having a specific width, is produced from a pulp suspension, comprising of an aqueous mixture of wood fibers and other materials, which undergoes various unit operations that are monitored and controlled by control system 4 . The network 6 facilitates communication between the components of system 10 .
[0026] The papermaking machine 2 includes a headbox 8 , which distributes a pulp suspension uniformly across the machine onto a continuous moving screen or wire 30 that moves in the machine direction (MD). The wire 30 is typically an open mesh material that can be made of metal such woven bronze or copper. Alternatively, the wire can be made of synthetic materials such as plastics (polyamides), in which case the wire is often referred to as a fabric. Headbox 8 includes any suitable structure for distributing a pulp suspension and includes a slice opening through which the pulp suspension is distributed onto moving screen or wire 30 which comprise a suitable structure such as a mesh for receiving a pulp suspension and allowing water or other materials to drain or leave the pulp suspension. The slice jet speed is the speed at which pulp stock exits the headbox. Besides the composition, consistency and temperature of the stock, the jet-to-wire speed ratio is another important operating variable. As used herein, the “wet end” forming portion of sheetmaking system 10 comprises headbox 8 and wire 30 and those sections before the wire 30 , and the “dry end” comprises the sections that are downstream from wire 30 .
[0027] Sheet 12 enters a press section 32 , which includes multiple press rolls where sheet 12 travels through the openings (referred to as “nips”) between pairs of counter-rotating rolls. In this way, the rolls in press section 32 compress the pulp material forming sheet 12 . This may help to remove more water from the pulp material and to equalize the characteristics of the sheet 12 on both of its sides.
[0028] As sheet 12 travels over a series of heated rolls in dryer section 16 , more water in sheet 12 is evaporated. A calendar 18 processes and finishes sheet 12 , for example, by smoothing and imparting a final finish, thickness, gloss, or other characteristic to sheet 12 . Other materials (such as starch or wax) can also be added to sheet 12 to obtain the desired finish. An array of induction heating actuators 24 applies heat along the cross direction (CD) to one or more of the rollers to control the roll diameters and thereby the size of the nips. Once processing by calendar 36 is complete, sheet 12 is collected onto reel 14 .
[0029] Sheetmaking system 10 further includes an array of steam actuators 20 that controls the amount of hot steam that is projected along the CD. The hot steam increases the paper surface temperature and allows for easier cross directional removal of water from the paper sheet. Also, to reduce or prevent over drying of the paper sheet, paper material 14 is sprayed with water in the CD. Similarly, an array of rewet shower actuators 22 controls the amount of water that is applied along the CD.
[0030] In order to control the papermaking process, the properties of sheet 12 are continuously measured and the papermaking machine 2 adjusted to ensure sheet quality. This control may be achieved by measuring sheet properties using one or more scanners 26 , 28 that are capable of scanning sheet 12 and measuring one or more characteristics of sheet 12 . For example, scanner 28 could carry sensors for measuring the dry weight, moisture content, ash content, or any other or additional characteristics of sheet 12 . Scanner 28 includes suitable structures for measuring or detecting one or more characteristics of sheet 12 , such as a set or array of sensors. Scanner 28 can measure the dry end dry weight, ash content, or other physical properties of the paper product. Measurements from scanner 28 are provided to control system 4 that adjusts various operations of papermaking machine 2 that affect MD and/or CD characteristics of sheet 12 . An MD characteristic of sheet 12 generally refers to an average characteristic of sheet 12 that varies and is controlled in the machine direction.
[0031] In this example, control system 4 is capable of controlling the dry weight of the paper sheet by adjusting the supply of pulp to the headbox 8 . For example, control system 4 could provide information to a stock flow controller that regulates the flow of stock through valves and to headbox 8 . Control system 4 includes any hardware, software, firmware, or combination thereof for controlling the operation of the sheetmaking machine 2 or other machine. Control system 4 could, for example, include a processor and memory storing instructions and data used, generated, and collected by the processor. Scanner measurements control operations of the papermaking machine with both the dry end control and wet end control loops operating.
[0032] FIG. 2 depicts a representative press section which is situated between the end of the forming section and beginning of the dryer section. The press section consists of a number of cooperating endless circulating loops, through which a sheet of wet stock is transformed into a sheet of partially de-watered wet-stock. This exemplary press arrangement includes three separate closed loops that include: (1) upper press felt 40 , (2) lower press felt 42 , and (3) dryer felt 44 . Press felts 40 , 42 serve as reservoirs to collect (absorb) water from the sheet of wet stock by pressing and capillary action. The forming wires, press felts, and dryer felts are collectively referred to as papermaking clothing. Dryer felt 44 is heated and water evaporates from the partially de-water wet stock as it is carried by the dryer felt. Upper and lower press felt 40 , 42 are typically made of synthetic materials whereas dryer felt 44 is typically made of cotton or synthetic materials. The structure of the felts used in the dryer section can have very high open areas to afford rapid evaporation. Coarse or grainy characteristics, chocking of felts, sticky materials on the felts, degraded porosity and excessive hardness on the press and dryer felts can cause marks or imperfections on the paper formed.
[0033] A sheet of aqueous wet stock 46 is transported from wire 30 of the forming section onto the wet-press section. Vacuum devices 62 , 64 referred to as Uhle boxes (vacuum boxes) under the wire and press felt remove water from the web. A sheet of wet stock 46 is transferred by suction to the bottom side of upper press felt 40 that is held by suction roll 62 and is thereafter retained and supported by surface tension on the upper press felt 40 as the sheet becomes disposed between the upper press felt 40 and the lower press felt 42 . The sheet of wet of stock, which is sandwiched between the two felts, advances toward a press nip that is created by press rolls 48 and 50 where compression forces water from the wet stock and into the felts. Papermaking machine can have multiple press sections depending on the machine configuration. Upon exiting the wet-press step, the partially de-watered and consolidated sheet is transferred onto the first dryer felt 44 which carries and supports the sheet as it passes over dryer cylinders 52 and 54 where some residual water is removed by evaporation. The sheet is then transferred onto the second dryer felt 58 which is heated by dryer cylinder 56 . Only one dryer cylinder is shown whereas a commercial papermaking machine typically has thirty to sixty, depending on the paper machine configuration. At this stage in the process, the relatively thin sheet dried paper product 60 is available for further papermaking processing, such as coating and calendaring, where the moisture content is reduced.
[0034] Forming wire 30 is washed and repaired offline whereas press and dryer felts can be cleaned and washed, wherein the process is generally referred as conditioning, using chemicals and/or water either online or offline. For example, as shown in FIG. 2 , upper press felt 40 is equipped with sensor 70 which measures characteristics of the fabric such as moisture level, porosity of the clothing materials and the like. A spray device 72 directs cleaning fluid onto the fabric as necessary and vacuum device 74 removes the cleaning fluid. Lower press felt 42 is similarly conditioned with sensor 82 , spray device 84 and vacuum device 86 and dryer felt 44 is equipped with sensor 76 , spray device 78 and vacuum device 80 . The quality of machine clothing is maintained in order to produce acceptable paper and paperboard products. Lighter basis weight paper products are preferably made when the felt is new or just cleaned offline whereas the highest basis weight products are produced later when the felt is less porous.
[0035] The operating parameters of the papermaking machine are tuned to produce paper products having specific characteristics such as paper grade. With the present invention, empirical operating data of the papermaking machine collected during actual production can be employed to develop a mathematical model to predict the useful life of the wire and press and dryer felts. The collected operating data forms a database that correlates actual useful lives of clothing to machine operating parameters. In this fashion, for any papermaking machine that is available for production, the expected remaining useful life the wire and felts can be calculated based on its operation history.
[0036] Operating parameters that are particularly suited for predicting useful clothing lives include, but are not limited to, press felt Uhle box vacuum, suction roll vacuum, clothing thickness, felt water permeability, felt air permeability, hardness of felt or wire, dryer section steam demand, wire speed, and MD and CD physical characteristic profiles of the felts. Felt air permeability measures the air flow rate through the felt while the felt is stationary or as the machine is operating. Felt water permeability measures the flow rate of water that is injected into the stationary or moving felt. Other attributes which can be employed with the collected operating parameters to predict the remaining clothing life are historical clothing data which consist of data of how the clothing was used previously. Exemplary historical clothing data include, for instance, clothing mounting date, average life of clothing, length of operation of clothing on machine, online conditioning regiment for clothing, offline conditioning schedule for clothing, type of clothing such as single or multi-layer fabrics and different grades and basis weights of paper products manufactured on a particular papermaking machine.
[0037] Typical attributes of an order for paper products are customer, a due date (ship date), production specifications (grade, basis weight), physical specifications (width, product roll diameter range or sheet length, core diameter and customer specific requirements) and order quantity with given tolerances. When an order has more than one product, in terms of physical and production specifications, the individual product is referred to as an order item. A typical large paper manufacturing enterprise has a number of paper mills in various locations, with each mill having one or more papermaking machines. A feature of the present invention order allocation process pertains to production planning and scheduling to decide where each order item will be produced. Orders can also include forecasted order items, which are standard orders that are based on forecasted quantities based on historical data.
[0038] Each papermaking machine can be tuned to produce different products at different production rates. The production costs, which comprise the major portion of the selling price, are usually different for different papermaking machines for the same product. To the reduce transportation cost, which is another major component to the selling price, it is preferable to produce order items in mills close to the order's final destination. Order allocation in the prior art that focused on production, fixed grade change time (the cost associated with change over production time loss and does not consider clothing performance), inventory and transportation costs without taking clothing performance into account often resulted in schedules with poor performance in on-time delivery, setup changeovers and trimming. The setup changeover cost, trim loss and on time delivery depend on how the production runs get form on individual machines.
[0039] A continuous papermaking machine makes one product at a time. A production run or time slot is the period of time over which the machine produces the same product. It should be noted that production runs or time slots can be of different time widths depending upon the quantities of the order items being processed simultaneously. When the product on a machine is changed, the machine can continue to operate but the paper produced is usually of lower quality for an initial period of time. This “transition time” or “grade change time” depends on the machine and on the products being manufactured before and after the changeover.
[0040] Planning and scheduling begins with obtaining customer orders to be delivered within a specific time frame and equipment availability. Customer orders can also include forecasted or anticipated future orders. Planning entails collecting standard or conventional order planning parameters which includes for example: (1) order details such as customer name, consignee, mode of transportation, stock or making order, order quantity, (2) order type such as roll, sheet, and cartons, (3) production route such as papermaking machine, winder, rewinder, sheeter, warehouse, and combination of different paper making, converting and wrapping machines (4) grade specification details such as writing and printing, paperboard, packaging, cartons, kraft, copier, newsprint, laser paper, tissue, and specialty papers (5) ship promise date and delivery date, (6) papermaking machine availability and downtime, and (7) different types of costs such as manufacturing, trimming, warehousing, opportunity lost, and freight cost. Next, for each papermaking machine that is available for production, it is necessary to measure and collect for each machine the above-mentioned operating parameters and ascertain the historical clothing data.
[0041] FIG. 3 shows the production process where the clothing performance of individual papermaking machines is considered in the planning stages so that orders for paper products are assigned to selected papermaking machines such that upon executed of the orders, the products are delivered on time and with minimal costs. The standard order planning parameters, operating parameters and ascertained the historical clothing data are inputs into a Planning and Scheduling Engine which employs a mathematical model that analyzes the data and generates solutions that identify the manufacturing time associated with each ordered item. For example, a plurality of time blocks is generated with each time block corresponding to a paper product having specific grade, quantity, and delivery time. Any planning tool generates a production plan that identifies the papermaking machines, order execution dates, type, size and quantity of paper products required. The trim planner fine tunes the production plan with external constraints that include, but are not limited to, the following parameters: (1) papermaking machine parameters such as throughput, machine configuration and specifications, (2) optional and urgent (hot) orders, (3) stock orders, (4) quantity tolerances, and (5) future orders. Production tracking monitors and controls the production process. The produced products are warehoused and thereafter shipped.
[0042] The foregoing has described the principles, preferred embodiments and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments discussed. Thus, the above-described embodiments should be considered as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present invention as defined by the following claims.
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Integration of clothing performance into production planning, scheduling and execution of papermaking machines yields paper products with consistent acceptable quality with minimum downtime and inventory. Linking the selection and operation of papermaking machines to their respective clothing performances improves clothing life cycle. Selected operating parameters of a papermaking machine and historical clothing data are indicative of the machine's clothing condition. Order scheduling engine identifies manufacturing times for particular grades of product and generates order blocks. Papermaking machines are assigned to execute specific order blocks with provision that each machine completes execution of the assigned orders without any anticipated breakage of the wire or felts.
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FIELD OF THE INVENTION
The present invention relates to a device for receiving the exhaust gas output of a reciprocating piston internal combustion engine, and more particularly discloses a muffler assembly that is particularly advantageous for use with a two-stroke gasoline engine, which assembly provides both an exhaust scavenging function and a supercharging function, and in addition, comprises a low profile and compact design.
BACKGROUND OF THE INVENTION
This invention discloses an exhaust gas handling assembly for an internal combustion engine, which is especially useful in small two-stroke gasoline engines such as in radio-controlled airplanes and wheeled vehicles for ground travel, such as motorcycles and all terrain vehicles. The device is commonly referred to as a muffler, but this is a term that is too restrictive for all the functions performed by the device. While the device does serve to muffle or dampen the noise of combustion in such internal combustion engines, it also serves at least two other critical functions, exhaust scavenging and fuel-charge densification.
The present invention has been found to be particularly advantageous when used on a two-stroke, internal combustion, piston and crankshaft type engine which burns a volatile fuel such as gasoline and/or alcohol, and which utilizes valving consisting of ports formed through the wall of the piston cylinder, controlled by movement of the piston within the cylinder to alternately expose and cover up said ports.
A typical two-stroke engine has one or more intake ports formed through each cylinder wall and one or more exhaust ports formed through the cylinder wall, usually located on the opposite side of the cylinder from the intake ports. These ports are positioned such that the piston opens and closes them in a carefully controlled sequential manner to allow intake and exhaust of the fuel/air mixture and the products of combustion, respectively. Many such engines pump the fuel/air mixture through the crankcase of the engine into the intake port in the cylinder wall.
During a normal intake/compression/combustion/exhaust cycle of the two-stroke piston-cylinder combination, when the exhaust port is opened by movement of the piston away from its blocking position over the port, a high-pressure exhaust gas pulse starts down the exhaust tube. The piston continues down and the exhaust pressure bleeds off into the tube. This occurs at around 90-110 degrees from piston Top Dead Center (TDC). At about 15-25 degrees later, the intake ports on the other side of the cylinder are exposed by the piston, and, because of crankcase compression, a fuel/air mixture begins to flow through the intake ports and into the cylinder while exhaust gas is still moving out the exhaust ports. After a small fraction of a second, the pressure pulse moving down the exhaust tube reaches an open area, or expansion chamber, and this starts an expansion wave back toward the exhaust ports. This expansion wave creates an action at the exhaust ports, which serves to draw additional flow of exhaust from the cylinder, including a portion of the new fuel/air charge entering through the intake ports.
As the expanding exhaust pulse reaches the end of the expansion chamber, it impinges the narrowed end of the tube at the downstream end of the chamber and is compressed, thereby creating a strong compression wave that moves back up the tube to the exhaust port. This results in some of the escaped fuel/air charge being pushed back into the cylinder before the piston closes the exhaust ports, thus achieving the desired charge-densification effect in the cylinder.
The “tuning” of the muffler is dependent upon the length and volume of the expansion chamber and its distance down the tube from the exhaust ports. This chamber effectively locates the positions of the expansion part of the tube, and the compression portion. The remaining portion of the exhaust tube downstream from the expansion chamber has little effect on the “tuning” of the exhaust.
Some exhaust mufflers, which are also commonly called “tuned pipes” or “tuned exhaust extractors”, which are currently available commercially for small two-stroke engines are sufficiently “tuned” to allow optimum scavenging of exhaust from the cylinder of the engine and a charge-densification of the incoming fuel/air mixture. This occurs by the advantageous utilization of the above-described impulse/compression wave nature of the exhaust muffler. There are also mass effects involved in exhaust processes, i.e., the volume of exhaust gas in a system does not move through the pipe with a smooth, linear velocity. The velocity rises and falls along with the pressure waves, so that being “in tune” with these differences amplifies the pressure differences. The expansion portion of the exhaust gas wave moving out of the cylinder, through the exhaust valve, and down the muffler tube serves to establish a subnormal pressure condition just outside the exhaust valve, which aids in removing additional combustion products from the cylinder while the cylinder interior is exposed to the open exhaust port. Shortly thereafter, the compression wave passing back up the muffler to the cylinder serves to “supercharge” the incoming fuel/air charge that has begun to exit the open exhaust port by forcing the charge back through the exhaust port and into the cylinder, thereby increasing the density of the fuel/air mixture in the cylinder before the compression and combustion cycles are achieved.
Unfortunately, prior art muffler devices for small two stroke gasoline engines offer chamber designs that are many times longer than the diameter of the cylinder in which the fuel/air mixtures are combusted. The most prevalent of such muffler devices commercially available for two-stroke gasoline engines suffers from having a length as much as 6-30 times the diameter of the cylinder it is attached to. The specific length of the tuned pipe is primarily a function of the RPM at which the engine designer wishes to “tune” the system. Often a particular torque curve is desired for an optimum match-up with the particular airframe chosen, and this can be achieved by designing the system to be longer or shorter. A short length tube will be utilized for a high-RPM, low torque engine, and a long length tube will be used for a low-RPM, high torque engine. This length is used to create the compression/expansion wave actions referred to above which establish the scavenging and densification functions previously described. If such muffler chamber is not properly sized, the two-stroke engine exhaust will not be “tuned” and performance of the engine will suffer drastically.
However, when the muffler chamber is properly sized for optimum performance, it results in a muffler having a physical presence that is many times larger than the entire engine to which it is attached. In the world of small engines, this is very undesirable for several reasons. One reason that such bulky and cumbersome exhaust device is undesirable is the ugly aesthetics that it presents. The present commercially available muffler is a long, cigar-shaped tube that must extend down the side of the vehicle to which it is attached. For those who desire authenticity in the appearance of their small gasoline-powered vehicles, the presence of such a bulky and obvious attachment, often extending down the full length of the airplane or land vehicle on which it is used, greatly mars the owner's enjoyment of the vehicle. This is particularly true in the field of radio-controlled (RC) airplanes and cars.
In addition to the aesthetically unpleasant feature of current muffling devices, they also are very aerodynamically inefficient, causing unbalanced weight and drag on the vehicles, especially on the RC airplane.
Commercially available “tuned” mufflers for small two-stroke engines generally comprise a long, cigar-shaped tube/chamber combination that begins with a small diameter next to the exhaust port of the engine cylinder. At this point the cross-sectional area of the muffler may be approximately the same size as the exhaust port of the small engine. As you progress down the tube of the muffler, the cross-sectional area increases several-fold to form the expansion chamber of the muffler to create the expansion wave which moves backward down the muffler to the exhaust port and provides the scavenging function mentioned previously. This serves to “suck” the remaining exhaust gases from the cylinder while also creating a low-pressure condition in the cylinder that aids in inducting a greater fuel/air charge through the intake port which is open at the same time.
Further down the muffler, the cross-sectional area is narrowed significantly to create the compression wave that then moves back up the muffler to the cylinder and serves to push back into the cylinder the portion of unburned fuel/air charge that had managed to flow partly out the exhaust port and into the muffler, thereby accomplishing the densification or “supercharging” effect of the muffler. When these two chamber sections, i.e. the expansion chamber and the compression chamber, are located in tandem along the same axis, the device must by necessity be very long, i.e., many times the diameter of the cylinder to which it is attached. This creates a muffler system that is sometimes longer than the vehicle on which it is used. This prior art exhaust device can thus be characterized as a Total-Axial-Flow muffler system.
A second prior art muffling device that is commercially available is similar to the “tuned pipe” system described above but adds a further element of a concentric annular outer shell which “wraps” around the tuned muffler and goes from the exit end of the first exhaust pipe, forward to the beginning of the inner pipe to obtain a dual concentric pipe effect. This creates an outer chamber around the inner tube, which chamber serves to act as an expansion/compression wave generating chamber. While this has the effect of providing the desired scavenging and densification effects on the engine and is shorter in length, this second device suffers from the disadvantage of being larger in diameter and less efficient than just the tuned pipe style of muffling system, thus detracting from the aesthetics and streamlining of the vehicle it is used on.
SUMMARY OF THE INVENTION
The present invention solves the problems of the prior art exhaust systems described above by providing a muffler device that is not total-axial-flow with respect to exhaust gases, but instead folds the several distinct functional aspects of the “tuned” muffler in on one another in a combined axial-circumferential flow, to greatly reduce the length and size of the device and thereby provide a muffler that can be secured entirely inside the cowling, cabin, or cockpit of the vehicle on which it is used. Thus the present invention presents a “tuned” muffler that is aesthetically pleasing and which eliminates aerodynamic drag on the vehicle.
The invention also teaches a tuned exhaust system for an internal combustion engine having at least one exhaust port for ejecting spent exhaust gases, said tuned exhaust system comprising:
A. a first enclosed exhaust flow channel adapted for attachment to an internal combustion engine, said first flow channel having at one end thereof an inlet port adapted for receiving exhaust gases from the exhaust port of an engine, an extended flow tube coiled in a first radial plane containing said inlet port, and an outlet port at the opposite end of said flow channel; and,
B. an expansion channel attached to said first flow channel and having an extended chamber folded into a second radial plane axially displaced from said flow channel, and having an inlet opening communicating with said flow channel outlet port, and an exhaust opening located an extended distance down said expansion channel from said inlet opening and adapted to exhaust gas flow into the atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front schematic view of the muffler device of the present invention;
FIG. 2 is side sectional view of the invention taken at line 2 — 2 of FIG. 1;
FIG. 3 is a side sectional view of the invention taken at line 3 — 3 of FIG. 1;
FIG. 4 is a front schematic view of a second embodiment of the invention;
FIG. 5 is a side sectional view of the embodiment of FIG. 4, taken at line 5 — 5 ; and,
FIG. 6 is a side sectional view of the second embodiment taken at line 6 — 6 of FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-3, and more particularly FIG. 1, the muffler device 101 is illustrated as it appears when viewing from the front of the engine 102 to which it is attached. Muffler 101 consists of three basic modules, the pipe section 103 , the can section 104 , and the cover plate 105 . As illustrated in this embodiment, the muffler 101 is cylindrically shaped, but as illustrated in the second embodiment herebelow, this shape could just as well be any geometrical shape desired, including square and rectangular.
FIG. 2 is a sectional end view of the pipe section 103 taken at line 2 — 2 of FIG. 1 . The pipe section 103 consists of a cylindrical outer housing shell 106 and a helical divider wall 107 spiraling inward from the outer wall 106 to a central chamber 108 . The axial height of spiral wall 107 is equivalent at all points to the height of shell 106 , so that the addition of the flat inner wall 109 of can section 104 against pipe section 101 serves to seal against the entire length of divider wall 107 , thereby creating a sealed spiral passage 110 . The only openings to passage 110 are the inlet opening 111 communicating with the exhaust valve of engine 102 , and an exhaust outlet opening 112 formed in wall 109 of can section 104 . One or more mounting holes 113 are formed through the left wall 114 of pipe section 103 for mounting the muffler device 101 to the engine 102 , allowing the passing therethrough of mounting screws or bolts from the wall section 114 to the engine block of engine 102 .
FIG. 3 is a side sectional view of the can section 104 of the muffler device 101 , taken at line 3 — 3 of FIG. 1 . Can section 104 consists of cylindrical housing or shell 115 which is machined for tight-fitting sealing engagement with housing 106 of pipe section 103 , a flat wall section 109 adapted to seal off and create the enclosed spiral passage 110 in pipe section 103 , and a chamber forming divider wall 116 which is attached to wall section 109 and is arranged to seal against cover section 105 to form an expansion and compression chamber 117 . An exhaust inlet opening 112 is formed through wall 109 to communicate with passage 110 in pipe section 103 , and is generally located at about the center of section 104 . The opening between pipe section 103 and can section 104 must be at or near the end of the spiral passage 110 for proper operation, i.e., at the center of the pipe section, designated as outlet 112 . The opening from the expansion chamber 117 to the atmosphere can be located through cover plate 105 so that it aligns with either end of expansion chamber 117 . In FIG. 3 this is indicated in phantom at 118 to show the location of the exhaust port with respect to opening 112 . An alternate location for the exhaust port in the cover plate 105 is also indicated in FIG. 3 at 119 . Either location, 118 or 119 , allows exhaust gas to be flowed out of the muffler device while still taking full advantage of the expansion/compression chamber 117 . However, the exact location of this port is not critical to the operation of the invention, because changing the location serves mainly just to change the back pressure that is created within the exhaust assembly and to also vary the temperatures reached within the exhaust assembly. Also, the size of port 118 determines pressures, temperatures and mass flow effects within the entire exhaust system. One skilled in the art, with only a minimum of trial and error, will be able to vary the size and location of port 118 to optimize the particular exhaust effects desired, depending upon the application of the engine on which the system is to be installed, and depending on the RPM range at which the operator wishes power from the engine to be optimized.
A cover plate 105 engages with can section 104 to enclose the chamber area 117 by sealing with housing 106 and having a flat wall section 109 that engages the top of divider wall 116 . An exhaust port 118 is formed through the wall of cover plate 105 and communicates with compression/expansion chamber 109 to allow spent exhaust gases to exit the muffler assembly into the atmosphere.
An assembly hole can be formed centrally in all of the three sections, 102 , 104 , and 105 so that a bolt, screw, pin, or other elongated fastening device may be passed through the separate assembly sections to secure them together into a single assembly 101 . Alternatively, the separate sections could be formed so that they telescope into each other, with telescoping sections along the outer periphery of each section that can be fastened securely by threads formed on each section, by fusion means such as welding, or by fasteners passing through the telescoped outer walls where they overlap.
In addition to the above described structure of the three elements consisting of the pipe section 103 , the can section 104 , and the cover plate 105 , it is possible to manufacture the assembly by forming the can section and the cover section as a single integral part, by making the flat wall section 109 of the can section as a separate individual divider plate that is inserted between the pipe section and the can section and held there by pressure from these two adjacent sections, and/or by one or more fasteners as described hereinabove.
Further modifications of the invention from the specific embodiment described above can be achieved without changing the efficiency and operation of the invention. For example, instead of having the pipe section and the can section located with respect to each other so that they are coaxial and concentric, it is possible to have the sections located so that they are still touching each other while being axially displaced from each other, but not concentric, as long as the outlet port from the pipe section still communicates with the inlet opening of the can section. It is possible to slide one section radially outward from the other and still maintain contact between the two sections sufficient to allow communication between the outlet port of one with the inlet port of the other, while maintaining the operation and efficiency of the invention, so long as they are still axially displaced one from the other and their diametral planes are still relatively parallel to each other and displaced axially.
The muffler assembly 101 may be made of any structural metal which is light, strong, and temperature-resistant, such as aluminum, steel, brass, copper, or alloys of these and other metals. Likewise, the assembly could be manufactured from a strong temperature-resistant thermosetting polymer known to those skilled in the thermosetting plastics art. Or, various parts of the assembly could be made of different metals, alloys, or polymers from other parts of the assembly without going beyond the limits of the herein described invention.
FIGS. 4-6 illustrate a second embodiment of the invention in which the overall general shape of the muffler assembly 201 is a rounded-corner rectangular shape rather than that of a right circular cylinder as disclosed in the first embodiment. FIG. 4 illustrates a schematic diagram of the muffler assembly 201 which consists of a rectangular pipe section 203 to which is attached a matching rectangular can section 204 , closed off by a rectangular cover plate 205 . The muffler is attached to the exhaust port of an internal combustion engine 202 .
FIG. 5 is a sectional side view of the pipe section 203 , which is the view taken at line 5 — 5 of FIG. 4 . In this figure the pipe section 203 is formed in a similar fashion to the pipe section 103 of the first embodiment, in that it consists of an outer housing or shell section 206 extending axially with the exhaust flow from engine 202 . Inside housing 206 is a barrier wall 207 extending down a substantial portion of the vertical length of section 206 and forming an exhaust flow channel 210 which is a U-shaped closed passage created by the sealing of wall 209 of can section 204 against wall section 207 and barrier wall 207 . An inlet port 211 is formed through wall 214 of the pipe section to communicate with the exhaust port of the engine to which the muffler 201 is attached.
FIG. 6 illustrates a side sectional view of the can portion 204 of the muffler of the second embodiment, which view is taken at line 6 — 6 of FIG. 4 . Can section 204 has an external housing shell 215 which is a constant-height rectangular wall forming the external shape of the can section 204 . Shell 215 is attached to a flat can wall section 209 and forms internal expansion/compression chamber 217 therein. This chamber is made into an ell shape by the addition of internal wall section 216 which is attached to can wall 209 and is of equal height to housing wall 215 .
A closed chamber or dead space 219 results from the ell shape of chamber 217 . An inlet port 212 is formed through wall 209 of can section 204 and communicates with U-shaped passage 210 of pipe section 203 . Preferably, inlet port 212 is located on the opposite side of barrier wall 207 from inlet port 211 coming from the exhaust valve of the engine. A rectangular cover plate 205 is attached to the can section 204 by sealing engagement of the outer edge of cover plate 205 with housing shell 206 of the can section. Also, cover plate 205 contacts the full length of barrier wall 216 to enclose chambers 217 and 219 . An exhaust port 218 is formed through the wall of cover plate 205 to exhaust spent gases to the atmosphere. As with the first embodiment, the exact location of port 218 is not critical to the operation of the invention, but allows the designer to vary pressures and temperatures within the exhaust system.
Typical Operation
In typical operation, an exhaust gas pulse enters the exhaust entry port 111 of pipe section 103 from the opened exhaust valve of engine 102 . The gas pulse enters the spiral passage 110 of the pipe section and traverses down this passage toward the outlet port 112 formed in the can section. The exhaust gas pulse flows through the port 112 and reacts with the volume of the expansion/compression chamber 117 , with the immediate result that the volume of the gas pulse is rapidly expanded, thus creating an expansion wave that moves back up the spiral passage 110 to provide the needed scavenging of the engine cylinder through the still-open exhaust valve and port 111 .
After the expansion pulse has moved around the full length and volume of chamber 117 it hits the ends of the chamber, thereby creating a compression wave that then travels back through the chamber 117 , port 112 , up the spiral passage 110 , and into the exhaust valve of the engine cylinder, thus providing the charge-densification effect previously mentioned.
The entire system is “tuned” according to the engine designer's desires by altering the length and/or volume of the individual chambers. The volume can be altered by making the pipe section or the can section, or both, wider or narrower in the axial direction. The lengths of the passages can be altered by changing the degree of curvature and length of the spiral wall section 107 , and/or the degree of curvature and length of wall section 116 . Volume and length of all the internal passages can be altered by increasing the radial diameter of the entire device 101 , thereby simultaneously increasing the length of the internal passages while also increasing their volumes.
The skilled mechanic in the art of muffler or “expansion chamber” design for two-stroke engines, such as those used in motorcycles and airplanes, can design the length and diameter of the internal passages of the muffler to obtain the particular results desired of the particular engine being “tuned” by the exhaust system. This requires that the designer know the speed at which sonic waves travel through the expansion chamber of the muffler device. This in turn depends upon the temperature of the exhaust gas moving down the chamber. Exhaust gases exit the combustion chamber at approximately 1200 degrees F. and drop to around 800 degrees F. at the outlet pipe. Because of the cooling from expansion in the chamber, they can be cooled to as low as 500 degrees or lower before reaching the final outlet pipe. Critical dimensions, besides the length and diameter of the expansion chamber, include the rate or angle of divergence of the expansion chamber wall section, and the cross-sectional shape of the chamber. Also critical is the angle of convergence in the compression section at the end of the expansion chamber.
These factors are more particularly spelled out for the skilled artisan in publications available commercially, such as the book “TWO STROKE TUNER'S HANDBOOK” by Gordon Jennings, copyright 1973 by H. P. Books, Box 5367, Tucson Ariz.; book number 41-ISBN 0-912656-41-7; the contents of which are incorporated herein by reference. It should be noted that according to this reference, the design of any muffler device for a two-stroke engine is an exercise in compromise, because of the many different end results that can be achieved by the engine designer. For example, some exotic racing engines are tuned to obtain a peak horsepower rating in a very narrow RPM range because of their close-ratio, multiple speed transmissions which are designed to keep the engine revved up and operating continually at a desirable high RPM. Alternatively, other two-stroke engines, because they do not enjoy the advantage of being able to “shift gears” while in operation, may need to utilize a muffler system with an expansion chamber designed to optimize the average power output over a broader range of RPM.
For example, the angle of divergence of the expansion chamber wall, called the “diffuser angle” determines the width of the engine “power band”. In a conventional “cigar-tube” expansion chamber, a diffuser angle of greater than 8 degrees creates a short-duration wave that results in maximum power at peak RPM. A more gradual taper, less than 8 degrees, spreads the power band out over a broader range of RPM. Likewise, the compression taper at the end of the expansion chamber has a similar but less dramatic effect on the power band of the engine. Thus it can be seen that the dimensions and angles of the expansion chamber section of the muffler of the present invention can be optimized in several different configurations to fit the designer's power goal, depending upon the desired final result of the engine designer, by using a very small amount of trial and error.
In the second embodiment of the invention, these same changes can be used to obtain the same variations in dimensions and capacities. In addition, in the second embodiment, the length and volume of the expansion/compression chamber 217 can be altered by increasing or decreasing the volume of the dead space 219 .
Thus, the present invention has provided both the scavenging and charge-densification effects necessary to have an efficient “tuned” exhaust system. These are the same functions provided by the extensively long and bulky prior art muffling devices; however, the present invention provides these features in a compact muffler that can be completely contained in the cowling, cabin, or cockpit of the airplane or ground vehicle to which the muffler is attached.
It has been shown how the present invention has solved the problem of the prior art devices by providing a compact and efficient “tuned” exhaust muffler assembly that is concealable within the confines of the vehicle on which the device is being used.
While multiple embodiments of the invention have been illustrated, it is to be understood that the invention is not confined to the precise disclosure, and it will be apparent to those skilled in the art that various changes and modifications can be made in the invention without departing from the spirit of the invention or from the scope of the appended claims. For example, whereas the device is illustrated in cylindrical and rectangular form, it is clear that other geometric shapes such as triangular or elliptical could also be used advantageously. Also, whereas it is noted that the material of which the device is manufactured is a strong light metal or thermosetting plastic, it is clear that other materials such as carbon fiber material could also be used advantageously.
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The present invention discloses a compact efficient exhaust handling device that is particularly advantageous for use with small two-stroke, piston-type internal combustion engines, which device provides both exhaust scavenging and charge densification in the cylinder of the engine by utilizing a first muffler section formed in a helical or wrapped configuration, and a muffler expansion chamber also formed in a wrapped configuration, and axially displaced from the first section.
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CROSS REFERENCES TO RELATED APPLICATIONS
(not applicable)
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
(not applicable)
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
(not applicable)
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON COMPACT DISC
(not applicable)
BACKGROUND OF THE INVENTION
1) Field of the Invention
The invention relates to systems used for enhancing the solar energy received by a solar array and, more particularly, to such systems which maintain the solar array in its desired position of facing the sun throughout diurnal operation of the system using the electrical power generated by a solar panel.
2) Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
Worldwide energy demands have been steadily increasing as more people in more countries use energy consuming technologies in their daily lives. Fossil fuel sources of energy have therefore been increasing in cost as a result of this increasing demand. However, many alternatives to non-renewable energy sources such as nuclear energy and wind power devices have not been able to meet this increasing demand with clean, safe and non-polluting methods of utilization.
In the current field of exploiting renewable energy sources, there is a great increase worldwide in the use of solar energy facilities that use photovoltaic cells. Photovoltaic cells used for converting sunlight into electrical energy are placed in arrays and used for a variety of purposes. They are used as utility interactive power systems, as power supplies for remote or unmanned sites, as cellular phone switch site power supplies and as housing complex power supplies. Such arrays are able to produce from several kilowatts to over a hundred kilowatts of energy and can be installed wherever there is a reasonably flat area with exposure to the sun for significant portions of the day.
Companies producing and designing solar panels are receiving considerable funding from government sources in order to produce more efficient and cheaper designs. It is thus expected that the use of solar panels will become more widespread in the near future as the funding yields the anticipated improvements in solar panel designs. Many of the new designs are expected to be in the chemistry and structural makeup of the photovoltaic cells which are the constituents of the solar panels.
The efficiency and output of solar panels have been increased by panel clustering into the smallest possible space by forming large surfaces at a single level. But, this solution hinders panel cooling, reducing their yield due to the temperature increase at a ratio of 0.5% per degree Centigrade. This clustering is further limited due to panel expansion since the support structures are rigid and occasionally surrounded by a frame enclosing them, generating stresses between panels due to nighttime and daytime temperature differences. Such designs also have the important shortcoming of inherent structural instability as a result of asymmetrical static loads which has limited their use. Consequently, other ways of improving the performance of the solar panels have been developed which focus on maximizing the sunlight received by the photovoltaic cells.
A general principal is that the power generated by a solar panel depends strongly on the angle between the direction of propagation of solar rays irradiating the panel and a normal to the surface of the panel. Various forms of solar trackers have been developed for use with arrays of panels of photovoltaic cells to optimize the orientation of the solar panels so that it is normal to the direction of propagation of the solar rays throughout the day thereby increasing the concentration of light energy on the panels.
One type of conventional tracker used for solar power panels and solar collectors to improve their efficiency mounts the collector on a north-south axis and rotates it from east to west to follow the sun's apparent movement from sunrise to sunset. Typically, such systems include a pair of photovoltaic cells mounted on the solar collector or panel one cell of which views the eastern quadrant (90 degrees) of the horizon (when the collector and the cell are positioned in a horizontal plane) and the other cell of which views the western quadrant of the horizon. A difference in outputs between the cells indicates an error point at the sun, and thus the outputs of the cells are used to correctly reposition the solar collector. However, such systems are error prone. The presence of clouds and especially a single bright cloud can draw a photocell away from pointing at the sun and cause a drive system to miss-position a collector.
Another type of solar tracker system has photovoltaic panels configured in rows supported on a torque tube that serves as an axis. A tracker drive system rotates or rocks the rows to keep the panels as orthogonally oriented (relative to the sun) as possible. Typically, the rows are arranged with their axes disposed in a north-south direction and the trackers gradually rotate the rows of panels throughout the day from an east-facing direction in the morning to a west-facing direction in the afternoon. Subsequently, the rows of panels are manually brought back to the east-facing orientation for the next day.
A solar collector arrangement of this type is disclosed in U.S. Pat. No. 6,058,930 to Shingleton. In the Shingleton system, a tracker is associated with at least one row of panels. A north-south oriented torsion tube defines a north-south axis and an array of flat rectangular solar are attached in a generally balanced fashion on opposite sides of the torsion tube. The system uses at least one pier, and the footing of the pier is supported in the earth. A pivot member is affixed to the pier above its footing and the torsion tube is journalled in this pivot member. This permits the array of solar panels to be rotated on the north-south axis to follow the motion of the sun relative to the earth. The Shingleton arrangement is designed to enable the system to tolerate the stresses and loads that are imposed on the components of pier mounted solar array systems. However, an important disadvantage of such arrangements is that since many such conventional pier mounted designs do not track the apparent movement of the sun solar energy collection is not optimum and the panels have to be made larger than otherwise would be deemed necessary in order to improve upon the solar energy received. This basic design thus requires that it be made large which imposes heavy loads on the components thereof rendering them more failure prone than smaller system designs.
The most efficient trackers, for absorbing maximum sunlight in a given day, have been multiple axis trackers, which rotate about more than one axis so as to follow both the azimuth variation (progression of the sun's bearing angle i.e., east to south to west), and the sun's change in elevation angle from the horizon. These types of trackers can provide annual energy output improvements of 30%. These types of trackers are particularly beneficial to concentrating solar collectors. In such concentrating solar collectors, the received solar radiation is converted into a concentrated radiation beam before it is directed to the solar cells, and such designs are very sensitive to the angle of incidence of the solar radiation. Of the two solar tracker axes, azimuth orientation and elevation (or tilt) orientation, the first is more important since it provides a substantially greater energy production gain. In addition, the azimuth tracking axis can furthermore be easily carried out since it is exclusively a time function and therefore uniform throughout the year. In contrast, the tilt axis varies according to both the elevation changes as the sun moves during the day and the seasonal changes due to the tilt of the earth's orbit and its tracking is therefore more complex. Consequently, most large trackers presently installed provide only single axis tracking, and conventional multi axis systems presently installed generally have an inordinate degree of complexity. Their complexity presents numerous potential malfunction problems and inaccuracies. Reversing motors and computer driven reversing mechanisms as utilized in some of these systems also add to the cost. Many such systems also utilize very sophisticated and high precision components that must be shielded from environmental elements to which exposed in order to provide a reasonable degree of longevity. The required shielding structures and subsystems add to the cost and also add to the weight of the system necessitating structural reinforcements or higher strength support structures along with higher power motors.
Due to the complexity and structural instability problems associated with conventional solar tracking systems in addition to their increased cost, solar panel installations are typically of the fixed position type. They are fixed in a position in which the panels are oriented toward the south, depending on whether the installations are located north or south of the equator. The angle of inclination depends on the latitude of the installation site. But for such solar panel installations that are fixed in position, the exploitation of the solar radiation received is not as high as it otherwise could be since the direction of the perpendicular to the solar panel coincides rarely if ever with the direction of the solar rays on an annual basis. Consequently, the annual energy output of such solar installations is much less than optimal.
What is therefore needed is a structurally simple yet accurate system for tracking the sun's apparent diurnal movement. What is also needed is such a system which is capable of maximizing the solar energy gathering efficiency of the system for which the tracking is provided.
BRIEF SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a solar tracker that will continuously and automatically track the sun's apparent diurnal movement.
It is another object of the invention to provide a solar tracker that will automatically reposition the tracker after the end of diurnal operations thereof for optimal reception of the solar rays at the beginning of successive diurnal operations.
It is an object of the present invention to provide a simplified solar tracker that is relatively inexpensive and which does not require a high degree of maintenance.
It is an object of the present invention to provide a solar tracker that is simple in structure and function so that it has a high degree of reliability.
It is an object of the present invention to provide a solar tracker that has relatively few components so that there are few components that can break down or malfunction thereby providing enhanced reliability.
It is an object of the present invention to provide a solar tracker that maximizes the duration of solar energy reception of its diurnal operation.
It is an object of the present invention to provide a solar tracker that is capable of providing a high degree of accuracy.
It is an object of the present invention to provide a solar tracker having a separate drive mechanism and a separate axle for each degree of rotational movement for improved accuracy.
It is also an object of the present invention to provide a solar tracker having a separate control subsystem for each degree of rotational movement for improved accuracy.
It is an object of the present invention to provide a solar tracker that may be used for various types of solar energy collection applications.
It is an object of the present invention to provide a solar tracker for a solar array that may be any suitable desired shape and size.
It is yet another object of the present invention to provide a solar tracker assembly capable of operation with substantially uniform tracking sensitivity throughout the year.
Basically, the assembly of the present invention utilizes motors powered by solar panels and controlled by other assembly components to track the sun's apparent diurnal movement. The assembly of the present invention thereby maintains the solar power array as well as any other suitable solar power panel, array or collector for which its tracking function may be used at a desired optimal orientation relative to the solar rays. The solar power array is independent of the solar panel or panels driving the axles. The power panel might therefore be utilized to convert solar energy to generate electricity and/or heat. The assembly utilizes driver solar panels that activate the motors that mechanically rotate the entire system.
In operation, when sunlight illuminates a driver solar panel of the tracker, the solar energy is converted to electrical energy which is transmitted to the motor for activation thereof. The motor will rotate the driver solar panel as long as the driver panel is receiving sufficient sunlight to match or exceed the electrical power requirement of the motor. When the solar energy converted into electrical power falls below the threshold power requirement of the motor, the motor stops and thereby the rotation of the driver panel stops. The driver panel thus powers the motor so that it rotates the driver panel to the point at which it is positioned/oriented relative to the solar rays such that the angle of inclination of the solar rays incident thereon yields the desired optimal aggregate solar radiation received by the driver panel, and beyond this point the motor stops The driver panel thus is stopped at an orientation where it does not receive the desired aggregate degree of solar radiation and in effect the driver panel is moved to the point where it is slightly ahead of the earth's rotation. Subsequently, the earth's rotation will “catch up” with the driver panel so that it approaches receiving the desired optimal solar radiation at which point the motor starts up and rotates the driver panel but again stops when it goes beyond the point at which the driver panel receives sufficient radiation to power the motor or to turn on activation output controls of associated control components and circuitry. Thus, the start and stop process of the motor continually repositions the driver panel so that the angle of incidence of the solar radiation on its face is ninety degrees, or that deemed optimal. In effect, the assembly of the invention follows the sun by avoiding it.
It is a crucial feature of the invention that the panel orientation control positions the panel so that it does not exceed a certain level of solar energy output. However, the power panel, which is generally what the tracker is intended to provide tracking for, need not be at the same orientation and thereby at the same degree of inclination relative to the solar rays as the solar driver (or tracker) panel. Instead, the power panel may be positioned at an angle relative to the solar panel such that the power panel is ahead of the tracker panel with regard to the sun's diurnal movement. Thus, the power panel may, for example, be positioned so that it is continually receiving the optimal solar energy while the solar tracker panel is receiving less than that optimal amount of energy. Moreover, the power panel may be angularly positioned relative to the solar panel at such a select angle that it receives any desired degree of solar energy relative to the maximal amount that can be received when the solar rays are at a normal angle of incidence on the power panel.
In order to ensure that the motor is started and stopped at the precise solar panel orientations which provide the desired energy output, a passive zener circuit is provided to prevent an “overshoot” of the optimal orientation and other spurious motion. The output of the zener circuit can be directly injected into the driving motor. This output can also be directed to a relay that can control the current flow from the driver panel to the motor. The control circuitry and optional relay operate to start the motor when the electrical voltage or current output from the solar panel rises to a predetermined value and stop the motor when it drops below a predetermined value. These components narrow the range of solar energy received and thereafter converted to electrical energy and utilized to power the motor. Consequently, they prevent the panel from being rotated too far beyond the optimal orientation position and additionally can be adjusted to prevent the motor from stopping too far below the optimal orientation position. These components thus effectively function to keep the panel at a desired optimal orientation (and, more specifically, within a desired range of orientation parameters) relative to the sun throughout the day.
The solar panel is mounted on a rotatable shaft or axle which is connected to the motor. Preferably, the motor is connected to a base shaft, and the base shaft is affixed to a base structure or ground such that the base shaft does not rotate relative to the base structure or ground. But, the motor rotates relative to the base shaft and thereby the base structure or ground. The base shaft can be vertically upright with the azimuth adjustment primary solar driver panel and motor positioned and affixed so as to enable rotation of the motor relative to the base shaft and thereby the azimuth primary driver panel in an east-west direction so that the azimuth primary driver panel tracks the apparent east-west movement of the sun. This azimuth tracking substantially provided by the azimuth adjustment primary solar driver panel enhances the solar energy collecting capability of the driver panels as well as a solar power array or any other structure which the assembly of the invention may be used for.
Since the angle of incidence of the solar rays on the solar panel varies in accordance with the tilt movement of the earth and the daily motion of the sun in the sky from dawn to sunset, second driver (or tracker) panels (more specifically a second pair of driver panels) and motor combination are provided to correct for this type of movement. For this set of components, the rotating shaft or axle is oriented in an east-west direction and can thereby control the elevation of the entire system. The rotating axle is orthogonal to the base shaft or axle so that they, in combination, provide two degrees of movement. Each of the second driver panels and second motor utilize a second control circuit and a second relay which function the same as the first control circuit and first relay. These second components enable elevation angle position adjustment of the panels in order to correct for seasonal changes in the tilt position of the earth. Additionally, the second driver panels as well as the first driver panels are rigidly connected to the rotatable axle. The rotatable axle is rigidly connected to the second motor so that the second motor and rotatable axle rotate both pairs of tracker panels simultaneously. Also, the first motor and base shaft (or axle) rotate the second motor as well as both pairs of panels simultaneously. The elevation adjustment panels and motor combination also correct for changes during the day in the apparent position of the sun relative to its midday position when it is at its highest apparent position in the sky. The initial positioning of the second axle (as well as the entire tracker) need not be set relative to the earth axis. Tilt thus need not be accurately set because the elevation components position the axle relative to the sun's apparent position and thereby relative to the earth axis as accurately as may be desired.
At the end of the day's operation the assembly is placed in position for the next day's operation by means of incorporation of an azimuth adjustment return panel. Thus, the assembly components used to provide azimuth position adjustment (or correction) incorporate essentially a pair of panels placed back to back with the panel faces i.e., the surfaces having solar cells to receive the solar rays, at opposite sides thereof. The same azimuth motor can be employed to rotate the rotatable axle and panels from the sunset position to the sunrise position. In effect there are two driver panels using the same motor but at different times of the day. The angle between the back to back panels is selected so that at the end of the day's operation, one of the pair that has not been illuminated during that day's operation is positioned for reception of solar rays at sunrise at the desired optimal angle of incidence. Thus, one of the pair that was the “back” (or return) panel during the particular day's operation is positioned facing the direction of the sun at sunrise for reception of solar rays at the succeeding sunrise at the desired optimal angle of incidence. Thus, the motors rotate the panels to follow the sun's apparent position in the sky until sunset. Due to the angular positioning of the panels, during operation one of the panels is always shading the other.
At sunrise the (return) panel facing east rotates the axles in the opposite rotational direction of the motion during the day. This is achieved by wiring the return panel to the azimuth motor in opposite polarity to the wiring for daylight operation. This electrical arrangement is made possible because of the blocking ability of the zener diodes. The sunrise-to-sunset connection of the panels to the motor and the return connection of the back (return) panel are connected to the same terminals of the azimuth motor with no adverse effect electrically. A little after sunrise, the daytime (primary) panel's voltage will take control of the motor's rotation. The reason for the reverse rotational motion is to avoid wrapping wires around axles and other components. Alternatively, sliding brush type contacts can be used to deliver power to the motors. However, if such sliding contacts are used, the motion of the azimuth motor relative to the base shaft can be made in the same direction throughout successive days' operation and not produce wrapping the wires around the axles with 360 degree motion. It should be noted that the elevation adjustment (second) panels at sunset are nearly ideally positioned by mirror symmetry for initial operation at sunrise if the azimuthal position of the panels is set via panel rotation so that the panel faces east at sunrise. This feature is provided by the integral construction of the elevation panels consisting of a pair of panels facing in the same general direction.
The faces of each pair of azimuth adjustment panels are facing outwardly and away from each other so that only one of the panel faces can be properly illuminated. Thus, the invention has the important feature that the daily tracking is provided without the necessity of either manual reset, or mechanical or electronic reset at the end of each day. It instead provides fully automatic operation day after day. The tracker invention also has the advantageous features that there are a minimal number of moving parts and a minimal number of components which provide reliability as well as weight savings. These features also enable the entire structural surface area of the assembly to be smaller thereby minimizing vulnerability of the entire installation to wind forces that compromise the practicality of conventional trackers.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the solar tracker assembly shown connected to a solar array which the assembly is designed to position in accordance with its tracking of the sun's apparent diurnal movement across the sky.
FIG. 2 is a top diagrammatic view of the first embodiment of the solar tracker assembly showing the first embodiment in more detail and also showing the return components thereof.
FIG. 3 is a side diagrammatic view of the first embodiment of the solar tracker assembly showing the invention in more detail and also showing the elevation components thereof.
FIG. 4 is a block diagram of the first embodiment of the assembly with a schematic representation of the means for controlling the motor component thereof.
FIG. 5 is a perspective view of the second embodiment of the solar tracker assembly shown connected to a solar array which the assembly is designed to position in accordance with its tracking of the sun's apparent diurnal movement across the sky.
FIG. 6 is a top diagrammatic view of the second embodiment of the solar tracker assembly showing the second embodiment in more detail and also showing the return components thereof.
FIG. 7 is a side diagrammatic view of the second embodiment of the solar tracker assembly showing the invention in more detail and also showing the elevation components thereof.
FIG. 8 is a block diagram of the second embodiment of the assembly with a schematic representation of the means for controlling the motor component thereof.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, FIG. 1 shows the solar tracker assembly of the invention generally designated by the numeral 10 . FIGS. 1 and 2 also show the assembly 10 connected to and being used to position a solar power panel array 12 so that the power array 12 is facing the sun throughout the day and so that the solar rays 14 illuminating the solar array 12 are at a desired angle of incidence to provide a desired concentration of solar energy on the solar array 12 and thereby enhance solar ray reception thereof.
As shown in FIGS. 1 and 2 , the assembly 10 of the invention includes an azimuth adjustment primary (or first) driver solar panel 16 consisting of a multiplicity of interconnected solar photovoltaic cells 18 . The driver panel is shown as rectangular but may be of any other suitable shape. The solar panel 16 has a front side or face 20 and a back side 22 . The face 20 is designed for reception of solar energy via solar rays 14 incident thereon.
The driver panel 16 is rigidly connected to a second rotatable shaft or axle 44 . A first electric motor 26 is rotatably connected to a first base shaft or axle 24 which in turn is rigidly connected to a secure base or foundational structure so that the axle 24 is rigid relative thereto. The motor 26 is electrically connected to the solar panel 16 via first electric wires or first set of electrical wires 28 so that the panel 16 can provide electric power to the motor 26 .
In operation, the driver panel 16 converts solar energy of the solar rays 14 irradiating it to electrical current which it feeds to the motor 26 causing the motor 26 to rotate itself relative to the axle 24 and thereby rotate the panel 16 relative to the base structure. The axle 24 and motor 26 are oriented to rotate to follow the azimuth of the sun. The axle 24 may be set so that it is generally parallel to the earth's axis (not shown). The motor 26 is set up and connected to the axle 24 such that it rotates the motor 26 and axle 44 and panel 16 in an east to west direction. Thus, the motor 26 rotates itself and the axles 44 and panel 16 away from and ahead of the sun's apparent movement relative to the earth (and the assembly 10 ). The motor 26 continues to rotate the panel 16 until it no longer receives sufficient electrical energy from the panel 16 to activate or actuate it. The motor 26 and the axle 44 and panel 16 therefore stop with the driver panel 16 at a position where the angle of incidence of solar radiation irradiating it is less than optimal. This angle of incidence a where the driver panel 16 as well as the power panel 12 are stopped may be slightly less than, or substantially less than, perpendicular depending on the particular requirements of the solar power panel or cooker 12 or the application for which the tracker assembly 10 is being utilized. FIG. 2 illustrates the angle of incidence a formed by the irradiation of the panel 16 by solar ray 14 , and it is representative of that formed by irradiation of other panels as well. The rotational movement of the solar panel 16 relative to and on said first axle 24 essentially functions to allow adjustment of azimuth angle orientation with reference to earth spherical coordinates of the solar panel 16 . This achieves the objective of providing position adjustment of the solar panel 16 such that it corresponds to rotational movement of the earth relative to the sun Additionally, this rotation function thus provides azimuth angle adjustment or tracking for the azimuth panel 16 as well as the power panel 12 and other associated structures. The solar power panel 12 is preferably rigidly connected to the axle 44 via a connector 11 so that rotation of the panel 16 also results in rotation of the power panel 12 .
Since the motor 26 is preferably a conventional electric motor, it characteristically may be able to rotate relative to the axle 24 and rotate the axle 44 and azimuth panel 16 throughout a broad range of electrical energy parameters. It is therefore desirable to narrow the range of voltage or amperage fed into the motor 26 and in this manner accurately control the operation of the motor 26 . To accomplish this goal, the assembly 10 incorporates a relay 30 and an azimuth electrical output control means 32 . The electrical output control means 32 preferably controls the voltage from the solar panel 16 being fed into the motor 26 and, more specifically, controls the voltage from the solar panel 16 being fed into the relay 30 . The energizing voltage of the relay is selected so that it is within the energy output range of the panel and the energy requirements of the motor 26 . The electrical output control means 32 feeds electrical current to the relay at a level high enough to energize the relay when the electrical output from the panel 16 is at a predetermined value or at a predetermined range of values. The control means cuts off the electrical current to the relay when the electrical output from the panel 16 is less than that predetermined value or range of values. Alternatively, the control means may cut off the electrical current to the relay when the electrical output from the panel 16 is at or less than another predetermined value or range of values such that there are two critical predetermined values or range of values, one for energizing and one for de-energizing. Since the motor rotates the panel in only one direction which is that in which it tends to attempt to place the panel 16 ahead of the sun's apparent movement, the fall below the predetermined value will occur when the motor 26 has rotated the panel 16 too far such that the sun's subsequent apparent movement will result in the panel becoming closer to the optimal position thereby increasing the energy output from the panel and activating the motor 26 again.
Preferably, the electrical output control means 32 comprises a voltage divider circuit which preferably includes a first resistor 34 , a second resistor 36 and a zener diode 38 , as shown in FIG. 3 . The electrical output voltage V is fed to the two resistors 36 and 38 which are connected in series and schematically shown as R1 and R2. The resistor 36 is preferably variable. The voltage across R2 is Vin=V×R2/(R1+R2). This voltage is less than the voltage V generated by the solar panel 16 . When the output voltage V is large enough, the voltage Vin exceeds the zener diode threshold and the relay is activated so that the motor receives sufficient energy for activation and thereby rotation of the axle and solar panel 16 . When the output voltage V drops to the level where Vin drops below the zener diode threshold the current to the relay cuts off and the electrical current to the motor 26 is also cut off so that the motor stops and rotation of the axle and solar panel stops. Upon further movement of the sun and the attendant increase in the voltage V, the zener diode will again conduct tripping the relay and producing motor activation. Setting the value of R2 can be done at the time of construction of the assembly 10 or in the field.
The azimuth angle tracking function provided by solar azimuth panel 16 , motor 26 and associated components provides substantial enhancement of the amount of energy the solar panel receives in diurnal periods of operation. However, adjustment for the tilt of the earth on its axis during the year is also desirable to further enhance the solar energy the solar panel receives annually. Elevation angle adjustment is therefore provided by means of elevation adjustment panels (or second pair of panels) 40 and 41 in conjunction with a second motor 42 , the second axle 44 , a second set of electrical wires 46 , a second relay 48 and a second electrical output control means 50 . The pair of preferably identical panels 40 and 41 are angularly positioned with respect to each other. The top panel 40 is tilted upward so that it is oriented to receive sunlight during the early (before noon) daylight hours. The lower panel 41 is preferably tilted downward and positioned underneath the top panel 40 so that it is oriented to not receive sunlight during the early daylight hours but is rather in the shadow of the panel 40 during these early daylight hours. Both panels 40 and 41 are connected to the elevation motor 42 via the set of electrical wires 46 (preferably a pair for each panel 40 and 41 ) but with opposite polarities. From sunrise to solar zenith the top panel 40 energizes the elevation motor 42 to follow the upward rise of the sun. During this time the lower panel is in the shade of the top panel 40 . After noon the sun's elevation decreases to the point where the upper panel's active surface goes into the shade and the lower panel's output takes control of the elevation motor until sunset. It is not necessary for both the panels in the elevation pair to have a common physical connection. The upper and lower panels can be located anywhere along axle 44 or any extension of shaft 44 as long as its angular orientation with respect to the rest of the elements of system 10 is maintained. Similarly, the panel 16 can likewise be located anywhere on axle 44 or any extension of axle 44 as long as its angular orientation with respect to the rest of the elements of system 10 is maintained. The second relay 48 , as with the first relay 30 , has an energizing voltage which is selected to conform to the energy requirements of the second motor 42 . The second electrical output control means 50 preferably comprises a pair of second output control means 50 with one of the pair connected to the panel 40 and the other of the pair connected to the panel 41 . The second output control means 50 includes a first elevation resistor 52 , a second elevation resistor 54 and an elevation zener diode 56 . Alternatively, however, since the solar panels can act as electrical diodes when an external current is fed into them, the panels per se may be substituted for the diodes and thus used to pass electrical current in one direction only and thereby eliminating the need for a diode in the output control means. With such an alternative design, the panels would be electrically connected to suitable resistors and not to diodes. The second output control means 50 (and its components) in purpose and function is the same as the first electrical output control means 32 . The upper solar panel 40 , as with solar panel 16 , has a front side or face 37 and a back side 39 . The face 37 is designed for reception of solar energy via solar rays 14 incident thereon. The lower solar panel 41 similarly has a front side or face 43 and a back side 35 . The face 43 is designed for reception of solar energy via solar rays 14 incident thereon.
In operation, the upper and lower panels 40 and 41 convert solar energy of the solar rays 14 irradiating them (depending on the time of day) to electrical current which one of these panels 40 or 41 feeds to the motor 42 causing the motor 42 to rotate the axle 44 and the panel 40 (as well as the panel 16 ). The axle 44 can have any convenient orientation and is preferably tangent to the earth's surface. The axle also may be oriented so that it is generally perpendicular to the earth's axis (not shown). The motor 42 is set up and connected to the axle such that it rotates the axle 44 and panels in a north to south as well as a south to north direction depending on which panel is powering it. As the sun's apparent position in the sky rises in the early daylight hours, the upper panel 40 energizes and activates and powers the motor 42 to rotate the axle 44 and panels upwardly in accordance with the sun's apparent upward movement. The motor 42 continues to rotate the axles and panel until it no longer receives sufficient electrical energy from the panel 40 to activate or actuate it (at approximately solar zenith or, more preferably, just past solar zenith). As the sun's apparent position drops after noon, the lower panel 41 comes out of the shadow of panel 42 and provides sufficient electrical energy to power the motor 42 . Due to the opposite polarity connection of the panel 41 to the motor 42 , the panel 41 powers the motor 42 to rotate the axle 44 and panels down as the sun's apparent position in the sky drops.
Basically, the motor 42 rotates the axle 44 and panels 16 and 40 away from and ahead of the sun's apparent movement relative to the earth (and the assembly 10 ). The motor 42 and the axle 44 and panels therefore stop with the panel 40 at a position where the angle of incidence of solar radiation irradiating it is less than optimal. This angle of incidence where the panel 40 as well as the power panel 12 are stopped may be slightly less than, or substantially less than, perpendicular depending on the particular requirements of the solar power panel or array 12 or the application for which the tracker assembly 10 is being utilized. This rotation function thus provides elevation angle adjustment or tracking for the panel 40 as well as the power panel 12 and other associated structures. Although the drive means are disclosed as electric motors, other alternative electromechanical means such as, for example, an actuator can also be utilized for rotating the axles 24 and 44 .
The first axle 24 may be set so that it is parallel to the earth axis. However, it need not be because the elevation angle adjustment provided by the invention 10 compensates for errors in parallel positioning of the first axle 24 relative to the earth axis. Moreover, the elevation angle adjustment components of the invention 10 allow the first axle 24 to be positioned on the installation site without reference to the earth axis.
Since at sunset the diurnal rotation of the azimuth primary panel 16 positions it so that it is facing away from the sunrise position of the sun, the assembly 10 incorporates an azimuth return panel 17 to reposition the assembly 10 for the succeeding day's operation. Thus, the azimuth primary panel 16 and the azimuth return panel 17 together provide proper azimuth angle adjustment during day after day operation. The first pair of panels (or pair of azimuth adjustment panels) 16 and 17 and the second pair of panels 40 and 41 are rigidly secured to each other at edges 25 and 27 thereof so that they maintain their relative angular position. The edge 25 is preferably approximately parallel to earth axis when in operation and preferably located at the east ends or end portions 31 and 33 thereof and, for panels 40 and 41 , the edges 27 are at end portions 47 and 49 thereof. Alternatively, the edge 25 may be other than approximately parallel to earth axis when in operation if the particular application has other angle of incidence requirements.
The first set of electrical wires 28 provides electrical connection from the solar panels 16 , 17 to the motor 26 for providing power thereto. The second set of wires 46 is also included for providing electrical connection from the solar panels 40 and 41 to the motor 42 for providing power thereto. The electrical wires 28 and 46 are also flexible to prevent interference with the operation of the axles 24 and 44 as well as associated structures.
The invention 10 has the first pair of panels (or first panels) 16 and 17 as well as the second pair of panels (or second panels) 40 and 41 positioned so that they are at an acute angle relative to each other. That acute angle is a select and specific angle determined by the position of the panels 16 and 40 at sunset and the desired position that the return panel 17 should be placed in at sunrise. The angle may, for example, be twenty-five degrees. The selection of that angle places the azimuth adjustment return panel 17 in position for facing the sun and receiving the solar rays at the optimal angle of incidence (or other desired angle) at sunrise following the end of the diurnal operation of the assembly 10 . During one day's operation, the panels 16 and 40 are being irradiated and therefore providing electrical power to the respective motors 26 and 42 . As a result of the controlled rotation of the panel pairs and the respective angles of each pair, on the sunrise of the succeeding day the return panel 17 is facing the sun and therefore providing electrical power to the respective motor 26 . The azimuth electrical output control means 32 preferably comprises a pair of azimuth electrical output control means 32 (which are structurally identical to each other) one connected to the panel 16 and the other connected to the panel 17 and both connected to the motor 26 . Since the panel 17 is wired, via respective pair of the first set of electrical wires 28 , with opposite polarity (with reference to the wiring of panel 16 ) to the motor 26 , the panel 17 rotates the motor 26 , axle 44 and panels in the opposite direction from that of the preceding day so that the panel 17 rotates the assembly components back to the position of the prior sunrise and thereby at a position to track the sun's apparent movement during that day's operation. Thus, there is no necessity for reset (either manual or by other external means) of the panels at the end of the day's operation. The assembly 10 automatically positions its components for optimal reception of the solar rays at every succeeding sunrise. In addition, the entire installation may be mounted on gimbals or other suitable mechanical structures capable of allowing bidirectional rotation.
FIG. 5 shows the second embodiment of the solar tracker assembly of the invention generally designated by the numeral 110 . FIGS. 5 and 6 also show the assembly 110 connected to and being used to position a solar power panel array 112 so that the power array 112 is facing the sun throughout the day and so that the solar rays 114 illuminating the solar array 112 are at a desired angle of incidence to provide a desired concentration of solar energy on the solar array 112 and thereby enhance solar ray reception thereof.
As shown in FIGS. 5 and 6 , the assembly 110 of the invention includes an azimuth adjustment primary (or first) driver solar panel 116 consisting of a multiplicity of interconnected solar photovoltaic cells 118 . As with embodiment 10 , the solar panel 116 has a front side or face 120 and a back side 122 . The face 120 is designed for reception of solar energy via solar rays 114 incident thereon.
As with embodiment 10 , the driver panel 116 is rigidly connected to a second rotatable shaft or axle 144 . A first electric motor 126 is rotatably connected to a first base shaft or axle 124 which in turn is rigidly connected to a secure base or foundational structure so that the axle 124 is rigid relative thereto. The motor 126 is electrically connected to the solar panel 116 via first electric wires or first set of electrical wires 128 for providing electric power to the motor 26 .
In operation, the driver panel 116 is functionally and structurally identical to driver panel 16 of embodiment 10 . Therefore, the description of driver panel 116 and its associated components will not be repeated to promote brevity.
Since the motor 126 as with motor 26 is preferably a conventional electric motor, it characteristically may be able to rotate relative to the axle 124 and rotate the axle 144 and panel 116 throughout a broad range of electrical energy parameters. It is therefore desirable as with motor 26 to narrow the range of voltage or amperage fed into the motor 126 and in this manner accurately control the operation of the motor 126 . To accomplish this goal, the assembly 110 incorporates a relay 130 and an azimuth electrical output control means 132 . The electrical output control means 132 and relay 130 are structurally and functionally identical to control means 32 and relay 30 of embodiment 10 so their description will not be repeated.
Preferably, the electrical output control means 132 comprises a voltage divider circuit which preferably includes a first resistor 134 , a second resistor 36 and a zener diode 138 , as shown in FIG. 7 . These components function the same as correspondingly numbered components of embodiment 10 so their description will not be repeated.
Elevation angle adjustment is provided by means of elevation adjustment (or a pair of second) solar panels 140 and 141 in conjunction with a second motor 142 , the second axle 144 , a second set of electrical wires 146 , a second relay 148 and a second electrical output control means 150 . The elevation angle adjustment components of embodiment 110 are generally the same as those of embodiment 10 . Similar to embodiment 10 , the pair of preferably identical panels 140 and 141 are angularly positioned with respect to each other. However, these components are different from those correspondingly numbered components of embodiment 10 in that the panels 40 and 41 of embodiment 10 are oriented so that they are angled outwardly relative to the axle 44 whereas the panels 140 and 141 are oriented so that they are angled inwardly relative to the axle 144 . The top panel 140 is similarly tilted upward, but in an opposite direction from panel 40 , so that it is oriented to receive sunlight during the early (before noon) daylight hours. The lower panel 41 is preferably similarly tilted downward, but in an opposite direction from panel 41 . As with embodiment 10 , panel 141 is positioned underneath the top panel 140 so that it is oriented to not receive sunlight during the early daylight hours but is rather in the shadow of the panel 140 during these early daylight hours. As with embodiment 10 , both panels 140 and 141 are connected to the elevation motor 142 via the set of electrical wires 146 (preferably a pair for each panel 140 and 141 ) but with opposite polarities. As with embodiment 10 , from sunrise to solar zenith the top panel 140 energizes the elevation motor 142 to follow the upward rise of the sun. During this time the lower panel is in the shade of the top panel 140 . After noon the sun's elevation decreases to the point where the upper panel's active surface goes into the shade and the lower panel's output takes control of the elevation motor until sunset. It is not necessary for both the panels in the elevation pair to have a common physical connection. The upper and lower panels can be located anywhere along axle 144 or any extension of shaft 144 as long as its angular orientation with respect to the rest of the elements of system 110 is maintained. Similarly, the panel 116 can likewise be located anywhere on axle 144 or any extension of axle 144 as long as its angular orientation with respect to the rest of the elements of system 110 is maintained. The second relay 148 , as with the first relay 130 , has an energizing voltage which is selected to conform to the energy requirements of the second motor 142 . The second output control means 150 preferably comprises a pair of second output control means (each of which is structurally identical to the other) 150 with one of the pair connected to the panel 140 and the other of the pair connected to the panel 141 . The second output control means 150 includes a first elevation resistor 152 , a second elevation resistor 154 and an elevation zener diode 156 . The second output control means 150 (and its components) in purpose and function is the same as the first electrical output control means 132 . The upper solar panel 140 , as with solar panel 116 , has a front side or face 137 for receiving solar radiation and a back side 139 . The lower solar panel 141 similarly has a front side or face 143 and a back side 135 . Unlike panels 40 and 41 of the first embodiment, the sides 139 and 135 are positioned so that they are facing inwardly generally toward each other. The face 143 is designed for reception of solar energy via solar rays 114 incident thereon. The faces 137 and 143 are oppositely positioned such that they face outwardly and generally away from each other. Although the drive means are disclosed as electric motors, other alternative electromechanical means can be utilized for rotating the axles 124 and 144 .
The operation and function of the upper and lower panels 140 and 141 are the same as of upper and lower panels 40 and 41 of embodiment 10 . Therefore, the description thereof will not be repeated to promote brevity.
The first axle 124 may be set so that it is parallel to the earth axis. However, it need not be because the elevation angle adjustment provided by the invention 110 as with embodiment 10 compensates for errors in parallel positioning of the first axle 124 relative to the earth axis.
As with embodiment 10 , embodiment 110 also includes an azimuth adjustment return panel 117 which functions in conjunction with panel 116 . The first pair of panels 116 and 117 and the second pair of panels 140 and 141 are rigidly secured to each other at edges 125 and 127 thereof so that they maintain their relative angular position. The edge 125 is preferably approximately parallel to earth axis when in operation and preferably located at the east ends or end portions 131 and 133 thereof and, for panels 140 and 141 , the edges 127 are at end portions 147 and 149 thereof. Alternatively, the edge 125 may be other than approximately parallel to earth axis when in operation if the particular application has other angle of incidence requirements.
The first set of electrical wires 128 provides electrical connection from the solar panels 116 , 117 to the motor 126 for providing power thereto. The second set of wires 146 is also included for providing electrical connection from the solar panels 140 and 141 to the motor 142 for providing power thereto. The electrical wires 128 and 146 are also flexible to prevent interference with the operation of the axles 124 and 144 as well as associated structures.
As with embodiment 10 , the invention 110 has the pair of panels 116 and 117 as well as 140 and 141 positioned so that each pair are at an acute angle relative to each other. That acute angle is a select and specific angle determined by the position of the panels 116 and 140 at sunset and the desired position that the return panel 117 should be placed in at sunrise. The angle may, for example, be twenty-five degrees. The selection of that angle places the return panel 117 in position for facing the sun and receiving the solar rays at the optimal angle of incidence (or other desired angle) at sunrise following the end of the diurnal operation of the assembly 110 . During one day's operation, the panels 116 and 140 are being irradiated and therefore providing electrical power to the respective motors 126 and 142 . As a result of the controlled rotation of the panel pairs and the respective angles of each pair, on the sunrise of the succeeding day the return panel 117 is facing the sun and therefore providing electrical power to the respective motor 126 . The azimuth electrical output control means 132 preferably comprises a pair of azimuth electrical output control means 132 one connected to the panel 116 and the other connected to the panel 117 and both connected to the motor 126 . Since the panel 117 is wired, via respective pair of the first set of electrical wires 128 , with opposite polarity (with reference to the wiring of panel 116 ) to the motor 26 , the panel 117 rotates the motor 126 , axle 144 and panels in the opposite direction from that of the preceding day so that the panel 117 rotates the assembly components back to the position of the prior sunrise and thereby at a position to track the sun's apparent movement during that day's operation. Thus, there is no necessity for reset (either manual or by other external means) of the panels at the end of the day's operation. In both embodiments 10 and 110 , the assembly ( 10 and 110 ) automatically positions its components for optimal reception of the solar rays at every succeeding sunrise. In addition, the entire installation may be mounted on gimbals or other suitable mechanical structures capable of allowing bidirectional rotation.
Accordingly, there has been provided, in accordance with the invention, an assembly which provides solar tracking and azimuth angle as well as elevation angle adjustment for enhanced annual tracking efficiency and which provides daily automatic solar tracking throughout annual usage thereof and thus fully satisfies the objectives set forth above. It is to be understood that all terms used herein are descriptive rather than limiting. Although the invention has been specifically described with regard to the specific embodiment set forth herein, many alternative embodiments, modifications and variations will be apparent to those skilled in the art in light of the disclosure set forth herein. Accordingly, it is intended to include all such alternatives, embodiments, modifications and variations that fall within the spirit and scope of the invention as set forth in the claims hereinbelow.
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An assembly is disclosed for adjusting the position of a solar array or device to enable it to maintain a desired solar energy reception throughout each day's operation of the assembly. Solar panels are mounted on a first axle and a second axle, and the axles are mutually orthogonal. The assembly also includes a first motor for rotating the array and the panels relative to the first axle in a direction providing azimuth angle position adjustment and a second motor for rotating the array and the panels and the second axle in a direction providing elevation angle position adjustment. The motors are electrically connected to and powered by their respective solar panels. Divider circuits control the current fed into the motors to control the rotational movement in order to control the azimuth and elevation orientation of the panels and also control the orientation of the array so that it continually faces the sun throughout the diurnal operation of the assembly and so that it maintains the desired degree of solar energy reception throughout the day. The orientation of one of the panels enables it to reposition the assembly for operation at each successive sunrise.
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FIELD OF THE INVENTION
[0001] The present invention relates to a scaffolding system that is temporarily placed underground for preventing the collapse of excavated earth while an underground structure is built and, more particularly, to a prestressed scaffolding system using tendons with vertical piles (e.g., H-beams) and horizontal piles (e.g., wales), whereby the number of struts supporting the vertical piles is considerably reduced.
BACKGROUND OF THE INVENTION
[0002] It is well known that excavation work for constructing a subway or a basement of a building is started by excavating holes into the ground surface to a designed depth on the basis of technical drawings, and then vertical piles are installed in the excavated holes. After the installation of the vertical piles, excavation is partially carried out, and then main girders and cover plates are placed. After the placement of the cover plates, additional works are repeatedly performed by alternately excavating and placing the struts.
[0003] Accordingly, in order to design a scaffolding system, the earth pressure on each excavation level and load applied onto the struts are repeatedly calculated, thereby enabling to design struts that can withstand the maximum load applied to the beams. As a result, a large number of struts are required. In most cases, the struts are closely arranged, e.g., within intervals of approximately 2-3 m, for primarily obstructing the delivery of construction materials in a working area, the transportation of heavy equipments, and performance of the construction works. The struts also give rise to a severe impediment to a molding or steel work when the main structure is built. For example, a plurality of holes is unavoidably formed in the main structure, such that the finished underground structure is subject to penetration of water.
[0004] In the conventional scaffolding system, steel H-piles are used as the vertical piles, while concrete piles for filling concrete into the excavated holes may be used as the vertical piles instead of using steel H-piles. Additionally, the steel piles and the concrete piles may be simultaneously used, or sheet piles may be used. However, the basic principle of supporting the load of excavated ah by making holes in the ground and then forming a wall by piles is almost identical to that of the aforementioned works. Preflexed beams may also be used as the vertical piles, and the H-piles may be attached to the sheet piles to strengthen the sheet piles.
[0005] The earth anchor system is used for supporting steel piles in the scaffolding system for constructing underground structures in place of systems using the aforesaid struts. According to this system, inclined holes are drilled into the ground behind the piles, tendons or high strength steel bars are inserted into the drilled holes, ends of the inserted bars are anchored by a mechanical method or a chemical method such as epoxy or cement grouting, and then the bars are tensioned and fixed to the steel piles. This system has an advantage in that the inner space of the scaffolding system is very spacious, allowing the earth works and the support works to be easily performed. On the other hand, there is a disadvantage in the system in that the works have to be placed in the vicinity of private properties when this system is applied in a crowded city, thus causing a lot of civil appeals from the neighbors. The high cost of the construction is another disadvantage.
[0006] Korean Utility Model Registration No. 258949 discloses a method using truss for removing struts, which pass across the excavated space of the scaffolding system. This method is expected to be applied to a case where the depth of the excavated ground is relatively shallow. H-beams are doubly placed in a grid-type near the earth surface. The H-beams are reinforced with vertical beams and inclined beams so that the earth pressure is supported by two floor trusses placed at the upper portion of the scaffolding system. This method has been proposed to overcome difficulties in excavating and constructing the structure, which occur due to the many struts of the scaffolding system for supporting the ground. Consequently, this method is useful for a construction to contain a wide structure at the bottom and a narrow structure at the top of the excavated ground.
[0007] Korean Patent No. 198465, Korean Utility Model Registration No. 247053, and Japanese Patent 837994 disclose a method for reinforcing a wale using prestressing. In this method, an additional wale is placed on top of the existing wale for tensioning the tendon and expanding the distance between the struts. This method may be performed by using an additional wale or by reinforcing the flange of existing H-beams. These two methods are expected to be effective in increasing the distance between the struts. However, since the tendon is linearly disposed, a constant support bending moment occurs, which is different from the parabola-shaped moment distribution generated on the wale by the earth pressure. Different moments and the distribution thereof in relation to the load restrict the length of the reinforced wale.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention provide a safe and effective method of greatly reducing or removing the number of struts, which interfere in structure work and cause an increase in construction costs, thereby obtaining an underground construction space and minimizing construction costs.
[0009] In one preferred embodiment of the present invention, a prestressed scaffolding system for supporting the excavated earth retaining wall by forming a polygonal closed section comprises a prestressed wale comprising a plurality of triangular tendon supports in the middle portion, a tendon-anchoring unit at both ends of the wale, and a connecting brace for connecting the supports and the tendon-anchoring unit. A strut is constituted by a truss or a plurality of H-beams or an H-beam leaving a large cross section and strengthened for supporting the tendon-anchoring unit.
[0010] The triangular tendon support is constituted by a vertical member and an inclined member, or only by vertical members, or only by inclined members for forming a triangle and supporting the wale. The triangular tendon support is supported and connected by an intermediate pile and a support beam for the tendon support.
[0011] The tendon-anchoring unit fastens a tendon and couples with the wale for applying the compression force and also couples with the inclined or vertical member for supporting the generated force.
BRIEF DESCRIPTION OF TUE DRAWINGS
[0012] For a better understanding of the nature and objects of the present invention, reference should be made to the following detailed description with the accompanying drawings, in which:
[0013] FIG. 1 is a plan view of a scaffolding system applied to a closed section according to an embodiment of the present invention;
[0014] FIG. 2 is a plan view of a scaffolding system applied to another closed section according to an embodiment of the present invention;
[0015] FIG. 3 is a cross-sectional view illustrating a scaffolding system applied to a closed section according to an embodiment of the present invention;
[0016] FIG. 4 is a cross-sectional view of a scaffolding system applied to one direction of a cross-section according to an embodiment of the present invention;
[0017] FIG. 5 is a cross-sectional view illustrating a scaffolding system applied to one direction of a cross-section according to an embodiment of the present invention;
[0018] FIGS. 6 a to 6 d are detailed views of a tendon support used in the scaffolding system according to an embodiment of the present invention;
[0019] FIGS. 7 a and 7 b are detailed views of a corner tendon-anchoring unit used in the scaffolding system according to an embodiment of the present invention;
[0020] FIGS. 8 a to 8 d are detailed views of a horizontal tendon-anchoring unit used in the scaffolding system according to an embodiment of the present invention; and
[0021] FIG. 9 is a detailed view of a vertical tendon-anchoring unit used in the scaffolding system according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] A preferred embodiment of the present invention will now be described in detail with reference to the attached drawings.
[0023] FIG. 1 is a plan view of the present invention applied to a closed section of an architecture site. According to an exemplary embodiment of the present invention, a prestressed wale 1 is disposed at four lateral sides of the closed section. A strut 3 made by a truss is placed at four corners and supports the wale. A conventional corner support beam 5 is situated behind the strut. The prestressed wale 1 of each lateral side includes three triangular tendon supports 12 , a triangular anchoring unit 13 , and a connecting brace 10 for connecting the triangular tendon supports 12 and the triangular anchoring unit 13 . An intermediate pile 23 is equipped to support the triangular tendon supports 12 , and a support beam for the tendon support 16 is fixed at the intermediate pile 23 by, for example, a bolt or welding. The support beam for the tendon support 16 supports the triangular tendon supports 12 during the installation of the scaffold system. The triangular tendon supports 12 and the support beam for the tendon support 16 are connected via a U-bolt in order to prevent a vertical buckling which may occur in the event of prestressing, carried out after the assembly work of the scaffolding system.
[0024] The truss strut 3 of each corner is positioned between two triangular anchoring units 13 to transmit the compression force of the anchoring units. The truss structure of the embodiment of the present invention may be substituted by, for example, an H-shaped steel having a large cross section, a plurality of H-shaped steels, or the like, as long as the structure can withstand high compression force. The constructional method of the corner support beam 5 behind the truss strut 3 is identical to that of the conventional system and illustrated in the drawing for explaining the present invention. The element numeral 60 is a tendon.
[0025] The configuration of FIG. 2 may be used when the excavating plane is small. A corner anchoring unit 14 substitutes the conventional corner support beam 5 and truss strut 3 of FIG. 1 . A T-shaped connecting brace 11 is used where the interval between the prestressed wale 1 and the corner anchoring unit is narrow. The rest of the figures and methods for carrying out the construction work are identical to that of FIG. 1 .
[0026] FIG. 3 is a cross-sectional view of FIGS. 1 and 2 and illustrates a horizontal prestressed scaffolding system 2 and main structure 7 according to an embodiment of the present invention. Unlike the conventional method, no equipment interferes the middle portion of the system and a wale 25 is arranged on four stages along the depth of the excavated underground. A soldier pile 22 is located at a distal external wall in a conventional way, and the wale 25 is mounted to support the soldier pile 22 . The support beam for the tendon support 16 and intermediate pile 23 are also illustrated in the drawing.
[0027] FIG. 4 , a cross-sectional view of a scaffolding system for a subway, includes a main structure 8 , vertical prestressed scaffolding system 6 , and horizontal prestressed scaffolding system 2 . The horizontal prestressed scaffolding system 2 illustrated at an upper portion of the drawing is identical in its fire and construction method to that of the embodiment of FIG. 2 , and thus, explanation of this system will be omitted. However, the vertical prestressed scaffolding system 6 illustrated at a lower portion of the drawing is supported at one side by a floor slab 9 of the main structure after the slab is hardened. The other side of the system 6 is supported by a conventional typical strut 26 .
[0028] The vertical prestressed scaffolding system is useful when the main structure is long such as a subway. In the vertical prestressed scaffolding system, a vertical H-beam 19 is inserted from behind the pre-installed wale 25 , and a short support 18 is attached to the opposite side of the wale 25 for supporting the tension of the tendon 60 . The tendon is placed at both ends of the H-beam 19 and is fixed to a separate tendon-anchoring unit 20 , which is pre-coupled with the vertical E-beam. Thus, the anchoring unit of the lower end of the vertical prestressed scaffolding system is configured to be supported by the hardened concrete slab 9 of the main structure, while the anchoring unit of the upper end is supported by the typical strut 26 . The element numeral 24 is an earth retaining plate.
[0029] FIG. 5 is a plan view of FIG. 4 and is used when the excavating plane is long, e.g., a subway or a channel construction. The prestressed wale 1 is arranged along both lateral sides, and the truss strut 3 is located at each place where the tendon of the prestressed wale is fixed. The configuration of the prestressed wale is identical to the wale of the closed-section of FIG. 1 , and thus, further explanation will be omitted.
[0030] The enlarged portion of the drawing illustrates the relative location of H-beam 19 in relation to the soldier piles 22 , in which the H-beam 19 for the vertical prestressed scaffolding system described in FIG. 4 is installed between the existing soldier piles 22 . In the vertical prestressed scaffolding system the earth retaining plate 24 should be mounted at a flange behind the existing vertical pile to thereby allow the installation of the H-beam of the vertical prestressed scaffolding system. Provided that the vertical pile is a sheet pile 21 in place of the soldier pile 22 , the vertical H-beam 19 is inserted into an empty space between the sheet pile 21 and the wale 25 .
[0031] FIGS. 6 a to 6 d illustrate various shapes and sizes of the triangular tendon support utilized in the embodiments of the prestressed scaffolding system of the present invention. The triangular tendon support is provided with a vertical member 32 and an inclined member 33 and is configured to reduce the number of support points 31 being in contact with the tendon. The trial tendon support is also configured to support a wale 30 having a long length. When the compression force is applied on the support point 31 making contact with the tendon, the force functions to support the long wale 30 via the vertical member 32 and inclined member 33 .
[0032] In FIG. 6 a , two inclined members are welded or connected by a bolt (not shown) to thereby form an isosceles triangle and support the wale 30 having a short length. FIG. 6 b is a second embodiment of the present invention and illustrates a pair of inclined members 33 connected to each other at a 45 degree angle extended laterally from the vertical member 32 . The inclined and vertical members are all connected to the wale 30 by, for example, a bolt or welding. According to a third embodiment in relation to the case that the length of the wale 30 is long, two pairs of inclined members 33 of FIG. 6 c are connected to both lateral sides of the vertical member 32 , respectively. A plurality of vertical members and inclined members are used in FIG. 6 d for supporting the long wale 30 . The structure of the triangular tendon support is not limited to the embodiments of the present invention, and thus, may be configured to form a triangle and support the wale by using the vertical member and inclined member, or only by vertical members, or only by inclined members.
[0033] FIGS. 7 a and 1 b are detailed views of the corner anchoring unit 14 of FIG. 2 that are designed to connect a wale 35 of the corner via reinforcing members 36 to thereby secure the tendon 60 . That is, when the tendon 60 , which is used for constructing the prestressed scaffolding system, passes through the reinforcing member 36 of the anchoring unit, the tendon is tensioned by a hydraulic jack 70 . The tensioned tendon is then fixed by an anchoring unit 71 , which anchors the tendon. The force pulled via the tendon transmits the compression force to an adjacent wale (not shown) via a length adjusting unit 72 , e.g., a precedent load jack or a screw jack. As another embodiment of the present invention, the configuration of FIG. 7 b is adapted to anchor the tendon only by a reinforcing member 38 without a gusset plate. The figures of the above embodiments may be varied in the scope of the basic concept and function of the present invention. The reference numeral 39 refers to an inlet of the anchoring unit.
[0034] FIGS. 8 a to 8 d illustrate various anchoring units of the horizontal prestressed wale. FIG. 8 a illustrates a small anchoring unit used when a small amount of tension is applied thereto. The tendon 60 supporting a wale 41 is supported by an inclined brace 43 or a vertical brace 44 . The anchoring unit is formed with holes, thereby the inclined brace 43 or vertical brace 44 may be inserted into the anchoring unit through the holes as illustrated in the drawing, or may protrude out (not shown). The inlet 39 of the anchoring unit may preferably be formed in a curved shape in consideration of the flexibility of the tendon. The tendon is fixed via the tendon-anchoring unit 73 at an opposite side of the inlet 39 . Further, the length adjusting unit 72 (e.g., precedent load jack or screw jack) is equipped to add the compression force to the corner support beam 5 after the tendon is tensioned.
[0035] FIG. 8 b illustrates an anchoring unit having an additional wale 42 for strengthening the wale in a case where the wale 41 gets lengthened and the compression force applied on the wale greatly increases thereby. FIG. 8 b is identical to FIG. 8 a in that the curve-shaped inlet 39 is formed where the tendon 60 supporting the wale 42 is inserted into the anchoring unit, and the tendon-anchoring unit 73 is placed oppositely from the inlet 39 . The difference from FIG. 8 a is that the inclined brace 43 for supporting the anchoring unit is doubly placed to withstand the increased compression force and earth pressure. In addition, when the compression force is applied on the double wale, the force may differently be applied on each wale, and thus the compression force between the two wales is intended to be equally adjusted by using the screw jack 72 of the high load.
[0036] FIG. 8 c illustrates the triangular anchoring unit 13 of FIG. 1 configured to secure the tendon 60 , which supports the wale 41 , via the tendon-anchoring unit 73 . FIG. 8 c is also configured to transmit the load to the truss strut 3 supporting the triangular anchoring unit 13 . In the triangular anchoring unit, an inclined member 47 of H-shaped steel is disposed to form an isosceles triangle to withstand the load applied on the unit. An apex at which these members contact each other is enhanced by an appropriate gusset plate 46 . A screw jack 74 is equipped to adjust the compression force of the double wale, and the precedent load jack 72 is equipped to add the compression force to the corner support beam 5 . The screw jack 74 is further connected with the truss strut, which supports the entire anchoring unit. A hydraulic jack 75 is provided to add a great amount of compression force between the anchoring unit and the truss strut. That is, after the tendon is tensioned via the hydraulic jack 70 , the hydraulic jack 75 applies a compression force to the truss strut 3 .
[0037] FIG. 8 d shows an anchoring unit used for the scaffolding system illustrated in FIG. 4 . The tendon 60 for supporting the wale 41 is tensioned via the hydraulic jack 70 and then secured by the tendon-anchoring unit 73 . The tendon is designed to pass through the inclined member 47 at its inlet portion. The truss strut 3 may be connected with the anchoring unit by the screw jack 74 and hydraulic jack 75 , or may directly be connected without the aid of these members. The proper gusset plate 46 is mounted for withstanding high compression force between a vertical member and a horizontal member 48 , which connects both sides of the anchoring unit. Since the member receives only the prestressing force and the compression force is small, a single, wale is illustrated in the drawing. However, a double wale may preferably be used depending on the case.
[0038] FIG. 9 is a detailed view of the anchoring unit 20 for the vertical prestressed scaffolding system 6 illustrated in FIG. 4 . Similar to the embodiment of FIG. 4 , the slab of the existing structure and intermediate strut are used as supports, and an H-beam is inserted from behind the built wale. A short support is attached to the front of the wale and the tendon fixed to the anchoring unit of both ends of the H-beam is supported by the tendon support. This method is for a vertical prestressed scaffolding system, which supports a channel-type excavating surface. In particular, the screw jack or precedent load jack 72 , connected with the horizontal strut 26 , is coupled with the anchoring unit 20 . If the anchoring unit 20 is placed at a lower end of the scaffolding system, the anchoring unit 20 can directly contact the existing slab (not shown) instead of the strut 26 . The vertical H-beam is coupled to the anchoring unit by being inserted into a vertical hole 50 . This contact or coupling part may be firmly connected by, for example, welding or a bolt, preferably by a bolt for facilitating the disassembly of the members. Once the tendon 60 for supporting the vertical H-beam is inserted into the anchoring unit, the tendon is fixed by the tendon-anchoring unit 73 at an opposite side of the anchoring unit. Accordingly, this anchoring unit is used in the vertical prestressed scaffolding system, wherein the wale or the vertical beam is removably manufactured.
[0039] As apparent from the foregoing, there is an advantage in the prestressed scaffolding, system of the present invention in that vertical piles or horizontal beams are prestressed by using a plurality of supports, anchoring units, and tendons. The number of struts and intermediate piles, which caused serious obstacles in carrying out conventional constructional works, is considerably reduced.
[0040] There is another advantage in that the excavation and scaffolding system together with the construction cost are remarkably improved.
[0041] Also, the formation of holes in the structure, which is inevitable in the conventional scaffolding system, is effectively eliminated, thus facilitating the steel reinforcing works and molding works, reducing the construction period and greatly improving the water-tightness and durability of the finished structure.
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An innovative prestressed scaffolding system is provided to use triangular tendon supports and tendons in place of a plurality of struts for supporting the earth pressure applied during an excavation or an underground construction structure, thereby removing the obstacles of the construction, e.g., intermediate piles or struts, and contributing to an improvement of the constructional efficiency of the underground space and reduction of construction costs.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to turn signal indicating means for motor vehicles and more particularly, to turn signal actuating mechanisms for motor vehicles.
2. Prior Art
With the advent of the legal acceptance and use of electrical devices for indicating left and right turns and lane changes has come several difficulties. One of such difficulties is associated with the fact that the mechanism which is operated by the driver of the motor vehicle is designed such that it automatically returns to the neutral position at the completion of a left or right turn. Since the mechanism is designed to only return to the neutral position upon the completion of a right or left turn, frequently when the electric turn signals are used to indicate a lane change, they are forgotten in the on condition. In an attempt to overcome this problem of the turn signals remaining in the on condition when a lane change is signaled, devices have been added in the prior art which make a noise and/or flash a light to indicate that the turn signals are actuated. Such prior art devices distract the operator's attention and frequently are ineffectual.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide a turn signal mechanism which overcomes the difficulties of the prior art.
In keeping with the principles of the present invention, the objects are accomplished by a unique turn signal indicating mechanism for use in motor vehicles comprising a housing, a movable bracket which is movable to left, right and neutral positions provided in the housing, a means for holding the movable brackets in the neutral, left and right positions, an operating lever pivotally coupled to the movable bracket which is pivotable back and forth from a neutral position and a turn signal which activated by the pivotable operating lever whereby turn signals for a lane change are generated by pivoting the operating lever without moving the movable bracket and turn signals for a left or right turn are generated by pivoting the operating lever until the movable bracket is moved either to the right or left turn positions.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features and objects of the present invention will become more apparent by reference to the following description taken in conjunction with the accompanying drawings, wherein like reference numerals denote like elements, and in which:
FIG. 1 is a plan view of a turn signal indicating mechanism in accordance with the teachings of the present invention;
FIG. 2 is a cross-sectional view of the embodiment of FIG. 1 along the lines II--II;
FIG. 3 is a plan view which illustrates the operation of the embodiment of FIG. 1;
FIG. 4 is a plan view illustrating the operation of the embodiment of FIG. 1;
FIG. 5 is a cross-sectional view of the embodiment of FIG. 1 along the lines V--V in FIG. 2;
FIG. 6 is a cross-sectional view of the embodiment of FIG. 1 looking along the lines V--V in FIG. 2; and
FIG. 7 is a cross-sectional view of the embodiment of FIG. 1 looking along the lines V--V in FIG. 2.
DESCRIPTION OF THE INVENTION
Referring to the figures, FIG. 1 is a plan view of a turn signal mechanism in accordance with the teachings of the present invention. The turn signal mechanism includes a housing 1 which is secured to the dash of the motor vehicle so that it does not rotate with the steering shaft which is inserted into the central tube 2. Cancelling cam 3 is freely rotatably coupled to the inside of tube 2 and is provided so that it rotates integrally with a steering wheel and steering shaft inserted through central tube 2.
A channel 12 is provided in one side of a movable bracket 7 which is provided within housing 1. A swinging plate 18 to which an operating lever 21 is attached is provided in channel 12. A pivot pin 19, which projects from the bottom of swinging plate 18, passes through movable bracket 7 and is inserted into a hole in body 1 thereby rotatably coupling the swinging plate to the housing 1. Furthermore, movable bracket 7 pivots on pivot pin 19. Detents 4, 5 and 6 are provided in housing 1 and hold movable bracket 7 in a neutral position and at angles which correspond to the left and right turn signal positions.
A spring-loaded roller 9 which is biased outwardly by a spring 8 is provided on the end of movable bracket 7 such that it engages with detents 4, 5 and 6, one at a time. The roller 9 and the detents 4, 5 and 6 form a well known retaining mechanism which holds the movable bracket 7 in a neutral position and in left and right turn signal positions. Well known cancelling paw 10 is coupled to movable bracket 7 by stoppers 11 and is driven in the cancelling direction by cancelling cam 3.
A shallow V-shaped sliding surface 13 is provided at the interior end of channel 12 of movable bracket 7. Identical stopping surfaces 14 and 15 are provided at each end of sliding surface 13 facing each other. A switch actuating stud 20 is provided on the bottom surface of swinging plate 18 and extends through an arc-shaped slot "a" provided in the bottom of channel 12 and in housing 1. Actuating stud 20 is coupled to a movable contact holder 25 of the turn signal switch 24. A spring-loaded roller 23 which is biased outwardly by spring 22 such that it contacts the center of the sliding surface 13, is provided in the inner end of operating lever 21.
Operating lever 21, together with the force applied by spring 8, is designed such that it can be pivoted back and forth without moving the movable bracket 7 when a force is applied which is not sufficient to offset the engaging force of the spring-loaded roller 9 against detent 4 from the neutral position shown in FIG. 1, and engages with the appropriate stopping surface 14 or 15 as illustrated in FIG. 3. From the description, it should be apparent that the angle of swing from a neutral position permitted is fixed. Furthermore, when the lever 21 is pivoted from the neutral position, loaded roller 23 rolls across the incline surface of sliding surface 13 and compresses spring 22. Therefore, when operating lever 21 is released, it is automatically returned to the neutral position by the force stored in spring 22. The V-shaped sliding surface 13 and the spring-loaded roller 23 constitute one example of an automatic return mechanism for the operating lever 21 of this invention.
As shown in FIG. 5, the power source terminal contact 28 and the load terminal contacts 29 and 30 which are connected to the turn signal lamps, are installed on an insulating plate 27 in the turn signal switch 24. A movable contact holder 26 is coupled to a movable contact holder 25 is coupled to stud 20. Movable contact 26 is arranged and configured such that it makes contact with source contact 28 and one of the load terminal contacts 29 or 30 when the operating lever 21 is caused to pivot through or nearly through the permitted angle when it contacts one of the stopping surfaces 14 or 15.
In addition, retreating surfaces 16 and 17 are provided in both sidewalls of channel 12 in order to permit pivoting motion of the swinging plate 18 caused by movement of the operating lever 21. These retreating surfaces 16 and 17 have a similar function to that of the stopping surfaces 14 and 15.
In operation, the movable bracket 7 is normally held in a neutral position by the engagement of the spring-loaded roller 9 with the detent 4 and the operating lever 21 is normally held in a neutral position by the engagement of the spring-loaded roller 13 with the center of sliding surface 13, as shown in FIG. 1.
When as shown in FIG. 3, the operating lever 21 is caused to pivot together with the swinging plate 18 so that the side of the inner tip of operating lever 21 contacts the stopping surface 15, this contact will transmit a mechanical shock to the person operating the operating lever 21 due to the fact that the movable bracket 7 is prevented from pivoting by the spring-loaded roller 9. Accordingly, if the pivotal motion of the operating lever 21 is terminated at the point at which this mechanical shock is felt, the movable contact holder 25 will at that time have been moved by the switch-actuating stud 20 of the swinging plate 18 so that the movable contact 26 is in contact with the power source terminal 28 and one load terminal contact 30 (as shown in FIG. 6), thereby causing one of the turn signal lamps to flash. Furthermore, if the operating lever is then released, the lever 21 and the swinging plate 18 are automatically returned to the neutral position by the force stored in spring 22 and the flashing of the turn signal lamp is cancelled. The above operation is used for the generation of signals which indicate a lane change and has no effect upon the movable bracket 7.
If, on the other hand, when the mechanical shock is felt, the operating lever is continued to be pushed in the same direction, the movable bracket 7 is pushed so that it swings into a turn signal position (as shown in FIG. 4) and the spring-loaded roller 9 engages the detent 6 so that the bracket 7 is held at an angle corresponding to a turn signal position. Accordingly, although the operating lever 21 and the swinging plate 18 will return to a neutral position if the lever is released at this time, the movable bracket 7 is still at an angle established by the movement of the lever 21. Therefore, although the turn signal switch 21 will temporarily assume the aspects shown in FIG. 7, it will afterwards assume much the same position as it did when the operating lever 21 was caused to swing as shown in FIG. 3 (see FIG. 6) so that the movable contact 26 makes contact with the terminals 28 and 30 thereby generating a turn signal by causing one turn signal lamp to flash.
When the steering shaft is allowed to rotate back to the neutral position, the movable bracket 7 will be returned to the neutral position in a conventional manner by the engagement of the cancelling cam 3 with the cancelling paw 10.
From the foregoing description of the design and operation, it should be apparent that the operating lever 21 can be caused to pivot relative to the housing 1 in such a way as to cause two different modes of operation of the turn signal system by pivoting the operating lever 21 through two different angles. Pivoting the operating lever 21 through the first angle causes no accompanying motion of the movable bracket 7 and therefore can be used to signal a lane change while swinging the operating lever 21 through an angle which is greater than the first angle causes the movable bracket 7 to rotate to either the right or left turn positions to indicate a right or left turn. In addition, the movable bracket 7, which in the prior art has been the part which actuates the turn signal, is in this invention converted into a part which either holds the operating lever 21, which is provided within the movable bracket 7 such that it automatically returns to a neutral position relative to the movable bracket by an automatic return device, in a turn signal position or returns it to the original neutral position by means of a well known conventional cancelling mechanism. Since the design of the turn signal mechanism has been improved by making the operating lever 21 the switch-actuating part instead of the movable bracket 7, there is no danger of the movable bracket 7 rotating so that the cancelling paw 10 is projected into the radius of rotation in the cancelling cam and engaged by the cam during the generation of the lane change signal. As was described above, a turn signal indicating mechanism in accordance with the teachings of the present invention therefore possesses the advantage of allowing easy, accurate and separate employment by means of one operating lever of the flashing turn signals to indicate a lane change or an abrupt change in direction of travel of the motor vehicle, such as a right or left turn.
In all cases it is understood that the above described embodiment is merely illustrative of but one of the many possible specific embodiments which can represent the applications of the principles of the present invention. It should be readily apparent to one skilled in the art that numerous and other variations can be devised without departing from the spirit and scope of the invention.
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A turn signal indicating mechanism for use in motor vehicles comprising a housing, a movable bracket movable to right, left and neutral positions provided in the housing, an operating lever pivotally coupled to the movable bracket which is pivotable back and forth from a neutral position and a turn signal switch actuated the pivotable operating lever whereby turn signals for a lane change are generated by pivoting the operating lever without moving the movable bracket and turn signal for a left or right turn are generated by pivoting the operating lever until the movable bracket is moved to either the right or left turn position.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/702,887, filed Feb. 9, 2010, which claims the priority benefit of U.S. Provisional Patent Application Ser. No. 61/151,122, filed Feb. 9, 2009, the entire scope and content of which are hereby incorporated herein by reference.
BACKGROUND
The present invention in general relates to fencing and railing systems, and in particular relates to connectors for fencing and railing systems.
SUMMARY
Briefly described, in a first example embodiment the present invention relates to a fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto. The assembly includes a plurality of pickets, a plurality of rails extending transverse to the pickets, and a connection between the pickets and the rails. The picket/rail connection is slidably mounted to the rail and pivotally connected to the picket to permit a sliding, pivotal motion. The sliding, pivotal connection allows the pickets to be oriented at greater angles relative to the rails (i.e., it allows the assembly to rack to a greater degree, thereby allowing the fencing/raining to follow more steeply changing terrain or contours).
In one preferred form, the fencing/railing assembly includes one or more elongated connector strips that are each concealed by the rail and that each span a corresponding set of multiple adjacent pickets. In another preferred form, the fencing/railing assembly includes a plurality of shorter connectors, one for each picket/rail connection.
The connectors, be they shorter individual-picket connectors or longer multi-picket connector strips, can include small projections (e.g., bosses) that extend from one surface thereof and engage holes (e.g., recesses) formed in the pickets. Advantageously, this provides a fastener-less but still pivotal connection. Preferably, the rails each have an inner profile that is sized and shaped to slidably retain or capture the connector between the rail and the picket, while permitting the connector strip to slide relative to the rail and be concealed by the rail during normal use. For example, the rail can have an inwardly extending shelf or ledge that slidingly supports the connector strip so that the connector strip slides atop the shelf.
The fencing/railing assembly, including the pickets, the rails, and the concealed connectors, can be made of extruded aluminum, plastic, or other materials. Also, the rails can be generally U-shaped and have picket openings formed in one portion thereof for receiving the pickets therethrough. Optionally, a leading, inner edge of the railing may be beveled or eased to facilitate slipping the rail over the connector during assembly.
In another aspect, the present invention relates to a pre-assembled fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto. The assembly includes the same components as those described above. But these components are pre-assembled at a factory or other assembling facility. And the assembly is shipped in this pre-assembled state, ready for installation, so this part of the assembly process is not done on-site in the field.
In yet another aspect, the present invention relates to a method of manufacturing a fencing/railing assembly to be positioned between a pair of posts and mounted thereto. One such example method includes the steps of: (a) providing a series of pickets each with one or more connector holes formed therein; (b) providing a connector strip with a series of connector bosses formed on at least one side thereof; (c) attaching the connector strip to the series of pickets by aligning and inserting the connector bosses into the connector holes formed in the pickets; (d) providing an at least three-sided rail (e.g., a generally U-shaped rail) with picket openings formed in an upper portion thereof; and (e) slipping the rail over the pickets and over the connector strip to secure the connector strip in place and conceal the connector strip.
These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of the invention are exemplary and explanatory of preferred embodiments of the invention, and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a fencing/railing assembly according to a first example embodiment of the present invention.
FIG. 2 is a side view of the fencing/railing assembly of FIG. 1 .
FIG. 3 is a side sectional view of a portion of the fencing/railing assembly taken at line 3 - 3 of FIG. 1 .
FIG. 4 shows the left portion of the fencing/railing assembly of FIG. 3 , with hidden features shown in phantom lines.
FIG. 5 is a perspective, exploded view of the fencing/railing assembly of FIG. 1 , depicting the fencing/railing assembly being assembled.
FIGS. 6A-6E are front, top, back, side, and perspective views of a connector strip of the fencing/railing assembly of FIG. 1 .
FIGS. 7A-7B are schematic illustrations depicting the range of movement of a prior art picket-and-rail arrangement.
FIGS. 7C-7D are schematic illustrations depicting the range of movement of a picket-and-rail arrangement of the fencing/railing assembly of FIG. 1 .
FIG. 8 is a perspective view of a connector of a fencing/railing assembly according to a second example embodiment of the invention.
FIGS. 9-12 are plan, side, bottom, and perspective views of a connector boss strip of a fencing/railing assembly according to a third example embodiment of the invention.
FIG. 13 is a side view of a boss of the connector boss strip of FIG. 10 .
DETAILED DESCRIPTION
The present invention may be understood more readily by reference to the following detailed description taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.
Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. 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. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, FIGS. 1-6E and 7C-7D show a fencing and/or railing assembly 10 according to a first example embodiment of the present invention. The railing assembly 10 is typically used to enclose yard spaces, decks, porches and the like.
Generally, the railing assembly 10 comprises a plurality of horizontally spaced pickets 20 and at least one support rail 30 . The pickets 20 are typically arranged generally vertically with the rail 30 transverse to them. In the depicted embodiment, the railing assembly comprises three support rails 30 a, 30 b, 30 c (as seen in FIG. 1 ) to space, align, and secure the pickets 20 and to provide for structural rigidity. Each picket 20 can also include an endcap 40 coupled to the top of the same (or formed in the top portion itself) to close off the top of the picket and/or to provide a decorative element to the railing assembly 10 . In example embodiments, the pickets 20 and railing 30 are formed from extruded aluminum, however, in alternative embodiments, the pickets and railing can be formed from solid aluminum, other metals and/or metal alloys, wood, rubber, plastic, and/or other materials known in the art. In example embodiments, the pickets 20 are hollow, square aluminum extrusions and the railings 30 roughly rectangular (but U-shaped) aluminum extrusions; however, in alternative embodiments, the pickets and railing can be formed in different shapes.
As seen in FIGS. 3 and 4 , the rails 30 can have a substantially “U” shaped cross-section and, in use, are generally oriented open-side-down such that the “bottom” of the “U” forms the top of the rail 30 . In alternative embodiments, the rails 30 can have a substantially “J” shaped cross-section or rectangular-shaped cross-section. In still other embodiments, the rails 30 can include other cross-section shapes as desired. The top wall of the rail 30 includes a series of horizontally spaced picket openings 39 through which the pickets extend. In depicted example embodiments the rail 30 is shown having a decorative bulge 38 on the exterior surface of the rail, however, in alternative example embodiments other exterior shapes can be utilized as desired.
As shown in FIGS. 3 and 4 , the rails 30 include at least one concealed ledge or shelf 32 for supporting a connector or boss strip 34 (or alternatively referred to as a dimpled strip) thereon. The shelf or shelves 32 extend inwardly from the inner surface of one or both sidewalls of the rail 30 . Optionally, the lower leading edges of the shelf 32 (or another portion of the rail 30 ) can be chamfered, ramped, or beveled to facilitate a slight outward deflection and smooth movement over the boss strip 34 during assembly. Once in place, the boss strip 34 is securely held there by the shelf 32 with the boss strip supported by the shelf and secured in place between the shelf and the top wall of the rail 30 . The boss strip 34 is captured between the corresponding sidewall of the rail 30 and the picket 20 but permitted to slide horizontally between the two and along the rail atop the shelf 32 . Additionally, the connector strip 34 can be made of a metal, plastic, or any other suitable material.
In addition, the boss strip 34 includes at least one inwardly extending boss (e.g., a nub, pin, or other protruding structure) 36 that is received in a pivot or connector hole 22 (e.g., a recess or through-hole) in one of the pickets 20 for rotatably coupling the boss strip to that picket (as will be described in greater detail below with reference to FIGS. 7C-7D ). In an alternative embodiment, the boss/nub extends outward from the picket and the pivot hole is formed in the connector strip (this is an “opposite” or “vice versa” arrangement of that described above). In another alternative embodiment, aligning pivot holes are formed in the connector strip and the picket, a pivot pin is provided, and the two ends of the pivot pin are inserted into the two pivot holes. In yet another alternative embodiment, the pivot hole is horizontally slotted to provide for additional sliding motion.
And in still another alternative embodiment, the connector/boss strip is eliminated, the pickets each include at least one horizontally slotted connector hole, and the rails each include at least one inwardly extending boss that is received into the slotted connector hole. In this embodiment, the pickets pivot about the boss and the boss slides along the slotted connector hole such that the rail/boss and picket slide too. The opposite or vice versa arrangement can alternatively be provided, with the boss on the pickets and the slots in the pickets. As no connector strips are provided, and the strips in the above-described embodiments provide structural support for the overall fence/railing assembly, the rails and/or pickets of this embodiment are designed with relatively greater strength (e.g., a stronger material and/or thicker walls).
Thus, the railings 30 each have an inner profile that is sized and shaped to retain the connector or boss strip 34 between the rail and the picket while permitting it to slide and pivot relative to the pickets. With this construction, a sliding, pivoting connection is obtained and also concealed. The connection is also achieved without the use of any threaded fasteners.
In use, the railing assembly 10 can be assembled as partially demonstrated in FIG. 5 . For example, the plurality of pickets 20 are first inserted into and extended through the picket openings 39 of the rails 30 . Next, the connector or boss strips 34 (better seen and understood by viewing FIGS. 6A-6E ) are coupled to pickets 20 by inserting the bosses/nubs 36 into the corresponding holes 22 formed in the pickets. Finally, the rails 30 are lowered (from the depicted positions of FIG. 5 ) vertically along the pickets 20 and over the boss strips 34 , where they are snapped into place by forcing each rail ledge or shelf 32 over the boss strip, for example, by the beveled or ramped leading edge riding over the strip and deflecting slightly thereby.
As shown in FIG. 5 , multiple connector boss strips 34 can be used with each rail in the railing assembly 10 , with each boss strip being long enough that it is coupled to a set of multiple of the pickets 20 . The set of pickets can include all of the pickets 20 in a fence/rail section (between posts) or only some of them. In the typical commercial embodiment depicted, each boss strip is long enough that it is coupled to approximately five pickets 20 , and thus it has five bosses/nubs 36 . This coordinates together the pivoting of all of the pickets 20 engaged by a connector strip 34 (those in the picket set) relative to the rail 30 and that connector strip 34 . For example, if a connector strip 34 were to be in engagement with five pickets 20 , movement of a single picket amongst the five pickets would result in the other four pickets moving in synchronization with the single picket that is originally moved. In addition, by spanning multiple pickets 20 , the connector strips 34 provide structural support for the overall fence/rail assembly 10 , so the pickets and/or rails 30 can be designed to provide less overall structural strength (e.g., with thinner walls and/or less-strong materials).
In alternative embodiments, longer or shorter boss strips 34 can be utilized as desired, such that each boss strip can accommodate less than five pickets or more than five pickets. In still other alternative embodiments, a relatively short, single boss strip or connector is used for each picket/rail connection. As seen in FIG. 8 , for example, a short boss or connector strip 134 according to a second example embodiment is so short that it doesn't span from one picket to another and it only includes a single boss/nub 136 .
In manufacturing the product, a simplified technique or method is accomplished. In an example method, a pre-assembled section of fencing/railing assembly is constructed and shipped for sale. This allows the sections to be assembled under factory conditions, rather than under field conditions, for maximum efficiency and quality control. The pre-assembled fencing/railing assembly includes a length of fencing/railing ready to be installed between a pair of posts or uprights. Thus, the user would install the pre-assembled section of fencing/railing between the posts in the field.
The manufacturing method for constructing the pre-assembled section can include the steps of:
(a) providing a series of pickets with connector holes formed therein;
(b) providing at least one connector strip with one or a series of connector bosses formed on at least one side thereof;
(c) attaching the connector strip to the one or series of pickets by aligning and inserting the connector bosses into the connector holes formed in the pickets;
(d) providing a rail with picket openings formed in an upper portion thereof and with at least one shelf formed on an inner surface thereof; and
(e) slipping the rail over the pickets (with the pickets extending through the picket openings) and over the connector strip to secure the connector strip in place on the shelf and conceal the connector strip.
This manufacturing method allows for easy and economical manufacture, as well as providing a consistently good manufacturing quality. Also, when the pre-assembled section of fencing/railing is assembled, the connector strip is not readily visible (it is concealed by the rail).
In addition to concealing the connection and being readily pre-assembled in a factory for later field-installation by a user, a fencing/railing assembly according to the present invention also adjusts to follow rising or falling terrain better than known fencing/railing. As demonstrated by comparing a known prior art railing assembly ( FIGS. 7A-7B ) to the present invention ( FIGS. 7C-7D ), it can be seen that the present invention is better able to pivot the pickets relative to the rails in comparison to known railing assemblies. For instance, known railing assemblies incorporate screws S and/or bolts to rotatably couple pickets P to rails R, as shown in FIGS. 7A-7B . Such couplings are time consuming to install and only allow for a limited range of rotation and little if any horizontal movement. In fact, the known railing assembly of FIGS. 7A-7B only allows the pickets to rotate about 15 degrees in either direction before being obstructed by the edge of the picket opening.
In stark contrast, the present invention utilizes a sliding pivotal connection between the pickets 20 and the rails 30 that is very easy and fast to install and allows for limited horizontal movement of the pickets 20 along the rails 30 . In particular, the connector boss strip 34 slides within the rail 30 in the transverse directions denoted by the arrows X when the pickets 20 are pivoted in the angular directions denoted by the arrows Y, thereby allowing the pivot point between the connector hole 22 of the picket and the rail to slide one way or the other, as shown in FIGS. 7C-7D . Because of this, the picket 20 is afforded a higher degree of rotation within the picket openings 39 of the rail, while the pickets and picket openings are the same size as in prior art systems. In typical commercial embodiments, utilizing the present invention permits the pickets 20 to rotate about the boss 36 at least 36 degrees (as compared to the known railing assembly's typical rotational limit of about 15 degrees), using a similar opening gap between the picket and the edge of the picket opening in the railing—the additional freedom of motion is not due to simply making the opening larger. The amount of rotation depicted in FIGS. 7C-7D is meant to be exemplary of the capabilities of the present invention and is in no way meant to limit the scope of the present invention.
The above-described embodiments can be provided pre-assembled, with the cost of the materials and assembly being about the same as the prior art systems unassembled. Alternatively, the above-described embodiments can be provided unassembled and assembled on-site in the field during installation.
FIGS. 9-13 show a connector or boss strip 234 of a fence/rail assembly according to a third example embodiment of the invention. The connector boss strip 234 can be used in fence/rail assemblies that are pre-assembled or field-assembled. In this embodiment, the connector boss strip 234 includes bosses 236 with ribs 250 that better secure the bosses into the connector holes of the pickets. This is particularly beneficial when used in fence/rail assemblies that are field-assembled. In addition, the connector boss strip 234 includes internal openings 252 that reduce the amount of material used without reducing the structural integrity of the connector strips. It will be understood that the dimensions shows in FIGS. 9-13 are representative of typical commercial embodiments and are not limiting of the invention; the connector boss strip 234 can be provided with other dimension ins larger or smaller sizes.
While the invention has been described with reference to preferred and example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.
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A fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto includes a plurality of pickets, a plurality of rails extending transverse to the pickets, and one or more pivoting, sliding connectors for connecting a picket to a rail, with the sliding, pivotal connection concealed by the rail. The connector is slidably mounted to the rail and is pivotally connected to the picket. In one embodiment, an elongated connector strip is concealed by the rail and spans multiple pickets. In another embodiment, the assembly includes a plurality of shorter connectors, one for each picket/rail connection.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of Ser. No. 11/891,168, filed Aug. 9, 2007, and entitled “Geonet for a Geocomposite”, the disclosure of which is hereby incorporated by reference.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
MICROFICHE/COPYRIGHT REFERENCE
[0003] Not Applicable.
FIELD OF THE INVENTION
[0004] The present invention is directed toward geocomposites for use in geotechnical construction sites, and particularly toward geonets usable with geotextiles in forming such geocomposites.
BACKGROUND OF THE INVENTION
[0005] Geotechnical engineering and the usage of geosynthetic materials are very common in today's civil engineering marketplace. One of the most common geosynthetic material available today are drainage products. Drainage products are generally comprised of a geonet or material or a geonet combined with a filtration fabric which may be one of many varieties. These products are used for a broad variety of applications. Common applications include drainage/leachate collection layers in waste storage facilities, leak detection layers in waste storage facilities, the use of a geosynthetic drainage material for gas venting in water and wastewater storage and treatment facilities, the use of geosynthetic drainage layers in roadway, rail and transportation applications and many others. In all of these applications, there are generally two performance factors which determine the suitability of the drainage media. These performance factors are the transmissivity (flow capacity) of the drainage media and the maximum allowable overburden pressure which the drainage media can support and still perform the functions required of it.
[0006] Waste collection sites are, of course, one well known type of geotechnical construction site, and are unavoidably required in today's societal structures, Such sites can require large amounts of valuable land, particularly in urban areas where large amounts of waste are generated and, at the same time, land is most in demand. Also, while desirable uses can be made of such lands (for example, golf courses have been built on such sites), such desirable uses typically have to wait until the land is no longer being used for collect further waste and the often high pile of waste has stabilized. While use and stabilization of such sites can take many years, there is nevertheless a desire to have that accomplished as quickly as possible, not only to increase the safety of those who might have to be at the site but also to allow for the desired use of others (for example, golfers) and to enhance the environment of those who live in the area as soon as is reasonably possible.
[0007] Toward that end, bioreactor landfills have been used to modify solid waste landfills by re-circulating and injecting leachate/liquid and air to enhance the consolidation of waste and reduce the time required for landfill stabilization. To accomplish this, generally horizontal flow of the leachate/liquid beneath the surface of the landfill is required. In some instances, vertical injection pipes and horizontal pipe fields have often been used to facilitate this leachate/liquid flow. With these structures, geocomposites are commonly provided in spaced layers of the built up land masses. Other masses may use such geocomposites where drainage (e.g., along a highway edge), leachate collection (e.g., at the bottom of a landfill), or gas removal (e.g., under a building slab) are required. Such geocomposites facilitate desired lateral drainage, collection and/or circulation of fluids (including liquids and/or gases) in the land mass. U.S. Pat. No. 6,802,672 discloses one advantageous system directed toward such problems.
[0008] It is desirable to provide geotextiles which will allow for large fluid flow rates along the geotextile. However, given the large loads which such geotextiles are subjected to as more and more layers of land mass are piled on top of the layers, compression and/or collapse of the geotextile and result, thereby reducing the flow rate through the geotextile. Further, while additional components, etc. may be added to strengthen the geotextile against collapse, those additional components may themselves block and thereby reduce the flow rate as well.
[0009] The present invention is directed toward overcoming one or more of the problems set forth above.
SUMMARY OF THE INVENTION
[0010] In one aspect of the present invention, a geonet for use in a geotechnical construction site is provided with a length substantially greater than its width. The geonet includes no more than first and second layers of strands, where a first plurality of substantially parallel strands extends in the lengthwise direction and defines the first layer of strands, and a second plurality of substantially parallel strands is disposed on top of the first plurality of strands and defines the second layer of strands, the second plurality of strands being at an angle relative to the first plurality of strands. The first and second plurality of strands are substantially incompressible and secured to one another at crossover locations.
[0011] In one form of this aspect of the present invention, at least one of the first and second plurality of strands is substantially round in cross-section.
[0012] In another form of this aspect of the present invention, the geonet is stored in a roll having X number of layers with each strand of the first layer of strands being rolled X times.
[0013] In still another form of this aspect of the present invention, the first layer of strands is the bottom layer of strands when installed, and strands of the first plurality of strands are substantially round in cross-section.
[0014] In yet another form of this aspect of the present invention, the strands of the second plurality of substantially parallel strands are at an angle of 45° to 70° relative to the first plurality of strands.
[0015] According to another form of this aspect of the present invention, the strands are polyethylene (PE).
[0016] In another aspect of the present invention, a geocomposite for use in a geotechnical construction site is provided, including a geonet having a length substantially greater than its width, and with no mare than first and second layers of strands. A first plurality of substantially parallel strands extends in the lengthwise direction and defines the first layer of strands, and a second plurality of substantially parallel strands disposed on top of the first plurality of strands defines the second layer of strands. The second plurality of strands is at an angle relative to the first plurality of strands, and the first and second plurality of strands are substantially incompressible and secured to one another at crossover locations. A geotextile is bonded to at least one side of the geonet.
[0017] In one form of this aspect of the present invention, at least one of the first and second plurality of strands is substantially round in cross-section.
[0018] In another form of this aspect of the present invention, both of the first and second plurality of strands are substantially round in cross-section.
[0019] In yet another form of this aspect of the present invention, the geotextile is non-woven textile laminated to the outer faces of the layers of strands. In a further form, the strands are polyethylene (PE) and, in another form, the geotextile is non-woven needlepunched textile laminated to strands on both sides of the geonet.
[0020] in still another form of this aspect of the present invention, the geocomposite is stored in a roll having X number of layers with each strand of the first layer of strands being rolled X times.
[0021] In another form of this aspect of the present invention, the geotextile is spun-bonded or needlepunched non-woven textile laminated to strands on both sides of the geonet.
[0022] In still another aspect of the present invention, a landfill includes alternating layers of fill and geocomposites, with the geocomposites each disposed beneath a layer of fill to facilitate draining of liquid from the landfill. The geonet has a length substantially greater than its width with a geotextile bonded to at least one side. The geonet has no more than first and second layers of strands, where a first plurality of substantially parallel strands extends in the lengthwise direction and defines the first layer of strands, and a second plurality of substantially parallel strands is disposed on top of the first plurality of strands and defines the second layer of strands. The second plurality of strands are at an angle relative to the first plurality of strands, and the first and second plurality of strands are substantially incompressible and secured to one another at crossover locations.
[0023] In one form of this aspect of the present invention, at least one of the first and second plurality of strands is substantially round in cross-section.
[0024] In another form of this aspect of the present invention, the strands are polyethylene (PE).
[0025] In yet another aspect of the present invention, a method of making a geonet for use in a geotechnical construction site includes first providing a mold for extruded material. The mold includes a first mold member having an outer boundary cylindrical about an axis and defining a first plurality of strand defining openings open at the outer boundary and spaced around the outer boundary, and a second mold member concentric with the first mold member and having a cylindrical inner boundary defining a second plurality of strand defining openings open at the inner boundary and spaced around the inner boundary. Further to the method, extruded material is forced through the first and second plurality of strand defining openings while one of the first and second mold members is stationary and the other of the first and second mold members rotates to define a cylindrical net with the strands defined by the openings of the one of the first and second mold members each extending substantially parallel to the axis and the strands defined by the openings of the other of the first and second mold members spiraling around the cylindrical net. According to the method, the strands defined by the other of the first and second mold members are then cut along a line substantially parallel to the axis, the cut cylindrical net is flattened to generally orient the strands in a plane, and the flattened net is rolled whereby the strands defined by the one of the first and second mold members are coiled.
[0026] In one form of this aspect of the present invention, the openings of the first plurality of openings are open to openings of the second plurality of openings when the openings of the first and second plurality of openings are aligned along a radius of the axis during relative rotation of the first and second mold members.
[0027] In another form of this aspect of the present invention, one of the first and second plurality of openings is substantially rectangular in cross-section,
[0028] In still another form of this aspect of the present invention, the other of the first and second mold members rotates at a rate whereby the strands molded thereby are at an angle of 45° to 70° relative to the strands molded by the one of the first and second mold members.
[0029] In yet another aspect of the present invention, a method of making a landfill includes alternating layers of fill and geonets so that the geonets are each disposed beneath a layer of fill to facilitate draining of liquid from the landfill. The method includes rolling a geonet made according to the previously described aspect of the invention beneath each layer of landfill in the direction of expected drainage flow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a perspective view of one embodiment of a geonet according to the present invention;
[0031] FIG. 2 is a cross-sectional view of the one embodiment of a geonet according to the present invention, taken along line 2 - 2 of FIG. 1 ;
[0032] FIG. 3 is an enlarged cross-section view of a geocomposite according to the present invention including a geotextile on both the top and bottom of the geonet of FIGS. 1-2 , oriented according to line 3 - 3 of FIG. 1 ;
[0033] FIG. 4 is a perspective view of another embodiment of a geonet according to the present invention;
[0034] FIG. 5 is a cross-sectional view of the geonet of the second embodiment, taken along line 5 - 5 of FIG. 4 ;
[0035] FIG. 6 is an enlarged side view of a geocomposite according to the present invention including a geotextile on both the top and bottom of the geonet of FIGS. 5-6 , oriented according to line 6 - 6 of FIG. 4 ;
[0036] FIG. 7 is an end view of a mold structure which may be used to make the geonets of Figs, 4 - 5 ;
[0037] FIG. 8 is a perspective view illustrating the unwrapping of the molded cylindrical geonet to a flat longitudinal layer;
[0038] FIG. 9 is a partial view of another mold structure which may be used to make other geonet configurations embodying some aspects of the present invention; and
[0039] FIG. 10 is a cross-section of a landfill in which the geocomposite of the present invention is used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] One embodiment of a geonet 12 according to the present invention is shown in FIGS. 1-2 . The geonet 12 consists of substantially incompressible longitudinal strands 14 (e.g., formed of polyethylene [PE], including but not limited to high density polyethylene [HDPE]), including a lower set of a plurality of substantially parallel strands 14 a and an upper set of a plurality of substantially parallel strands 14 b . Advantageously, one set of strands 14 a extends parallel to the longitudinal direction of the geonet 12 , and the other set of strands 14 b is at an angle of 45° to 70° relative to the longitudinal strands 14 a so that a crisscrossed grid 20 is formed (see FIG. 1 ).
[0041] It should be understood that as used herein, “substantially incompressible” is meant to refer to materials such as HDPE which, though susceptible to bending, breaking, fracture and/or creep, does not appreciably compress in the vertical direction when vertical forces are applied,
[0042] At their overlapping intersection, the strands 14 a, 14 b are suitably secured together whereby a relatively rigid geonet 12 is provided in the plane of the geonet 12 (Le., the geonet 12 is substantially rigid against compressive forces directed along the plane of the geonet 12 , while still providing some flexibility for bending when laid on uneven ground).
[0043] In accordance with this embodiment, the lower set of strands 14 a of the geonet 12 are substantially round in cross-section with connected areas 24 at the overlapping intersections. Such a cross-section provides a reduced risk of failure due to the strands 14 a laying or folding over due to the pressures encountered in use. Advantageously, the diameter of the strands 14 a, 14 b may, for a given design use, be substantially the same as the longer dimension of the prior art flat strands.
[0044] A geocomposite 28 incorporating the geonet 12 of FIGS. 1-2 is shown in FIG. 3 . In the illustrated geocomposite 28 , geotextiles 30 , 32 (such as, e.g., non-woven needlepunched geotextiles, spun-bonded or laminated textiles, as are known in the art) are suitably secured to both sides of the geonet 12 , such as by heat laminating.
[0045] A second embodiment of a geonet 12 according to the present invention is shown in FIGS. 4-5 . (Comparable reference numerals to those used in describing the FIGS. 1-2 embodiment are used herein, with similar but modified components having the same reference numeral with prime [′] added [e.g., 12 in FIGS. 1-2 is 12 ′ in FIGS. 4-5 ]).
[0046] The geonet 12 ′ consists of substantially incompressible longitudinal strands 14 ′ (e.g., formed of polyethylene [PE], including but not limited to high density polyethylene [HDPE]), including a lower set of a plurality of substantially parallel strands 14 a ′ and an upper set of a plurality of substantially parallel strands 14 b ′. Advantageously, one set of strands 14 a ′ extends parallel to the longitudinal direction of the geonet 12 ′, and the other set of strands 14 b ′ is at an angle of 45° to 70° (advantageously 60°) relative to the longitudinal strands 14 a ′ so that a crisscrossed grid 20 ′ is formed (see FIG. 4 ).
[0047] At their overlapping intersection, the strands 14 a ′, 14 b ′ are suitably secured together whereby a relatively rigid geonet 12 ′ is provided in the plane of the geonet 12 ′ (i.e., the geonet 12 ′ is substantially rigid against compressive forces directed along the plane of the geonet 12 ′, while still providing some flexibility for bending when laid on uneven ground).
[0048] In accordance with this embodiment, both the lower and upper sets of strands 14 a ′, 14 b ′ are substantially rectangular in cross-section with connected areas 24 ′ at the overlapping intersections. Advantageously, the height of the strands 14 a ′, 14 b ′ may, for a given design use, be substantially the same as the longer dimension of the prior art flat strands.
[0049] A geocomposite 28 ′ incorporating the geonet 12 ′ of the FIGS. 4-5 is shown in FIG. 6 . In the illustrated geocomposite 28 ′, geotextiles 30 , 32 are suitably secured to both sides of the geonet 12 ′, such as by heat laminating.
[0050] FIG. 7 illustrates an exemplary mold structure through which extruded material may be forced (pulled) to advantageously form the geonet 12 ′ of FIGS. 4-5 , Specifically, the geonet 12 ′ may first be formed in a tubular shape with a cylindrical inner mold 60 having rectangular strand defining openings 64 spaced around the exterior boundary of the mold 60 . An outer mold 70 is supported for rotation around the central axis 72 and includes strand defining openings 74 spaced around its inner cylindrical surface.
[0051] As generally illustrated in FIG. 8 , the formed cylindrical geonet 80 may be longitudinally cut as it is molded with the geonet 80 then spread out to a suitable flat configuration ( 82 ) having, a width substantially equal to the diameter of mold 60 times π (pi) and virtually any selected length in the direction of arrow 84 . It should be appreciated that maintaining mold 60 stationary while rotating mold 70 during molding will result in the desired longitudinal orientation of strands 14 a ′ in the direction of arrow 84 and the angled orientation of strands 14 b ′. Desired significant lengths of the geonet 80 may be cut, geotextiles 30 ′, 32 ′ added as desired, and then rolled into a coil for convenient transport and handling. When rolled, the geonet 80 is in a coil having X number of layers (as measured outwardly from the coil center) with each of the longitudinal strands 14 a ′ being rolled X times (meaning that each longitudinal strand 14 a ′ is coiled from the center of the roll to the outer layer of the roll).
[0052] FIG. 9 shows an alternate mold configuration, in which the inner mold 60 ′ includes round openings 64 ′ and the outer mold 70 ′ also includes round openings 74 ′, such as may be used to provide round strands in both sets of strands. Round strands have been found to be particularly advantageous in some applications as disclosed in U.S. patent application Ser. No. 11/271,396, filed Nov. 10, 2005, the disclosure of which is hereby incorporated by reference. It should, however, be understood that various advantages of the present invention could be obtained with a wide variety of strand shapes. For example, round openings in the inner mold and rectangular openings in the outer mold would be used to produce the geonet 12 illustrated in FIGS. 1-2 .
[0053] FIG. 10 illustrates, in cross-section, a landfill 90 in which geocomposites 28 according to the present invention may be advantageously used. As the landfill is made, a first layer of geocomposites 28 a is laid down on the surface of the area on which the landfill 90 is being formed. Of course, the area being covered may be extremely large, and therefore more than one section or roil of geocomposite 28 a will typically be required to cover the entire area at each layer. In accordance with this aspect of the invention, the geocomposite 28 a is rolled in the direction of expected fluid flow so that the longitudinal strands 14 a are oriented in the direction of expected fluid flow.
[0054] Fill 92 a will then be placed on top of the geocomposite 28 a to a desired depth such as is known in the art, and then a second layer of geocomposites 28 b is then laid down on that area in the orientation of expected fluid flow for that layer. Further layers of fill 92 b - 92 e and geocomposites 28 c - 28 e are similarly added according to the design of the landfill 90 . As is known to those skilled in the art, geocomposites 28 a - 28 e such as illustrated may be used to facilitate fluid flow through the landfill 90 . Moreover, other structures, such as pumps and vertical and horizontal pipes, may also be used in conjunction with such geocomposites 28 a - 28 e if desired to intentionally circulate leachate through the landfill and thereby facilitate stabilization of the landfill 90 so that it may thereafter be returned to other productive uses more quickly. Further, geocomposites 28 only about 0.200 inch thick may be used, for example, in place of twelve inch layers of sand and aggregate, thereby requiring much less height and concomitantly having less environmental impact and/or allowing for more fill (e.g., waste in a landfill).
[0055] It has been found that desired high transmissivities may be provided by geonets having the strands configured according to the present invention, with transmissivities maintained in the direction of the bottom strands 14 a, 14 a ′ under the wide range of conditions which may be encountered (including interface, gradient, seat time and pressure). Moreover, this configuration allows for extremely high flow rates while at the same time using a very low weight per unit are of the material for such geonets 12 , 12 ′. For example, at higher pressures such as 10,000 pounds per square foot, such as may be encountered in site designs involving several hundred thousand to over a million square feet and projected overburden heights of zero to over two hundred feet, significantly greater fluid flow along the generally horizontal geonet 12 may be provided, and/or significantly less geonet materials may be used, than with geonets not embodying the present invention, Thus, geocomposites 28 such as described herein may be advantageously used particularly in large landfills where they are subjected to high pressures over long periods of time. However, it should further be understood that geonets 12 and geocomposites 28 according to the present invention, though advantageously usable in geotechnical construction sites such as landfills 90 as described above, may also be advantageously usable in a wide variety of geotechnical construction sites, including not only common horizontal orientations facilitating drainage over a site but also vertical orientations such as in mechanically stabilized earth walls.
[0056] Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained.
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A geonet having a length substantially greater than its width and including no more than first and second layers of strands. A first plurality of substantially parallel strands extends in the lengthwise direction and defines the first layer of strands, and a second plurality of substantially parallel strands is disposed on top of, and at an angle relative to, the first plurality of strands and defines the second layer of strands. The first and second plurality of strands are substantially incompressible and secured to one another at crossover locations. Geocomposites include geotextile bonded to at least one side of the geonet. The geonets/geocomposites are laid in geotechnical construction sites in the direction of expected drainage flow.
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FIELD OF THE INVENTION
The present invention pertains to a process for operating a cash register terminal and to a cash register terminal, especially for self-service for gaming casinos, with bill-receiving and bill-dispensing as well as coin depositing and coin-dispensing devices and with at least one coin box and further to a cash register terminal, especially for self-service in gaming casinos, with bill-receiving and bill-dispensing as well as coin-depositing and coin-dispensing device and with at least one coin box.
BACKGROUND OF THE INVENTION
Cash register terminals for self-service have been known in gaming casinos in the form of bill changers. The customer can change a bill into coins there. All other wishes of the customer, e.g., the changing back of coins, must be satisfied by the personnel manually and semiautomatically. The necessary manpower requirement in the casinos for the frequent filling of the bill changers with coins and the associated risk involved in the transportation of coins across the gaming casino, as well as the low speed of work and the small storage capacity of the bill changers set up for the coins are disadvantageous.
SUMMARY AND OBJECTS OF THE INVENTION
The primary object of the present invention is to provide a process for operating a cash register terminal and a compact, modular and ergonomically designed cash register terminal which can attain a high speed of work and large storage capacity for coins.
According to the invention, a process is provided for operating a cash register terminal, especially for self-service in gaming casinos, with bill-receiving and bill-dispensing as well as coin depositing and coin-dispensing means and with at least one coin box. The process includes conveying the coins from the bottom from a coin box, of which there is at least one, in the upward direction. The coins are dispensed above the coin box at at least one outlet.
According to another aspect of the invention, a cash register terminal, especially for self-service in gaming casinos is provided with bill-receiving and bill-dispensing as well as coin-depositing and coin-dispensing devices and with a coin box, of which there is at least one. A conveying device (coin elevator) is provided whereby the coins are conveyed from the bottom from the coin box in the upward direction. An outlet and a dispensing device are provided. The coins are dispensed above the coin box at at least one outlet.
By dispensing the coins above the coin box, the coins are delivered from bottom to top in a simple manner, so that the weight of the heavy coin container remains close to the floor. Due to the use of a coin elevator for the vertical delivery of the coins, a compact design and high speed of processing are reached. The equipment of the coin elevator with at least one outlet guarantees the performance of important functions of the cash register terminal, such as rapid and reliable processing of the coins.
The cash register terminal is provided with a large storage capacity for coins and it makes possible the circulation of the coins in the system for depositing and dispensing processes and a high speed of processing, as well as the changing of bills into coins and vice versa, wherein checking for authenticity and the return of counterfeit bills and coins is guaranteed.
An outlet at the end of the sorting section is used to fill the coins into boxes, such as filling bags or the like, on the rear side of the cash register terminal, which are not accessible to the customers. Via a coin shunt or a fourth outlet, this outlet may also be used to dispense coins to the customers on the front side of the cash register terminal. Another outlet is used to sort which remain in the cash register terminal, e.g., the remaining money during the changing of coins into bills by the customer. Yet another outlet is used to return coins to the sorting section for filling the coin box.
The coin box according to the present invention with deflecting plates is able, in conjunction with oscillating conveyors, to store a large amount of coins and to release them in small amounts in a reliable manner, and it guarantees a compact design. The coin box is emptied by means of the oscillating conveyors.
According to the present invention, the heavy coin boxes are arranged in the lower area of the cash register terminal beneath the coin-dispensing opening. The coins are conveyed upward for dispensing. As a result, the size of the coin boxes may be selected almost freely, so that a simple and convenient filling is possible. The statics of the entire cash register terminal is favorably affected by the center of gravity being shifted downward. The coin-dispensing opening is arranged at a convenient height for the user in an ergonomically favorable manner.
To prevent the cash register terminal from constantly going out of operation due to the coin boxes being full, circulation of the coins is provided for the depositing and dispensing of the coins. All depositing and dispensing processes take place from one coin box, so that coins received will also be returned to the customer from the same coin box. An equilibrium of the coins is thus established in the cash register terminal, so that interventions become necessary only occasionally, e.g., for maintenance or the like.
According to the present invention, coins are removed from the cash register terminal in the upper area of the vertical guide path with a very high level of accuracy by checking the preliminary decision made already in the upstream vertical guide path once again and making a final decision to leave the selected coin in the cash register terminal or to sort it out.
The introduction of the self-service cash register terminal in gaming casinos leads to the more rapid supply of the customers with coins and to the avoidance of waiting lines for changing coins back into bills due to the higher velocity of delivery. Higher safety is guaranteed and all requirements imposed on a functional self-service cash register terminal are met due to the automatic, mechanical recognition and rejection of counterfeit bills and coins. The rejection of counterfeit bills and coins is guaranteed even at high speeds of processing. With the cash register terminal according to the present invention intended for self-service in a modular design with user prompting via a user computer with a display with touchscreen,
the assembly units can be replaced simply and rapidly for maintenance,
comfortable operation via display with touchscreen is possible,
bills can be changed into coins, coins into bills and bills into other bills,
a plurality of types of coins can be processed,
coins and bills are checked for authenticity and counterfeit coins and bills are returned to the customer,
all transactions are stored and evaluated,
additional cash register terminals may be integrated within a network,
disturbances are recognized automatically and they lead to the cash register terminal being switched off.
The present invention will be explained in greater detail below on the basis of an exemplary embodiment of a cash register terminal with a coin elevator and a plurality of coin boxes, which is shown in the drawings.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a front view of the cash register terminal according to the invention with assembly units drawn by broken lines;
FIG. 2 is a side view thereof;
FIG. 3 is a rear view thereof;
FIG. 4 is a front view of the coin elevator according to the invention;
FIG. 5 is the side view of the lower part of the coin elevator according to the invention;
FIG. 6 is the side view of the upper part of the coin elevator according to the invention;
FIG. 7 is a first embodiment of the coin box according to the invention;
FIG. 8 is a second embodiment of the coin box according to the invention;
FIG. 9 is a front view of the coin box according to FIG. 8;
FIG. 10 is a top view of the coin box according to FIG. 8;
FIG. 11 is a top view of the oscillating conveyors located under the coin boxes according to the invention;
FIG. 12 is a front view of the oscillating conveyors according to FIG. 11;
FIG. 13 is a side view of the oscillating conveyors according to FIG. 11; and
FIG. 14 is a view of the upper part of the coin elevator in a modified form compared with that shown in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in particular, the cash register terminal according to the representations in FIGS. 1 through 3 comprises a housing 1 bulging ergonomically forward in an arc-shaped manner on the front side V intended for the user with an attachment part 44, in which the assembly units important for the function are accommodated: These are four large coin boxes 2 on the right-hand side with an oscillating conveyor 50 arranged under them and a rotary table 34 for the coins 17; a small coin box 5 for intermediate sorting on the left next to the large coin box 2; a sorting drive 9 for coins 17 above the coin box 2; a coin elevator 3 with its horizontal coin delivery section 33 under the coin boxes 2, 5, and the vertical guide path 15 extending into the attachment part 44 of the housing 1 on the left next to the small coin box 5 and with a deflecting path 35 connecting the guide paths 15, 33; a coin cup 11 in the attachment part 44 on the left next to the upper end of the vertical guide path 15 of the coin elevator 3; a coin-receiving box 51 in the middle of the attachment part 44; a bill-receiving slot 7 on the right-hand side of the attachment part 44; a bill-coin dispenser 4 under and in front of the coin cup 1 at the upper end of a bill-processing device 68; a coin change box 52 and a foreign coin dispenser 6 in the center of the housing 1; a customer computer 8 with display and touchscreen in the middle on the front side V of the attachment part 44, as well as an office computer 10 for controlling all functions on the rear side R of the housing 1 shown in FIG. 1, on which a plurality of closable and pivotable doors 45 on the housing 1 and an outlet 21 for filling coins into bags are arranged.
The coin elevator 3, comprising a horizontal and vertical guide path 33 and 15, respectively, will now be described in detail. The coins 17 arrive from a coin box 2 on a coin tray 23 (FIGS. 7 and 8), which is provided with an oscillation generator 36 and is arranged under the coin box 2, and from there on a rotary table 34 (FIG. 7) adjoining the coin tray 23, which is driven by means of a drive motor 59 via a belt drive 65, from there on the adjoining, lower, horizontal guide path 33 (FIG. 4), and on the vertical guide path 15 (FIGS. 4, 5 and 6) via a quadrant-like deflecting path 35 (FIG. 4). The horizontal guide path 33, the deflecting path 35 and the vertical guide path 15 consist of strip steel with guide rails 46, 47 attached on both sides, the distance between which is somewhat greater than the diameter of the largest of the coins 17 to be conveyed. Guides 48, whose inner edges are located at more closely spaced locations from one another than the distance between the inner edges of the guide rails 46, 47, are screwed onto the guide rails 46, 47. A C- or U-shaped guide channel 43 is thus formed for the coins 17 on the guide paths 15, 33 and the deflecting path 35, the guide rails 46, 47 and the guides 48. The guide channel 43 is formed between a left-hand guide edge 40 and a right-hand guide edge 41 (broken lines in FIGS. 5 and 6).
To make it possible to dispense the coins 17 via the outlets 19 and 20 (FIG. 6), it must be ensured that the coins 17 move at the right-hand guide edge 41 as a reference edge. This is brought about by a baffle plate 39 arranged in the vertical guide path 15. This baffle plate 39 is formed by bulges of the guide edges 40, 41 up to the outer edges 42, 43. The distance D between the outer edges 42, 43 of the bulges of the guide edges 40, 41, which outer edges 42, 43 are located in the area of the baffle plate 39, is selected to be such that the smallest coin 17 to be conveyed will be deflected to the right to the right-hand guide edge 41 acting as a reference edge, rather than being able to pass straight through the baffle plate 39. It is guaranteed as a result that the coins 17 are located at the right-hand guide edge 41. Due to the conveyor belt 49 being led slightly obliquely toward the right-hand guide edge 41 used as a reference edge, it is achieved that the coins 17 do not leave the right-hand guide edge 41.
Since the static friction between the conveyor belt 49 guided by deflecting rollers 66 and spring-loaded pressing rollers 67 and the coins 17 is stronger than the sliding friction between the coins 17 and the guide paths 33, 15 as well as the deflecting path 35, the coins 17 are guided at first nearly slip-free horizontally, then deflected into a vertical direction in the area of the quadrant-like deflecting path 35 and they are subsequently conveyed vertically upward along the vertical guide path 15, and problem-free vertical conveyance of the coins 17 up to the upper outlet 38 of the vertical guide path 15 and then to the outlet 21 (FIG. 3) on the rear side R of the cash register terminal for filling coins 17 into bags takes place because of the stronger static friction between the coin 17 and the conveyor belt 49 and the weaker sliding friction between the coin 17 and the guide paths 15, 33.
Recognition and counting of the coins 17 may be performed by means of a recognition and counting means, not shown, in the area of the lower, horizontal guide path 33, while the sorting and the dispensing of the coins 17 takes place in the area of the vertical guide path 15 (FIG. 4) in the coin elevator 3. The horizontal and vertical guide paths 33, 15 are of identical design. The conveyor belts 49 are driven by means of pulling by a chain drive 16 driven by the drive motor 59. Corresponding to the representation in FIG. 6, the vertical guide path 15 of the coin elevator 3 has a sorting device 12. A decision is made at this point individually for each coin whether it will remain on the guide path 15 or whether it will be sorted out via one of the outlets 19, 20, 38.
As soon as the recognition and counting means arranged in the horizontal guide path 33 has detected a coin 17 that shall not remain on the guide path 15, sorting out is ordered. After this coin 17 has passed by a second recognition means 53 in the vertical guide path 15, the sorting device 12 is activated, i.e., an electromagnet arranged in this sorting device 12 is excited, and this electromagnet moves a horizontal pin 14 into the guide path 15 of the coin 17 such that the coin 17 will be deflected from the guide edge 41 acting as a reference edge and thus from the guide path 15. The coin 17 tilts into the outlet opening 19 and is deflected by the coin-deflecting element 18 onto a chute, not shown, and it is returned onto the sorting drive 9 (FIG. 1) from there.
The coins 17 let through by the sorting device 12 are moved forward to the outlet 20 for the coin return and they can be delivered into a shaft there, which is opened or closed by a servodrive 22. The customer can remove the requested coins 17 from the shaft. When the coin return shaft is closed, the coins 17 are conveyed to the outlet 38 at the end of the vertical guide path 15 and removed via the outlet 21 (FIG. 3) and optionally returned into the slot machines of the casino. The outlet 21 is arranged on the rear side R of the cash register terminal (FIG. 3) and is not accessible to the customers. The emptying of the coin box 2, which becomes necessary, is performed from the rear side R of the cash register terminal by the operator via an operating console provided there. Coin types may also be selected and filled via this console.
If the depositing or dispensing of coins or bills is desired by the customer, all necessary commands are sent by the computer 8 for the customer and by the computer 10 for the office to the assembly units of the cash register terminal to perform the depositing or the dispensing.
In the case of the dispensing of coins 17, a bill is inserted by the customer into the bill-receiving slot 7 on the right-hand front side V of the attachment part 44. The desired type of coin is selected on the display of the computer 8 with the touchscreen. Coins 17 are then conveyed from one of the four coin boxes 2 by means of the associated oscillating conveyor 50 (FIG. 7) via the rotary table 34 onto the horizontal guide path 33 of the coin elevator 3. From this coin elevator 3, the coins 17 enter the coin cup 11 via the outlet 38 at the upper end of the vertical guide path 15. The coin elevator 3 is stopped according to the amount of coins selected and dispensed. The remaining change is returned in the case of depositing in a similar manner, the coins 17 being dispensed via the outlet 20.
The sorting device 12 (FIG. 6) is needed to let through to the outlets 20, 38 (FIG. 6) only the coins that are to be dispensed. This is necessary because the coin boxes 2 are open and not closable on one side and undesired coins 17 may enter the coin elevator 3 at any time. The coins 17 having unintendedly entered the coin elevator 3 are charged via the sorting device 12 onto the sorting drive 9 (FIG. 1) and are again sorted into the coin boxes 2 from there.
There are bottlenecks in prior-art self-service cash register terminals due to the storage capacity of the coin boxes 2, which are often emptied too rapidly or are overfilled and interfere with the operation, being too small. Due to the special design of the four large coin boxes 2 (FIG. 7) and of the area in which the coins 17 are taken over from the rotary table 34 onto the lower guide path 33 of the coin elevator 3, as well as due to the coin boxes 2 being arranged in the lower area of the cash register terminal, it is achieved that the coin boxes 2 can receive a sufficiently large amount of coins and thus guarantee the reliable operation of the cash register terminal. Due to the center of gravity being shifted into the lower area of the cash register terminal, the size of the coin boxes 2 may be selected almost freely.
FIG. 7 shows a section of the lower area of the coin box 2 in the first embodiment with the coin outlet 29 onto the coin tray 23 and the connection to the coin tray 23. The coin box 2 is designed to accommodate and dispense a larger amount of coins 17 with a heavy weight. The coin box 2 is emptied by means of the oscillating conveyor 50. For conveyance by means of oscillation generators 36, a counterweight is usually needed for the weight of the coin box 2, including the coins 17 contained therein, which counterweight is higher than the weight of the coin box 2 and the coins 17 contained therein. To make possible a compact design, the weight of the coins 17 and of the coin box 2 can be compensated to minimize the counterweight while guaranteeing the full functionality of the oscillating conveyor 50.
To compensate the weight of the coins, a roof-shaped deflecting plate 24 is arranged in the coin box 2 such that its side plates 27, which are arranged essentially rectangularly to one another, are located with their free front sides 28 outside the bottom outlet of the coin box 2 formed by the coin outlet 29, as is indicated by the broken line 30 (FIG. 7). The pressure of the coins is laterally compensated as a result and shifted to the side walls 32, 37 of the coin box 2. The coin tray 23 located under the coin outlet 29 and the bottom opening of the coin box 2 is relieved. In the case of a defective oscillation generator 36, the coin box 2 can be opened by folding down a front-side side wall 37 or door 63, so that convenient removal of the coins 17 is possible.
The deflecting plate 24 is adjustable by means of an elongated hole 31 and is set at a distance d from the bottom opening 29 of the coin box 2, which is at least twice the largest diameter of the coins 17 located in the coin box 2. Wedging of the coins 17 in the coin outlet funnel formed from the oblique surfaces 32 of the coin box 2 is thus prevented.
The coin tray 23 is shaken via the oscillation generator 36 and via vibratory spring elements 25 independently from the coin box 2. Due to the deflecting plate 24 being arranged in the coin box 2 and the compensation of the coin weight thus achieved, it is achieved that the necessary counterweight 26 under the coin tray 23, which counterweight is rigidly connected to the housing, needs to have a substantially smaller weight than the filled coin box 2. The counterweight 26 is connected to the chassis 69 via rubber buffers 51.
It is very important in the case of a cash register terminal for operating errors not to lead to the cash register terminal going out of operation. To avoid jamming due to the insertion of foreign objects, such as crown caps or the like, the rotary table 34 of the sorting drive 9 (FIG. 5) is equipped with a flap mechanism, not shown in this embodiment. The rotary table 34 is emptied via the flap mechanism and its contents, containing foreign objects, are returned to the customer into the coin return compartment 6 (FIG. 1).
The assembly units installed in the cash register terminal for processing coins and bills may be used equally for the customer area on the front side V (FIG. 1) and for the operator area on the rear side R (FIG. 3) of the cash register terminal. The operator of the cash register terminal can perform the emptying of the cash register terminal from the rear side R without interfering with its ability to function during ongoing operation on the front side V accessible to the customer (FIG. 1). The customer area has priority. The emptying process of the coin boxes 2 is interrupted when a customer requests coins 17 on the front side V from the box 2 just being emptied. The customer's request is delayed only briefly, namely, until the emptying process is interrupted and the priority of the customer's request has become effective.
The possibility of returning the amount of cash inserted by the customer into the cash register terminal is provided for checking purposes in an embodiment of the present invention. The customer can initiate the return of the coins 17 inserted by him on the touchscreen of the computer 8 in order to check, e.g., the counting performed and the display of the amount of cash on the display of the computer 8 by repeating the process. To do so, the small coin box 5 next to the large coin box 2 is provided in the representation in FIG. 1 with a dropout opening in the bottom, not shown. The coins 17 inserted by the customer drop onto the sorting drive 9 and are conveyed into the coin box 5 via a special sorting opening after the counting process. If the customer does accept the amount of cash displayed on the display of the computer 8 by touching a corresponding key, the bottom flap in the small coin box 5 is opened, and the coins 17 drop onto the horizontal guide path 33, on which they are conveyed upward onto the sorting drive 9 via the vertical guide path 15 and are sorted into the coin boxes 2 from there.
If the customer does not accept the amount displayed on the display of the computer 8 by touching a corresponding key, the coins 17 are ejected from the coin box 5 onto the horizontal guide path 33 and are conveyed upward into the cup 11 via the vertical guide path 3 from there.
FIGS. 8, 9 and 10 show an alternative embodiment of the large coin box 2, in which the roof-shaped deflecting plate 24 according to FIG. 7 is replaced with a plurality of oblique deflecting plates 60, which are passed through slots in the side walls 61 of the coin box 2 from the outside and are welded to the side walls 61, so that there are no screw connections hindering the flow of coins on the inside of the coin box 2. The individual deflecting plates 60 have various shapes according to FIGS. 8, 9 and 10 and are always directed obliquely downward toward the coin outlet 29. The oblique deflecting plates 60 are used to support the weight of the coins 17 located in the coin box 2 in order to prevent the coins 17 from being jammed, such as forming bridges. The coin outlet 29 proper has an arc-shaped or round design, as is shown in FIG. 9. This brings about a favorable flow of the coins 17 onto the coin tray 23, which is located under the coin box 2, with the oscillating conveyor 50.
FIG. 8 shows a rubber flap 62, which hangs down freely on the left next to the coin outlet 29 and is used to guide the coins onto the coin tray 23. A door 63, which can be pivoted around an essentially horizontally arranged axis located in its lower area in order to make it possible to reach into the coin box 2 for eliminating jamming, is also arranged on the left-hand side of the coin box 2 as shown in FIG. 8. An attachment 64 of the door 63, which attachment extends downward in FIG. 8, is used to prevent the coins 17 from falling out on opening the door 63.
FIGS. 11 through 13 show the oscillating conveyor 50 located under the coin box 2 with the associated coin trays 23 and with flaps 54, which are associated with the said coin trays and surround the rotary table 34 of the coin elevator 3 located under them in a U-shaped pattern. The coin trays 23 arranged under each coin box 2 are covered by angle plates 55 on the rear side of the housing 1. The oscillation generators 36 of the respective coin trays 23, which are articulated to the counterweight 26, which is a rigid part of the housing, via the vibratory spring elements 25 (FIG. 13) and rubber buffers with spring elements, are arranged under the coin trays 23. The flaps 54, which are associated with each coin tray 23, which can be vibrated, are mounted on hinges 56 which are rigidly attached to the housing and are pivotably mounted by means of servodrives 57 arranged rigidly on the housing. The flat flaps 54 arranged on the free outlet side of the respective vibrating coin tray 23 are used to prevent coins 17 from flowing out of the actually vibrating coin tray 23 due to the flaps 54 themselves being mounted rigidly on the housing via the hinges 56 independently from the vibrating coin tray 23. The corresponding flap 54 is folded down by means of the servodrive 57 to bring about the flow of coins onto the rotary table 34 only to empty the respective vibrating coin tray 23 onto the rotary table 34.
FIG. 12 additionally shows the clamps 58 arranged between the respective hinges 56 of each flap 54 to hold the respective flap 54.
FIG. 14 shows an alternative embodiment of the upper end of the vertical guide path 15 of the coin elevator 3. A total of four outlets 70 through 73 are arranged here, of which the upper outlet 70 leads to the outlet 21 for filling the coins 17 into bags on the rear side R of the housing 1, while the next outlet 71 guides the coins 17 to the coin cup 11 on the front side V of the housing 1, and the outlet 72 located under it guides the coins 17 to the sorting drive 9, and the lowermost outlet 73 guides the coins 17 to the change dispenser 52.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A cash register terminal and process for operating a cash register terminal especially for self-service in gaming casinos, with bill-accepting and coin-deposition as well as coin-dispensing structure and with at least one coin box. To design the cash register terminal for high speed of operation and a large storage capacity for coins, the coins (17) are conveyed upward from the bottom from the coin box (2), of which there is at least one, and the coins (17) are dispensed above the at least one coin box (2), to at least one outlet (19, 20, 21).
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This application is a CIP of PCT/IB2005/054213 filed on Dec. 13, 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a security system, and in particular a security system for securing a set of keys to, in order to enable the ease of location thereof in the case of an emergency, such as a house fire or the like, in addition to providing a straightforward security system for preventing the theft of house or vehicle keys or the like.
2. Related Background Art
With the introduction of more anti-theft devices in vehicles, it is becoming more common for burglaries to be committed simply to obtain a set of keys such as vehicle keys. In many cases the owner of the vehicle is unaware that the keys have been taken until they see that the car is no longer parked outside the premises. It is therefore becoming more and more common, particularly at night when occupants are asleep, not to leave keys within easy reach of possible burglars.
However, placing keys out of reach can often have fatal consequences. Many house fires lead to injury or death when the occupants cannot exit the house because the doors thereto are locked. In the panic that ensues during a fire, the people affected may not be able to locate the keys because of the shock experienced, or due to heavy smoke which leads to additional confusion, especially when the keys are not immediately to hand. House fires normally incapacitate some but not all people within the household. Children often lose their lives or are seriously injured in searching for parents to unlock doors and offer assistance in exiting the premises, while the parents themselves are often unaware as to the exact location of the keys, and thus valuable time is wasted.
It is therefore an aim of the present invention to provide a security system adapted to secure a set of keys thereto, in order to prevent the unauthorised removal thereof. In addition the invention seeks to provide a fixed location at which the keys may be found and also a warning system if for example a fire breaks out in a home.
SUMMARY OF THE INVENTION
According to the present invention, as seen from a first aspect, there is provided a security system comprising a housing having an aperture for receiving a security tag which is to be attached to one or more keys, the aperture being associated with a locking mechanism operable to secure the security tag in or release the tag from the aperture, a sensor to monitor the presence of the security tag in the aperture, and alarm means for generating a warning signal if the security tag is removed from the housing without operation of the locking means.
In use, a security tag can be fitted to a bunch of keys and the keys can be securely stored by inserting the tag into the aperture of the system.
The system will not release the tag until the locking mechanism has been de-activated, thereby preventing the theft of the keys. A warning signal will be generated if the keys are removed without de-activating the system.
The locking mechanism may be arranged to releasably engage the tag, so that the keys can be removed from the system in an emergency, thereby triggering the alarm to alert other persons of the emergency. It is envisaged that the system may be able to optionally releasably engage the tag, so that the removal of car keys can be prevented, whilst the removal of house keys is permitted.
Preferably, means are provided for monitoring one or more environmental conditions in proximity to the housing and for actuating the alarm means if predetermined parameters for the monitored environmental conditions are not met.
In a preferred arrangement, said monitoring means is arranged to monitor for one or more environmental conditions selected from one or more of noise, smoke, heat or carbon-dioxide levels.
It is preferred that the locking mechanism is operated by a keypad which receives an input to lock or disengage the security tag in or from the aperture.
In a preferred arrangement, the security tag includes a microchip that can be read by a detector in the housing in order to verify the authenticity of the tag.
It is envisaged that the housing includes a memory, whereby different inputs can be allocated to different key holders.
It is further envisaged that the memory can be programmed to store varying data relating to the security level required for each key associated with a security tag. For example, if a security tag is attached to keys such as a front door key or a car key where only certain persons are meant to use the key, a memory for the security system can be programmed so that a more complicated or different code input would have to be input via the keypad to release the key from the housing than for say an internal door.
It is envisaged that the alarm means can generate an audible warning signal.
Further, the alarm means is operable to generate a visible warning signal. However, it is envisaged that if required, both and audible and a visible warning signal can be generated.
In a preferred arrangement, the housing also includes one or more lights which are operable to illuminate the security device when the warning signal is generated. This inclusion of lights has the benefit that the housing and keys can be more easily found in a smoke filled environment which improves the chances of householders being able to escape in an emergency situation. The lights can also be used to illuminate an exit for people to escape from a smoke filled room.
Preferably the lights are arranged to illuminate a keypad of the system.
Preferably, the housing also includes an override that is operable to turn off the alarm means. The override is in the form of an on/off switch for a power supply to the security device. This feature is useful in case there is inadvertent operation of the device, for example if a child rather than an intruder tries to remove the key without permission.
In a preferred arrangement, the security system includes switch means so that the system can be switched between sensing the presence of a security tag and environmental conditions or only monitoring the presence of a security tag or environmental conditions. By having the facility to switch between different levels of functions, this provides for maximum adaptability of the device. It may be that at certain times, for example during the day, the only need is to monitor for unauthorised removal of a key, while at night there is also the need to detect whether a fire has started so that house occupants can be alerted to escape as quickly as possible.
It is envisaged that the invention is also directed to a kit of parts comprising a housing as previously described, together with one or more security tags as herein mentioned.
In a preferred arrangement, the security tag is arranged for attachment to the key by a wire cable, preferably a twisted wire cable passing through an aperture in the key.
Preferably, the wire cable is secured to the fob by lockable securing members, such as nuts, which can be released to change keys for the tag or put more keys on the wire cable for a security tag.
Preferably, the securing means is in proximity to the security tag such that when the tag is placed in the aperture of the housing, the securing means are not accessible so that the securing means cannot be released to release the key from the security tag.
In an alternative arrangement, the security tag is secured to the body of the key, with the key being inserted in the aperture in the housing and locked in position.
It is envisaged that the security tag is provided as a plastic key which is attachable by a cable to a domestic key. However, the security tag can be a device which is clipped to the key itself.
Further, the invention is also directed to security tags as mentioned, which can be supplied separately for householders to attach to existing keys so that these existing keys can be secured by the security system.
Also, according to the present invention, as seen from a second aspect, there is provided a security system comprising a housing having an aperture for receiving a key, the aperture being associated with a locking mechanism operable to secure the key in or release the key from the aperture, a sensor to monitor the presence of the key in the aperture, and a signal generator that is operable to actuate a warning signal if the security key is removed from the housing without operation of the locking means.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described by way of examples only with reference to the accompanying drawings, in which:
FIG. 1 illustrates a front elevation of an embodiment of security system according to the present invention and a key and fob for releasable engagement with a housing of the system; and
FIG. 2 illustrates a front elevation of an embodiment of security system according to the present invention with a key inserted in a housing of the system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 of the accompanying drawings, there is illustrated an embodiment of security system, generally indicated as 10 , which serves to both locate and secure a key 28 or set of keys such as house or car keys, at a given location, for both safety and security reasons.
The security system 10 consists of a housing 12 which may be formed from any suitable material, for example plastic, preferably a thermosetting plastic or other heat resistant material. The choice of a heat resistant material for the housing 12 is important as the security system 10 , as will be described hereinafter, is intended to serve as a beacon or guide during emergencies such as house fires, where significant heat may be experienced, under which conditions the security system 10 must continue to operate. The housing 12 defines a chamber in the form of a slot 14 on the underside of the housing, which is shaped and dimensioned to receive a security tag 26 which may be in the form of a fob or a key.
In use, security tag 26 is securely connected to the key 28 or set of keys (not shown), by way of a shackle which is secured by nut 31 on either side of a mounting plate 32 which is attached to an end of the security tag 26 closest to the key. The key 28 may then be secured to the security system 10 via the security tag 26 . It should however be appreciated that the slot 14 could be adapted to directly receive the key 28 , although the use of the security tag 26 lends greater versatility to the security system 10 , allowing same to be used with keys (not shown) of varying shape and size.
The security system 10 is provided with a keypad 16 which, once the security tag 26 has been inserted into the slot 14 , may be used to lock the security tag 26 within the slot 14 . The keypad 16 may be configured to accept a single or multi-digit code which, when entered, locks the security tag within the slot 14 , by any conventional means. The slot 14 is configured to position the tag 26 in such a position that the nuts 31 securing the shackle 30 are inaccessible, such that when the tag 26 is locked in-situ, it is impossible to undo the nuts 31 to release the key 28 . The keypad 16 is preferably backlit, or otherwise rendered highly visible in darkness or low visibility (for example in the presence of smoke), in order to ensure that the keypad 16 may be actuated, without delay, during an emergency. The security system is also configured to effect release of the security tag 26 , and thus the key 28 , from the slot 14 upon a code being entered on the keypad 16 . Different lock and release codes may be utilised, however it will be appreciated that using the same code for both operations simplifies the use of the security device 10 , which is an important consideration given the intended function thereof.
Once the security tag 26 has been inserted into the slot 14 , and the keypad 16 utilised to lock same, the security system 10 is armed, and will emit an alarm signal if any attempt is made to remove the security tag 26 without first entering the correct release code. In order to generate an alarm signal, the security system 10 is provided with a plurality of lights 18 disposed about the housing 12 to provide a visible warning. In addition a speaker 20 can provide an audible alarm and the speaker is actuated by internal control circuitry (not shown) preferably of conventional electronic form. The control circuitry may be configured and adapted to trigger either a visual or audible alarm signal, or both, in response to a large number of external events.
One such way in which the alarm may be triggered is when an incorrect code is entered on the keypad 16 , although the device 10 may be configured to permit one incorrect entry of the release code, before triggering the alarm.
The security system 10 is also preferably provided with a sound detector 22 of any suitable form, which is operable to trigger the alarm in response to smoke or a certain frequency/pitch/volume, in particular to the audio alarm emitted by household smoke alarms (not shown). Thus, in the event of a fire, in addition to the sound of a smoke alarm, the security system 10 itself will issue a further audible/visual alarm. The visual alarm effected by the plurality of lights 18 is of particular benefit, in the event of a fire, as the lights 18 will serve to guide a person directly to the system 10 , and so the key 26 located and secured therein, even in the presence of smoke.
As an alternative, the security system 10 could be provided with an on board smoke/heat/carbon monoxide detector (not shown), which would be configured to trigger the alarm of the security system 10 directly. In addition, the security system 10 is preferably provided with internal vibration detectors (not shown), for example a conventional piezo-electric accelerometer based detector or the like. These detectors (not shown) are operable to detect any tampering with the security system 10 , and trigger the alarm in response thereto.
Thus, in use, the security system 10 is secured at a desired location, via a pair of fixing screws 24 , or indeed any other suitable means. The security system 10 is preferably secured close to an exit, such as a front door (not shown), in order to act as a guide to direct any occupants to both the exit and the keys necessary to unlock same. Once the security system 10 is fixed in position, and an occupant is present on the premises, the key 28 to the premises, or indeed the occupants vehicle, is secured to the security system 10 as hereinbefore described. The security system 10 will then serve two purposes. If as detailed above, the premises are broken into to obtain the keys to the occupant's vehicle, the keys cannot be removed from the security system 10 without triggering the alarm, thereby alerting the occupant to the attempted robbery. In addition the security system 10 serves as a fixed location at which the occupant's keys are located, avoiding the possibility of misplacing the keys.
The second function of the security system 10 is to serve as an emergency indicator, preferably pinpointing the location of an exit (not shown), in addition to the keys for same. Thus, in the event of a fire, the lights 18 will be activated as hereinbefore described, guiding the occupants to the security system 10 , and therefore the key 28 . The occupant then disarms the security system 10 by keying in the release code on the keypad 16 , and removes the key 28 to unlock the door. Any further occupants will then be guided to the opened door by the lights 18 , guiding the further occupants to safety.
The security system 10 may be configured to automatically disarm in the event of a fire, preventing the need to key in the release code, thereby reducing the time taken for the occupant to open a given door to exit the premises.
Alternatively, the keypad 16 may be entirely omitted, and possibly replaced with a simple on/off switch (not shown), such that the security system 10 still serves to guide an occupant to the key 28 , which can then be quickly and easily removed to enable the door to the premises to be unlocked.
Referring now to FIG. 2 of the accompanying drawings, there is illustrated an alternative embodiment of security system which is similar to the system of FIG. 1 and like parts are given reference numerals. In this embodiment the key 28 is received directly in the slot 14 .
While the preferred embodiments of the invention have been shown and described, it will be understood by those skilled in the art that changes of modifications may be made thereto without departing from the true spirit and scope of the invention.
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A security system for securing a set of keys comprises a housing having an external aperture for receiving a security tag which is attached to the keys, the aperture being associated with a locking mechanism which is operable by a keypad to secure the security tag in or release the tag from the aperture. A sensor monitors the presence of the security tag in the aperture, and an alarm is activated if the security tag is removed from the housing without releasing the locking mechanism. The security system eases the location of the keys in an emergency and also provides a straightforward security system for preventing the theft of house or vehicle keys or the like.
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CROSS-REFERENCE TO RELATED APPLICATIONS
60/841,602 filed Aug. 31, 2006
FEDERALY SPONSORED RESEARCH
None
SEQUENCE LISTING
None
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to the method of preparing various fabrics for the installation of a decorative crocheted edge. To be more specific, the invention relates to a template used to guide a piercing, cutting or marking instrument as part of the preparation process.
2. Prior Art
Crafters have been putting decorative edgings on handcrafted or purchased articles for many years. For example, adding a decorative crocheted edge onto blankets, towels, bed linen, table linen, window dressings and many others. There are numerous patterns and books of instruction on how to make many styles of crocheted edgings, however, very few indicate a method to affix the edging onto the article. The few books and patterns that do indicate a method of installation instruct the consumer to pierce the article using the sharp end of a barbecue skewer, ice pick, the tip of scissors or other such pointed instrument. None that would provide consistency in spacing or a tool or method that would be safe for the consumer. What is needed is a template that would provide a safe and consistent method of preparing the article to receive the decorative edging.
3. Objectives and Advantages
The main objective and advantage of the invention is that it provides the consumer with a unique and convenient template with which to prepare an article that is to receive a decorative edging. The preparation method allows for holes to be safely pierced at consistent intervals that will be utilized to crochet or otherwise sew the edging to the article. Additionally, the invention can be used in the squaring and trimming processes of fabric or materials. Additional objectives and advantages will become apparent from a study of the following description and the accompanying drawings.
SUMMARY
The present invention provides a template for accurately piercing or marking numerous variations of fabric for the purpose of installing a decorative crocheted edge. The template is in the shape of an isosceles right triangle that embodies holes at equally spaced intervals along the 3 straight sides with equal distances from the edge. The larger radius corner contains holes with slightly lesser spaced intervals with equal distances from the edge. The template is formed of a material of sufficient thickness to provide constant rigidity to guide a sharp pointed handheld awl to pass through the template and fabric leaving a visible hole. The template's edge is used as a pattern to guide a rotary cutting device to round off the corner of the fabric. The template is formed of a substantially transparent material for viewing the fabric to be trimmed, pierced or marked through the template assuring accurate positioning. The template is used in the fabric squaring process prior to trimming, piercing or marking.
DRAWINGS REFERENCE NUMERALS
10
template
12
PETG thickness .125″
13
hole diameter .1097″
14
.500″ hole spacing
15
.375″ from edge
16
.375″ hole spacing
17
radius corner
18
alignment pin
20
fabric
DRAWINGS
FIG. 1 —plan view of the template according to the invention.
FIG. 2 a - f —perspective view drawings of the invention operation.
DETAILED DESCRIPTION OF THE INVENTION
This invention provides a trimming and piercing template ( 10 ) for accurately preparing various fabrics ( 20 ) for the installation of a decorative crocheted edging. The nature of the fabric ( 20 ) may vary according to the intended purpose. By way of example, the fabric ( 20 ) may take the form of fleece as used for making blankets or the fabric ( 20 ) may take the form of cotton as used in table linens, bed linens and the like. In practicing the invention, it is preferred that the fabric be placed upon a surface suitable for use with a rotary type cutter for trimming or a fiberboard type material for piercing.
Referring to FIG. 1 , the template ( 10 ) is in the shape of an isosceles right triangle, formed of a substantially transparent material. The two equal sides of the template ( 10 ) are 15.56″ in length and the remaining side has a length of 21.70″.
The template ( 10 ) is intended to be transparent and reusable. Therefore, the template ( 10 ) is constructed from the material Polyethylene Terephtalate Glycol (PETG) that is relatively inexpensive, transparent, resists wear, and which allows trimming and piercing. The transparency of the template ( 10 ) allows for viewing and/or aligning the fabric ( 20 ) prior to trimming with a cutting tool or piercing with an awl, as shown in FIG. 2 .
Referring to FIG. 1 , the template ( 10 ) is formed of a material of sufficient thickness ( 12 ) to provide constant rigidity to guide a rotary cutter safely and firmly around the template ( 10 ) edges to trim the fabric ( 20 ) and to guide an awl safely and firmly into the holes ( 13 ) to pierce the fabric ( 20 ).
The template ( 10 ) embodies holes ( 13 ) that are of a dimension of 0.1097″ ( 3/32″) and that are at equally spaced intervals ( 14 ) along the 3 straight sides with equal distance of 0.375″ from the edge ( 15 ). These holes ( 13 ) are used to guide a sharp pointed handheld awl to pass through the template ( 10 ) and fabric ( 20 ) leaving a visible hole. The hole that has then been pierced into the fabric ( 20 ) will be the instrument to attach the decorative edging.
The larger radius corner ( 17 ) has a radius of 3.00″ and is a 90-degree corner. This corner ( 17 ) contains holes ( 13 ) with slightly lesser spaced intervals ( 16 ) with equal distances from the edge ( 15 ). The lesser spacing allows for the decorative edging to lay flat when being attached to a rounded corner in the fabric ( 20 ). The outside edge of the larger radius corner ( 17 ) of the template ( 10 ) is used as a guide for the rotary cutter to round the fabric ( 20 ) corners during the trimming process.
The holes ( 13 ) on both straight edges of the template ( 10 ) and larger radius corner ( 17 ) of the template ( 10 ) can also be used to insert a marking instrument to mark a consistent and accurate layout onto the fabric ( 20 ) for later piercing.
The template ( 10 ) edges are substantially straight and can be used in the fabric ( 20 ) squaring process prior to trimming, piercing or marking.
Operation
The manner of using the template ( 10 ) may vary according to the intended purpose. For purposes of example and to provide an operational instruction, the example of a blanket made of fleece will be used.
The fabric ( 20 ) will be laid out flat on the cutting surface. Fold the fabric ( 10 ) in half keeping the edges as straight and even as possible. Fold the fabric ( 20 ) in half again so that the fabric ( 20 ) is now quartered (4 layers).
To trim the fabric ( 20 ), refer to FIGS. 2 a - c.
FIG. 2 a . Using the right angle of the template ( 10 ), align one edge of the template ( 10 ) to one of the folded edges of the fabric ( 20 ). Align the straightedge parallel to the opposing edge of the templates ( 10 ) right angle. Move the template ( 10 ) and straightedge, maintaining alignment, along the folded edge until the proper amount of fabric ( 20 ) to be trimmed is exposed (4 layers). Cut along the straightedge using a rotary cutter.
FIG. 2 b . Align the template ( 10 ) with the newly trimmed edge of the fabric ( 20 ). Following the procedure in FIG. 2 a , align the straightedge parallel to the opposing edge of the templates ( 10 ) right angle. Move the template ( 10 ) and straightedge, maintaining alignment, along the trimmed edge until the proper amount of fabric ( 20 ) to be trimmed is exposed (4 layers). Cut along the straightedge using a rotary cutter.
FIG. 2 c . Align the right angle of the template ( 10 ) along the trimmed edges of the fabric ( 20 ). Using the rotary cutter, trim along the radius corner ( 17 ) of the template ( 10 ) to round off the fabric ( 20 ).
To pierce the fabric ( 20 ), refer to FIGS. 2 d - f.
FIG. 2 d . Position the fabric ( 20 ) onto the piercing surface, maintaining trimmed edge alignment (4 layers). Place the template ( 10 ) onto the fabric ( 20 ) aligning the right angle of the template ( 10 ) along the trimmed edges of the fabric ( 20 ) as in FIG. 2 c , matching up the trimmed rounded corner of the fabric ( 20 ) and the radius corner ( 17 ) of the template ( 10 ). Hold the template ( 10 ) into position firmly with one hand. Using an awl, pierce one hole ( 13 ) at the center of the radius corner ( 17 ) through the template ( 10 ), all 4 layers of fabric ( 20 ) and into the piercing surface. Place one alignment pin ( 18 ) into the hole ( 13 ) just pierced, through the fabric ( 20 ) and into the piercing surface. Pierce the holes ( 13 ) at both ends of the right angle of the template ( 10 ), piercing through all 4 layers of fabric ( 20 ) and into the piercing surface and insert alignment pins ( 18 ). The alignment pins ( 18 ) maintain accurate template ( 10 ) placement on the fabric ( 20 ). Continue fabric ( 20 ) piercing through the remaining holes ( 13 ) on the right angle and radius edge ( 17 ) of the template ( 10 ).
FIG. 2 e . Leaving alignment pins ( 18 ) in place, lift and remove the template ( 10 ). Using the long side of the template ( 10 ), place the template ( 10 ) over one of the remaining pins ( 18 ) along the trimmed edge. Align the template ( 10 ) with the trimmed edge. At the corner of the folded and trimmed edge, pierce the fabric ( 20 ) through the hole ( 13 ) closest to the corner and insert an alignment pin ( 18 ). Continue fabric ( 20 ) piercing through the remaining holes ( 13 ) between the pins ( 18 ).
FIG. 2 f . Repeating the process in FIG. 2 e , lift and remove the template ( 10 ). Using the long side of the template ( 10 ), place the template ( 10 ) over the remaining pins ( 18 ) along the trimmed edge yet to be pierced. Align the template ( 10 ) with the trimmed edge. At the corner of the folded and trimmed edge, pierce the fabric ( 20 ) through the hole ( 13 ) closest to the corner and insert an alignment pin ( 18 ). Continue fabric ( 20 ) piercing through the remaining holes ( 13 ) between the pins ( 18 ). At this point the process is complete and the fabric is prepared to receive the decorative edging.
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A template designed to prepare various fabrics for the attachment of a decorative crocheted edge. The transparent triangular shaped template contains holes at equally spaced intervals with uniform distance from the edge of the template. The corner of the template has been designed with a radial edge for use as a pattern to cut fabric. This is done with a rotary cutter. An awl is inserted into each hole of the template piercing the fabric leaving it with exposed holes to affix the decorative crocheted edge. A marking instrument can be inserted into the holes to mark a consistent layout on the fabric for future piercing. Further, the template can be used for squaring and trimming the fabric prior to the piercing process.
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This application is a continuation of the inventor's copending application Ser. No. 192,467, filed May 10, 1988.
BACKGROUND OF THE INVENTION
The present invention relates to an arrangement for facilitating the setting of the controls of a sewing machine.
As far as electronic sewing machines are concerned, it is known that built-in units for pre-programmed seams are used which are chosen by the electronics of the machine on indication of the operator. Such a sewing machine is known from, for example, Swedish Patent Specification No. SE-P-7910201-8. As to a mechanical sewing machine, the corresponding "pre-programming" can be carried out through indication of recommended values for the several controls of the machine. Usually, the operator must consult an instruction book to get several values of the controls before starting the sewing. An obvious simplification of this procedure can be gained by marking reference values at the controls when a stitch selector is actuated and set on the stitch wanted. Then it is easy to move the controls to those values, which then are empirically tested in order to obtain best results.
SUMMARY OF THE INVENTION
By the invention, an arrangement is presented having dials for reference values and setting devices placed in direct connection to each other. The reference value indicators are operated synchronously with a stitch selector, by which the desired seam is being set, and the reference values shown thus refer to such a setting. The advantage of this system is that the operator need not choose among various settings of the controls, but need only follow the recommended reference values indicated by the dials. The preparatory work is thereby facilitated and the setting is made uniform for one and the same seam. The advantages are gained when the arrangement is carried out with the characteristics more precisely described and claimed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will be described in the following with reference to the accompanying drawing, as follows:
FIG. 1 is a partial elevational view of a sewing machine and control panel incorporating the present invention;
FIG. 2 is a top plan view of the control panel of FIG. 1;
FIG. 3 is a rear elevational view of the sewing machine;
FIG. 4 is a perspective view of the sewing machine with the panel moved away; and
FIG. 5 is a top plan view of the movable tape.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the machine includes a zigzag mechanism (not shown) located in the pillar of the machine body. At the upper end of this pillar, there is a stitch selector knob 10 used for choosing pattern stitches. The stitches that can be produced are shown by symbols 11 on a panel 12 forming a front piece of the machine. At each symbol there is a marker 13, in this case, a round hole with an index which is moved between the holes at the symbols when the knob 10 rotates. The symbols are divided into two lines 14, 15 which are separated so that the upper one 14 has one color and the lower one 15 has another color. On the shaft of the knob 10 there is also mounted a zigzag control in the form of a knob 16 by which the stitch width is determined. This knob is graded with numerals from, for example, 0-5. In the middle of the panel, there is a stitch length control 17, which is also in the form of a graded knob. Finally, there is a thread tension knob 18 arranged to the left of the panel with the corresponding grading. As to the knob 17, this has been provided with the capability of changing symbols between the lines 14 and 15. In connection with the selection of line by means of the knob 17, the marker 13 adopts the same color as the symbols in the line selected. The system thus far described is of prior art and need not be-reported in detail.
With reference to FIGS. 2 through 5, an indication unit is arranged as windows 19, 20. 21 at each one of the knobs 16, 17, 18 on the upper side of the panel 12. Below the windows, there is a movable tape 22 with figures that can be read in the window. The tape is operated during the setting of the stitch selection knob 10 by a cog wheel 23 which rotates simultaneously with the knob and advances a new figure in the window at each step through which the knob rotates. The tape has three groups of figures placed on the tape so that the figures of zigzag, stitch length, and thread tension, belonging together, are visible in the relevant window. Furthermore, the tape has a bright index flap 24 bent down to serve as a reflector in the round holes denoted as markers 13 in FIG. 1. When the flap stands behind such, a hole, it is illuminated, owing to the fact that the index flap reflects the incoming light, in contrast to the other ones, which remain dark. The flap then indicates a pattern seam in the line 14 (see FIG. 1) on which the machine is set at present, but can be moved along the whole line. In order to obtain the pattern from the line 15 (see FIG. 1), the marker must have a specific color. In the embodiment presented, a further tape 25, which is generally transparent, is used and it is located between the holes and the index flap 24. This second tape 25 has a number of boxes of the same color as the line 15, but these are normally placed between the round holes and are not visible in front of the flap 24. The tape 25, however, can be moved so that the boxes appear in the round holes and then the flap reflects the incoming light in the hole where it is placed for the moment and, consequently, shines with the color of the colored box, i.e., the color of the box carried by tape 25 changes the apparent color of the flap 24. Therewith, the marker thus indicates that the machine is set on the pattern stitch according to the lower symbol (which thus belongs to the line 15).
The arrangement by which those functions are obtained is shown in FIG. 3. The cog wheel 23 is fixed on a bushing 26 which is supported in a hub through the panel and is provided with a driver 27 in which a driving member from the knob 10 is meshing. The tape 22 is put around the wheel so that the teeth fit into the perforation in the tape, which is further pulled over slide surfaces 28,29. The other knobs 16, 17, 18 are mounted in the sewing machine body, and therefore the panel is lowered over them so that a segment 30, 31, 32 becomes visible when the knobs appear in their respective openings 33, 34. 35 on the top side of the panel. With a grip on the segment, the operator can rotate the knob to the setting desired. The knobs are provided with figures and the figure standing upwards is a value of the setting of the knob.
In FIG. 3. a color changing arrangement is also shown which gives the marker one color or the other, respectively. On a shaft 36 a double-armed lever 37 is journaled in bearings, which lever in one end has an attachment for the tape 25. The other end of the tape is fixed to a spring 38, keeping the tape tense. The lever is actuated at its lower end by a curve surface 39 positioned on the knob 17 or by a pin which, through a half of the periphery of the knob, pushes the lower end to the left to the position shown by dashed lines. Thereby, the boxes on the tape are moved to a position just in front of the round holes, and the flap 24 behind each box adopts the color of the box, as previously described. When the curve surface 39 has been moved beyond the lever end, the tape resumes its normal position, due to the spring 38. The figures on the knob 17 which are visible on the segment 31 above the panel during the influence of the lever end then refer to the stitch symbols in line 15. These stitch symbols are principally performed in consequence of a change in cloth-feeding in the machine.
An extension of the system is possible by supplying several kinds of boxes on the tape 25 and the relevant lines of the symbols below the lines 14 and 15.
The embodiment now described shows how to achieve by simple means an arrangement for facilitating the setting of the control members of the machine. However, the individual details should not be considered as predominating the inventive idea which has a scope which is more closely defined in the claims.
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A display arrangement for seams on a sewing machine has lines (14,15) of symbols (11) and a marker (13) for each symbol in a line. The marker adopts an individual color for each line of symbols, whereby the number of marker devices is reduced. The setting values of the stitch, zigzag, and tension controls (16,17,18) are indicated on a tape (22) operated by a seam selector knob. The tape includes a flap (24) for the marker.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority right of prior U.S. patent application 60/864,648 filed Nov. 7, 2006 by applicants herein.
BACKGROUND TO THE INVENTION
Dangerous goods include liquid or solid substances, and articles containing them, that have been classified according to internationally-agreed criteria, and found to be potentially dangerous (hazardous) during transportation and/or storage. Most countries base their legislative requirements for storage and transportation of dangerous goods on the “ Recommendations on the transport of dangerous goods ” issued by the United Nations and the United Nations' prescribed testing codes for establishing the acceptability of various packaging and transportation methods.
Dangerous goods are assigned to different Classes depending on their predominant hazard, and on the basis of the specific chemical characteristics posing the risk. Such Classes include the following: class 1, explosives; class 2, gases; class 3, flammable liquids; class 4, flammable solids; class 5, oxidizing materials and organic peroxides; class 6, toxic and infectious substances; class 7, radioactive materials; class 8, corrosives substances; and class 9, miscellaneous (including asbestos, dry ice, engines, etc.). Except for very small packages, all packages and containers, shipping containers, unit loads, tankers, etc. which hold dangerous goods for transport must carry the correct Class Label. This label shows the nature of the hazard by the colour and symbol, and the Class of the goods by numeral. The Recommendations specify how storage areas are to be designed, constructed and located to minimize risks. The Recommendations are designed to assist the authorities and other emergency services, and to ensure that they have enough information to deal with incidents.
According to the United Nations classification system, explosives are also assigned compatibility group letters to facilitate their segregation during transportation. The letters used range from A-S, except for the letters I, M, O, P, Q and R. Also, they are sub-classified using the following sub-classes: 1.1 for explosives with a mass explosion hazard; 1.2 for explosives with a severe projection hazard; 1.3 is for explosives with a fire, blast or projection hazard but not a mass explosion hazard; 1.4 stands for minor fire or projection hazard (includes ammunition and most consumer fireworks); 1.5 is for an insensitive substance with a mass explosion hazard; and 1.6 for extremely insensitive articles. In the explosives industry, it is preferred to attempt to package some explosives such as detonators in such a way as to reduce their hazard classification from 1.1 to 1.4, so that the explosive substances as packed represent only a minor fire or projection hazard. This provides far greater levels of safety and allows for much cheaper transportation costs. In the case of detonator packaging, this certification relies on the fact that they are packed and designed so as to confine most of the effects of any accidental explosion or ignition within the package itself, and if there are multiple devices, one detonator exploding will not lead to mass detonation of the others in the package.
In order for detonators to be certified as 1.4, they must pass the UN Test Series 6 external fire test (Bonfire test), which may include Tests 6(a), 6(b), 6(c), and 6(d). The packaging can have a significant influence on the explosive effects of substances and articles. The type of packaging can change the response of packed explosives or explosive articles in Test Series 6. One and the same explosive substance or article can therefore be assigned to different hazard groups, or even be rejected from Class 1 for transport depending upon the packaging used. The Bonfire test is performed on packages of explosive substances or explosive articles, or unpackaged explosive articles, to determine whether there is a risk of mass explosion or a potential hazard from dangerous projectiles, radiant heat and/or violent burning or any other dangerous effects. Typically, a stack of test substances or articles is placed on a non-combustible surface (steel grate) above a lattice of dried wood soaked with diesel fuel or equivalent source. A wire basket or clamps may be used to hold the articles in place. Sufficient fuel is used to provide a 30-minute fire. Three aluminum witness plates, each having a surface area of 4 m 2 (2 m×2 m), are placed away from the edge of the packages at a distance of four meters. The fire is ignited and the material is observed for:
a) Evidence of detonation, deflagration or explosion of the total contents;
b) Potentially hazardous fragmentation; and
c) Thermal effects (i.e. size of the fireball, etc.).
The results are used to determine whether a reaction from an explosive article in its package, which was accidentally fired or initiated, would propagate to other articles or parts of the process. The package product is assigned a 1.4 certification if it meets the following requirements:
1) no indentations of the witness plates are observed; and
2) no projection, thermal effect or blast effect is observed.
With respect to the transportation and storage of detonators, the relevant criteria are generally accepted to be the UN 1.4 Code of testing. This certification relies upon the fact that when detonators are packed together for storage and/or transportation, inadvertent initiation of one detonator will not lead to mass detonation of other detonators present. This is especially important for air transportation since it is the most restricted mode of shipping. For such transportation, the 1.4S classification is required, the “S” being indicative that any hazardous effects arising from accidental functioning of the detonators in a package is confined within the package (unless the package has been degraded by fire, in which case all blast or projection effects are limited to the extent that they do not significantly hinder or prohibit fire fighting or other emergency response efforts in the immediate vicinity of the package).
Previously, packaging methods for the storage and transport of shelled detonators have included the use of protectors on the detonators or specially designed transportation boxes. For example, International Patent Publication WO95/19539 published Jul. 20, 1995, discloses a protector for use in the transportation and storage of detonators, comprising a detonator holder which is open at one end for insertion of a detonator, and closed at the other end, and which radially encloses the base charge of said detonator, at least one detonator retaining means integral with the detonator holder, and a first wall which is radially spaced around the holder and wherein the holder and wall define a space. In use, the detonator retaining means holds the detonator within the holder such that a free volume is provided around the base charge of the detonator.
Another example is U.S. Pat. No. 5,133,258 issued Jul. 28, 1992, which discloses a safe transportation holder and package for explosive devices such as blasting caps. Each cap is contained in an internal cavity in a holder, and surrounded by radially-spaced, elastomeric walls. The holders are arrayed in a container, and absorb the energy released by accidental detonation of one cap to prevent sympathetic detonation of others in the packages.
U.S. Pat. No. 6,454,085 issued Sep. 24, 2002 discloses a system and method for packaging shaped charges for transportation. Each shaped charge includes a housing and a liner having a high explosive disposed therebetween. A jet spoiler is positioned proximate the liner of each of the shaped charges to prevent the formation of a jet in the event of an inadvertent initiation of a shaped charge. The shaped charges are then oriented in first and second layers such that the jet spoilers positioned proximate the liners of the shaped charges in the first and second layers oppose one another. A shielding panel is disposed between the shaped charges of the first and second layers. The shaped charges including the jet spoilers and the shielding panel are placed within an expandable bag which is in turn enclosed within a transportation container. The jet spoilers may be constructed of a suitably dense material such as wood, plastic, foam, rubber, plaster, cement and the like. Ideally the material would be one that is environmentally friendly for easy disposal, lightweight to facilitate shipping and handling and economical. For example, biodegradable cardboard, balsa wood or compressed sawdust are suitable materials. The expandable bag is preferably made from a ballistic cloth, and the container may preferably be a corrugated cardboard box or a wood box.
U.S. Pat. No. 6,629,597, issued Oct. 7, 2003, discloses a system and method for packaging shaped charges for transportation. Each shaped charge includes a housing and a liner having a high explosive disposed therebetween. A jet spoiler is positioned proximate the liner of each of the shaped charges to prevent the formation of a jet of shrapnel in the event of an inadvertent initiation of a shaped charge. The jet spoilers may be comprised of a metal or non-metal material. Wood, plastic, rubber, plaster, cement, cardboard, balsa wood, or compressed sawdust are disclosed as particularly suitable attenuator materials for the jet spoilers. The shaped charges are then oriented in first and second layers such that the jet spoilers positioned proximate the liners of the shaped charges in the first and second layers are opposite one another. A shielding panel is disposed between the shaped charges of the first and second layers. The shaped charges, including the jet spoilers and the shielding panel, are placed within an expandable bag which is in turn enclosed within a transportation container.
As a further example, U.S. Pat. No. 4,286,708 discloses a package wherein the sympathetic or chain reaction detonation of stacked munitions is prevented by confining any random explosion essentially to a single explosive unit or container. Frangible inhibitor plates are located between adjacent munitions, such as artillery shells, so as to isolate the adjacent explosive units from a residual shock wave or case fragment that would otherwise trigger sympathetic detonation. The inhibitor plates may be constructed as part of a container in which an artillery shell may be stored, or the plates may be separately inserted between any adjacent warhead in any conventional storage pallet or transporting configuration. The plates are designed to absorb only that amount of explosive energy required to prevent sympathetic detonation, without requiring that the explosive forces be redirected away from adjacent shells, thus reducing the problem of redirected blast.
Other packaging methods involve wrapping a detonator in its down-hole wire, and caging a box of detonators within its cardboard box. For example, Canadian Patent application 2,118,528 discloses a non electric detonator assembly for its safe transport in bulk wherein a detonator is located substantially along the axis of a coil of initiation tubing, the initiation tubing being wound such that it may be unwound by drawing from the centre of the coil.
Another method used for packaging explosive devices such as detonators is one inspired by the military industry. It involves the use of a cardboard tube having a clay plug or equivalent thereof at one end. Such equivalents to a clay plug may include, but are not limited to, a plug comprising wood, compressed sawdust, cement, granulated sand, plaster, dry wall materials, and other materials. The device is enclosed in the tube, with its explosive end at or near the clay plug end. The plug acts, at least in certain circumstances, as a jet spoiler to absorb shrapnel from an explosion, and the tube functions as a flame retardant. The tube is preferably made of cardboard because this material is not too dense, inexpensive and environmentally benign. Examples of this packaging method can be found in United States Patent Applications published as 2005/0150781 and 2006/0108237 on Jul. 14, 2005 and May 25, 2006 respectively. US 2005/0150781 discloses a detonator protector including a housing fitted with an end cap at one end and a plug at the other end. US 2006/0108237 discloses a tubing assembly having opposed ends and a thick wall of relatively low-density fibrous material, and having an impact absorbing element positioned at each end of the tube.
Although numerous methods for the storage and transport of dangerous goods have been developed, there remains a continuing need to develop improved methods to increase security and safety of dangerous goods, and in particular explosive devices such as detonators. Moreover, there remains a continuing need to develop packaging methods for storage and transportation of detonators, with improved protection against inadvertent mass initiation of other detonators within a package.
SUMMARY OF THE INVENTION
It is an object of the present invention, at least in preferred embodiments, to improve the safety of transportation and/or storage of detonators.
It is another object of the present invention, at least in preferred embodiments, to provide a protector for use in transportation and/or storage of detonators
It is another object of the present invention, at least in preferred embodiments, to provide methods for packaging a plurality of detonators.
Certain exemplary embodiments provide an assembly comprising:
(a) a detonator comprising a detonator shell, and an explosive end comprising a base charge of explosive material;
(b) a detonator protector comprising a recess for receiving and covering at least the explosive end of the detonator shell to contain shrapnel and/or explosive energy derived from the detonator in the event of inadvertent actuation of the base charge, said detonator protector being dimensioned such that a most of the detonator shell is not covered by the protector, thereby to allow the explosive material of said base charge to deflagrate in the event of inadvertent actuation of the detonator and/or exposure of the assembly to the heat of a fire.
Certain exemplary embodiments provide a detonator protector for covering at least an explosive end of a detonator, to contain shrapnel and/or explosive energy derived from the explosive end in the event of inadvertent actuation of a base charge contained within the explosive end, said detonator protector being dimensioned such that in use most of the detonator shell is not covered by the protector, thereby to allow the explosive material of said base charge to deflagrate in the event of inadvertent actuation of the detonator and/or upon exposure of said detonator and detonator protector to the heat of a fire.
Certain exemplary embodiments provide a method of protecting a detonator from emitting shrapnel and/or explosive energy during transportation and/or storage, the method comprising the step of: applying to an explosive end of the detonator, a detonator protector as disclosed herein.
Certain exemplary embodiments provide a method of packaging a plurality of detonators each comprising a detonator shell and an explosive end comprising a base charge, the method comprising the steps of: applying to each explosive end a detonator protector as disclosed herein, thereby to form protected detonators; and placing the protected detonators into a container.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a sectional view of an assembly of the present invention.
FIG. 1 b is a perspective view of the assembly shown in FIG. 1 a.
FIG. 2 is a sectional view of a preferred double-protecting device of the present invention
FIG. 3 a is a sectional view of a preferred alternate packaging
FIG. 3 b is a sectional view of another preferred alternate packaging
FIG. 3 c is a sectional view of another preferred alternate packaging
FIG. 3 d is a sectional view of another preferred packaging
FIG. 3 e is a side, perspective view of stacked rows of assemblies
DEFINITIONS
Base charge: refers to any discrete portion of explosive material in the proximity of other components of the detonator and associated with those components in a manner that allows the explosive material to actuate upon receipt of appropriate signals from the other components. The base charge may be retained within the main casing of a detonator, or alternatively may be located nearby the main casing of a detonator. The base charge may be used to deliver output power to an external explosives charge to initiate the external explosives charge.
Blasting machine: any device that is capable of being in signal communication with electronic detonators, for example to send ARM, DISARM, and FIRE signals to the detonators, and/or to program the detonators with delay times and/or firing codes. The blasting machine may also be capable of receiving information such as delay times or firing codes from the detonators directly, or this may be achieved via an intermediate device to collect detonator information and transfer the information to the blasting machine.
Central command station: refers to any device that transmits signals via radio-transmission or by direct connection, to one or more blasting machines. The transmitted signals may be encoded, or encrypted. Typically, the central blasting station permits radio communication with multiple blasting machines from a location remote from the blast site.
Explosive end: refers to a portion of a detonator where a base charge is located within the detonator, generally at an end opposite an end of a detonator that receives a signal transmission line or other means for receiving signals from an external source. Actuation of the base charge upon receipt by the detonator of a command signal to FIRE, optionally following count-down of a delay time, causes a release of explosive energy at or about the explosive end. As discussed herein, the base charge may also be accidentally or inadvertently actuated when a physical shock or unwanted electrical current is applied to the detonator, for example during transportation and storage.
Preferably: identifies preferred features of the invention. Unless otherwise specified, the term preferably refers to preferred features of the broadest embodiments of the invention, as defined for example by the independent claims, and other embodiments disclosed herein.
Flame retardant/flame retardant additive: refers to any substance, material, or composition that exhibits at least some degree of flame retardant properties. In selected embodiments, such a flame retardant may help impart fire resistance to a protector as disclosed herein. In selected embodiments, little or no flame retardant additive may be required. In other embodiments, such as those relating to paper and polymer-based protectors, fire retardant materials such as those described, for example, in “Fire Retardant Materials”, by Dennis Price and A. Richard Horrocks, CRC, Woodhead Publishing Limited, February 2001 may be utilized. Such families of flame retardant materials may include but are not limited to halogen-based compounds (e.g.: brominated compounds such as PBDE, and PBB), phosphorus based compounds (e.g.: ammonium phosphate), borates, metal hydroxides (e.g.: aluminum hydroxide) and other hydrated inorganic additives (e.g.: plaster). Flame retardant materials can also be added to the silicone rubber to improve its heat resistant properties, such as those available from the Dow Chemical Company and other suppliers. Numerous silicone rubber compositions that include flame retardant additives are known in the art. U.S. Pat. Nos. 4,310,444 issued Jan. 12, 1982, 4,366,278 issued Dec. 28, 1982, and 4,678,827 issued Jul. 7, 1987, are just a few examples of references disclosing such compositions and flame retardant additives. Further flame retardant additives that are known in the art may be used with a protector as disclosed herein. A skilled artisan may select a flame retardant additive that is suitable for use with a protector material or composition.
Protector: refers to a device of the present invention as described herein that substantially covers an explosive end of a detonator, and optionally additional portions of a detonator, and helps to prevent movement away from the explosive end of shrapnel and/or explosive energy upon actuation of a base charge located at or near the explosive end. The term “protector” may, at least in selected embodiments, be interchangeable with the term “cap”.
Shrapnel: refers to any fragments or debris thrown out by any exploding object, more particularly from an explosive end of a detonator upon actuation of a base charge located at or near the explosive end.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides, at least in preferred embodiments, for protectors, protected detonator assemblies, and methods for the storage and transport of detonators, preferably to achieve 1.4 packaging requirements in accordance with UN Recommendations. A protector or “cap” is used to cover at least the explosive end of a detonator shell while the rest of the detonator may be left at least substantially uncovered by the cap. Preferably, the protective cap is made of material resistant to high temperature and flame, which means having the property to at least substantially maintain its shape and cohesion upon actuation of a nearby base charge, or exposure to high temperatures or flames. More preferably, the cap may comprise a resiliently deformable material, for reasons that will become apparent below. For example, any polymers, plastics, elastomers, vinyls, rubbers, having that property can be used. (An agent that is not merely fireproof, but which calcines upon burning or concretes upon heating, may be less suitable for this invention since it may provide less protection for the detonator when burnt.) In preferred embodiments, the material also has a certain degree of malleability and/or elasticity to fit on the explosive end and stay in place. Preferably, the material used is a cross-linked polymer, and more preferably silicone rubber. In other embodiments, the protector may comprise less resilient materials such as resins and plasters, or wood-derived products. In a most preferred embodiment, the material further comprises a flame retardant additive.
The present invention has been developed by virtue of multiple discoveries by the inventors, which in combination provide optimal results to achieve the advantages outlined above. One discovery relates to the need for maintaining a sufficient mass of explosive energy-absorbing material generally or immediately adjacent the explosive end of a detonator. The inventors have discovered that a mass, specifically located adjacent the explosive end of the detonator, helps to impede the acceleration of shrapnel derived from the explosive end upon actuation of the base charge, and thus limits the final velocity and the inertia of the shrapnel. In this way, the protector contains the shrapnel created when the detonator explodes. This is achieved by designing the detonator protector in such a way that a portion of its mass is located at the axial end of the explosive end, preferably in direct contact with the detonator, so that it effectively “catches” the shrapnel when the base charge is actuated.
In preferred embodiments, the detonator protector comprises a resiliently deformable material that is able to form a tight fit around the explosive end of the detonator. Resiliently deformable materials are particularly preferred, since they may better assist in deceleration of shrapnel material being ejected or emanating from the explosive end, thereby reducing the inertia of the shrapnel. Moreover, the preferred tight fit of the detonator protector, by virtue of the resilient deformability of the detonator protector material, results in a tightly sealed interface leaving little or no gap between the detonator protector and the explosive end. In this way, any shrapnel will have neither time nor space to accelerate prior to encountering the detonator protector, further contributing to the advantages of the device. Moreover, a tight fit reduces the possibility of the protector being removed from the detonator before, during, or after actuation of the base charge, so that its protective function is maintained.
The protectors herein are not, however, limited only to those that stay in place by interference or friction fit. A protector may be held on an explosive end of a detonator by any means, including for example, screw-thread fitting, snap-fitting, or any other form of suitable engagement, optionally assisted by friction fitting such as that provided by the use of resilient materials.
Another important discovery by the inventors relates to the need for the protector, at least in preferred embodiments, to allow the detonator (to which it is attached) to burn or “cook off” in as full and complete a manner as possible, in the event of inadvertent detonator actuation. Indeed, failure of detonators to “cook off” sufficiently during a standard UN Test Series 6 external fire test (Bonfire test), can result in an unacceptable quantity of unburned explosive material remaining within the detonators after the test is complete. The inventors have discovered that by protecting principally the explosive end of the detonator, whilst leaving other portions of the detonator at least substantially unprotected by protector materials, improved detonator “cook-off” is achievable, even when the protectors of the invention remain attached to detonators during the testing procedures. In this way, the portions of the detonator shell not covered by a protector permit the heat of a test fire to be conducted more efficiently to the explosive material in the base charge at the explosive end of the detonator, thereby allowing it to burn or cook off more rapidly and/or efficiently. A more rapid cook-off also helps to reduce burning or other consuming of the protector material by the fire, so that a sufficient mass of the protector can be retained at the explosive end, for sufficient time for the protector to provide the required protective function. Preferably, the protector is designed to stretch onto and to fit tightly upon the explosive end of the detonator, so that it can maintain its position and its protective function throughout all the packaging, storing, and transporting procedures. This may be facilitated by selecting an appropriate material as discussed above.
When packaging multiple detonators, it is preferred to favour alternate “head-to-tail” orientation of adjacent detonators in the package. This helps to maintain at least a limited distance between the percussion-actuation ends of adjacent detonators within the package. With this arrangement there is a reduced possibility that inadvertent actuation of the base charge of one detonator may be directed to cause actuation of the base charge of a second detonator. Therefore, propagation to further detonators is less unlikely. The present invention therefore further provides for a method of packaging multiple detonators by protecting each detonator with the protector of the invention, and positioning each detonator in an alternating pattern, the explosive end of a first detonator facing one side of the package as the explosive end of its adjacent protected detonator is facing the opposite side of the package and so on, thereby to form a row of alternately oriented detonators. If required, multiple rows of alternately oriented detonators may be stacked so that the detonators within one row are oriented in an opposite, alternating manner to detonators in a row stacked immediately above or below. Multiple rows may also be present in a single layer of detonators. Most preferably, any space in between adjacent protected detonators in a row, and in between adjacent rows or stacked rows, may be filled with an energy-absorbing and/or isolating material. Such isolating material may comprise any suitable material including but not limited to paper products, resins, plastics and foams. Any kind of packaging material, suitable for transport and storage of detonators, may be used, preferably having a capacity to absorb explosive energy, as well as flame retard properties. Such materials may also be used to surround protected, stacked arrays of detonators, once packaged.
Copper alloy shelled detonators are known in the art to be more shock resistant than aluminum detonators. They are also known to project shrapnel at a longer distance and with a greater energy. Such shrapnel may be more penetrating, due in part to the fact that copper is a denser metal than aluminum. Copper has the property to have superior electrical and thermal conductivity than aluminum, and well as superior shock resistance. For those reasons, there is a trend in the explosive industry to favor copper detonators over aluminum ones. Preferably, the present invention permits safe packaging and transport of copper-shelled detonators in compliance with UN 1.4 standards.
The detonator protectors of the present invention may be comprised of any metal or non-metal material. Silicone rubber, wood, plastic, rubber, plaster, cement, cardboard, balsa wood, resin, or compressed sawdust are a few examples of suitable attenuator materials for the protectors. Silicone rubber and plaster have been demonstrated to exhibit particularly preferred properties. The testing by the inventors has enabled silicone detonator protectors to pass at least UN Test Series 6(d) testing to date, and corresponding plaster detonator protectors have passed 6(a), 6(c), and (6d) testing to date. Silicone rubber also represents a preferred material due to its resiliently deformable properties, that are particularly suited to tight securing of the protector onto the percussion-actuation end of a detonator. Plaster and silicone rubber, as well as other materials listed therein, are generally non-toxic and thus may present little environmental concern if discarded or otherwise not recovered from a blast site.
The invention thus provides, in selected embodiments, for both detonator assemblies (comprising a detonator in combination with a detonator protector as described herein), as well as for a detonator protector per se. The invention also provides for methods of protecting detonators involving the detonator protectors described herein, as well as methods for packaging detonators so as to improve the safety of the finished package.
Certain exemplary embodiments thus provide for an assembly comprising:
(a) a detonator comprising a detonator shell, and an explosive end comprising a base charge of explosive material;
(b) a detonator protector comprising a recess for receiving and covering the explosive end of the detonator shell and having a mass sufficient to contain shrapnel and/or explosive energy derived from the detonator in the event of inadvertent actuation of the base charge, said detonator protector being dimensioned such that most of the detonator shell is not covered by the protector, thereby to allow the explosive material of said base charge to deflagrate in the event of inadvertent actuation of the detonator and/or exposure of the assembly to the heat of a fire. As discussed above, such a detonator assembly exhibits the desired attributes of excellent containment of shrapnel and/or explosive energy in the event of inadvertent actuation of the detonator, combined with rapid and/or efficient cook-off of the explosive material of the base charge.
Preferably, the detonator protector is made of a material having a resilience to maintain its shape and cohesion upon exposure to a high temperature, a flame, or upon actuation of a base charge located in said explosive end. In particularly preferred embodiments the material may be selected from any cross-linked polymer or silicone rubber, and may optionally further comprise any flame retardant as an additive. Such substances and additives are well known in the art. Silicone-based materials are particularly preferred, since they provide excellent cohesion, flame-retardancy, and resiliently deformable properties. In further exemplary embodiments, the protector may comprise a polymer that in the event of exposure to fire is capable of conversion to a ceramic-type material. Such polymers are known in the art such as those manufacture and/or utilized in Pyrolex® Ceramifiable® cables manufactured by Olex Cables of Tottenham, VIC, Australia,
Regardless of the material, the detonator protector is preferably comprised of a resiliently deformable material to facilitate placement or securing of the protector onto the explosive end of the detonator, and to help achieve a tight fit and secure grip by the detonator protector on the explosive end, thereby to keep the protector in place during transportation, storage, or detonator actuation. Furthermore, dimensioning of the detonator protector is preferably such that it covers less than one-third of a length of the detonator from the explosive end. As discussed above, by leaving most of the detonator shell exposed, this improves the speed or efficiency of cook-off the detonators for example by virtue of improved heat conductance to the base charge. This helps to reduce the possibility of explosive materials remaining in the detonator following inadvertent actuation thereof.
In selected embodiments, a detonator assembly of the invention may comprise more than one detonator associated with a detonator protector. For example, the assembly may comprise two detonators each with their explosive ends contained within each of two recesses in a detonator protector. In preferred embodiments, such a protector may be configured so that insertion of the explosive ends of both detonators causes the detonators to attain an opposing, aligned orientation, with their respective explosive ends separated by a portion of the detonator protector. The portion of the detonator protector between opposing explosive ends of the detonators may be perforatable by shrapnel and or explosive energy emitted upon inadvertent actuation of one of the detonators, such that said inadvertent actuation causes cook-off of a base charge in the other of said detonators, said detonator protector substantially containing shrapnel from one or both of said detonators. In other related embodiments, the protector may not include any material between the opposing ends of the detonators, so that the protector is effectively in the form of a tube of material, with each open end of the tube being dimensioned to receive an explosive end of a detonator.
Other exemplary embodiments pertain to a detonator protector per se, for covering at least an explosive end of a detonator to contain shrapnel and/or explosive energy derived from the detonator in the event of inadvertent actuation of a base charge contained within the explosive end. The detonator protector may be dimensioned such that in use most of the detonator shell is not covered by the protector, thereby to allow the explosive material of said base charge to at least substantially deflagrate in the event of inadvertent actuation of the detonator. The preferred properties and features of a detonator protector of the invention are described herein with reference to a detonator assembly.
Still further exemplary embodiments pertain to methods of protecting a detonator from emitting shrapnel and/or explosive energy during transportation and/or storage. Such methods may comprise the step of: applying to an explosive end of the detonator, a detonator protector as described herein.
Still further exemplary embodiments pertain to methods of packaging a plurality of detonators each comprising a detonator shell and an explosive end comprising a base charge. Such methods comprise the steps of: applying to each explosive end a detonator protector as described herein; and placing the protected detonators into a container. Preferably, the step of placing comprises: disposing each protected detonator within a container according to an alternating pattern, wherein when a protected detonator has its protected explosive end facing one side of the package, each adjacent detonator having its protected, explosive end facing a side opposite said one side thereby to form a row of protected detonators. The step of placing may additionally or alternatively involve placing more than one row of detonators into the container, with explosive ends of at least one pair of adjacent detonators from adjacent rows facing generally into the package in aligned opposition, and disposed explosive end to explosive end, each pair of detonators protected by a detonator protector comprising two recesses for simultaneously receiving each explosive end of said pair, to hold the detonators in said aligned opposition, with their respective explosive ends separated by a portion of said detonator protector. The step of placing may also comprise placing multiple rows of protected detonators into the container, stacked one top of another, wherein adjacent rows of protected detonators and/or multiple rows of protected detonators stacked one on top of another, are preferably separated by a flame-retardant material.
For the purposes of still further clarification of the invention, specific preferred embodiments of the invention will now be described with reference to the appended drawings, which are in no way intended to be limiting. FIG. 1 a illustrates a detonator assembly of the invention, which comprises a detonator protector 1 of the invention shown in section, which generally covers the explosive end 2 (comprising a base charge) of the detonator 3 by way of recess 6 in detonator protector 1 , leaving the rest of the detonator uncovered 4 . The Figure also illustrates that a portion 1 a of the mass of the protector is located in an axial position or otherwise adjacent the explosive end of the detonator to “catch” or otherwise contain shrapnel from actuation of the base charge. FIG. 1 b illustrates the assembly shown in FIG. 1 a , in perspective view.
It should be noted that although the protector illustrated in FIG. 1 a (and the following figures) is generally rectangular in section, the protector may have any shape or size, providing that it is adapted for catching or otherwise containing shrapnel, and preferably fitting securely upon the detonator. Also for purpose of clarity, the figures may illustrate a gap between the protector and the detonator surfaces. However, this is merely for illustrating the components present and is in no way intended to be limiting. Any such gap may be small or absent, as long as the functions of the detonator protector are maintained.
FIG. 2 illustrates a “double” protector 5 of the invention in section, which is designed to protect two detonators at the same time. Detonator protector 5 has two recesses 6 a and 6 b at opposite ends to cover explosive ends of two different detonators. It may be noted that part 11 between the explosive ends of the detonators as represented in FIG. 2 is in no way intended to be limiting. This part can be absent, thin or otherwise perforatable by shrapnel and/or explosive energy derived from a detonator being protected by the protector, thereby to cause the second detonator to at least substantially cook off in the event the first one accidentally explodes.
FIG. 3 illustrates a package of detonator assemblies generated according to a packaging method of the present invention. FIGS. 3 a and 3 b illustrate a plurality of detonators oriented according to an alternating pattern. Each detonator 3 is protected by a detonator protector 1 (each shown in section). Each detonator assembly is disposed according to an alternating pattern from adjacent detonator assemblies in a row of detonator assemblies. In FIG. 3 a , the first detonator assembly 30 has its protected end 7 facing side 8 of package 20 , the adjacent detonator assembly 31 has its protected end 7 facing the opposite side 9 of package 20 , the third detonator assembly 32 has its protected end facing side 8 . This pattern may be repeated to generate several rows of detonator assemblies in the package.
Another option for an alternate packaging is illustrated in FIG. 3 b . The first detonator assembly 30 has its protected end 7 facing generally into package 20 , so that its uncovered part 4 is facing the side 9 of the package. The adjacent detonator assembly 32 also has its protected end 7 facing generally into the package but with its uncovered part 4 facing opposite side 8 .
FIG. 3 c illustrates an alternative packaging arrangement wherein pairs of detonators 3 are side-by-side, but the pairs of detonator assemblies are also packaged in an alternating pattern. When two detonators of a pair have their explosive ends 2 facing generally into the package in alignment, disposed explosive end 2 to explosive end 2 , the two detonators can be protected by a double protector 5 shown in FIG. 2 . The other pair adjacent detonator assemblies each have their protected ends 7 facing sides 8 and 9 of the package according to an alternating pattern.
FIG. 3 d shows a package comprising pairs of detonator assemblies 3 each being disposed explosive end 2 to explosive end 2 and protected by a double cap 5 as shown in FIG. 2 .
FIG. 3 e illustrates how rows of detonator assemblies may be stacked within a container, one row on top of another, so that each row has opposite orientation of detonator assemblies compared to a row immediately thereabove or therebelow, i.e. the first detonator assembly 3 A of a row 20 is in an opposite position compared to the first detonator 3 B of row 21 beneath row 20 , and that the first detonator assembly 3 C of row 22 is in the same orientation as detonator assembly 3 A. For convenience and ease of illustration, only the first detonator assemblies 3 A, 3 B, and 3 C are shown in rows 20 , 21 , and 22 . Additional detonator assemblies may be present in each row in alternating orientation as previous discussed.
While the invention has been described with reference to particular preferred embodiments thereof, it will be apparent to those skilled in the art upon a reading and understanding of the foregoing that numerous detonator protectors, corresponding detonator/protector assemblies, and methods for transportation and storage of detonators, other than the specific embodiments illustrated are attainable, which nonetheless lie within the spirit and scope of the present invention, It is intended to include all such methods, systems, and equivalents therefore within the scope of the appended claims.
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Detonators comprising a base charge of explosive material present a safety hazard for transportation and storage, especially when a plurality of detonators are packaged together. Disclosed herein are detonator protectors for the explosive ends of detonators that, at least in preferred forms, prevent ejection of shrapnel and/or explosive energy upon detonator actuation. Also disclosed are corresponding detonator assemblies, packages comprising protected detonators or detonator assemblies, and corresponding packaging methods.
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The invention described herein was made in performance of work under a NASA contract and by an employee of the United States Government and is subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958, as amended, Public Law 85-568 (72 Stat. 435; 42 U.S.C. §2457), and 35 U.S.C. §202, and may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor. In accordance with 35 U.S.C. §202, the Contractor elected not to retain title.
FIELD OF THE INVENTION
The principal utility of the present invention is in outer space, where it is useful for powering spacecraft subsystems, charging battery systems, raising the orbit of a satellite or lowering the orbit of a satellite. The satellite may be a manmade object, e.g., a spaceship or a telecommunications satellite or a space station, or a smaller celestial body orbiting a larger celestial body. Such operations are accomplished with the use of an electro-dynamic tether system.
BACKGROUND OF INVENTION
Various tests have verified the utility of electro-dynamic tethers in space such as the Small Expendable Deployer System (SEDS 1 & 2), the Plasma Motor Generator (PMG) and the Tethered Satellite System flights (TSS-1 & TSS-1R). Electro-dynamic tethers, in a relatively vertical gravity-stabilized manner, interact with the magnetic fields of the Earth's or other celestial bodies magnetic fields to produce either electrical power or thrust. These tethers generally consist of a wire extending from a satellite or connected between two satellites, each containing plasma contactors, which are orbiting the Earth or other celestial body. An electromotive force (emf) is induced across the length of the tether.
The emf acts to create a potential difference across the tether by making one end of the tether positive with respect to the other end. In order to produce a current from this potential difference, the tether ends must make electrical contact with the Earth's plasma environment. Both plasma contactors and large conductive surfaces at the ends of the tether provide this contact, establishing a current loop through the tether, external plasma and the ionosphere around the Earth, sometime called a phantom loop. An example of the phantom loop is shown in FIG. 1 . Two field lines 13 a and 13 b representing levels of the magnetic field of the Earth 12 are shown. As the tether 100 connects the field regions 13 a and 13 b of the Earth 12 in the orientation as shown, the electrons are moved towards the other end, near plasma contactor 300 , of the tether, thus charging the ends of the tether, positive near a plasma contactor 200 and negative near plasma contactor 300 . When these plasma contactors or conductive surfaces are placed on the ends of the tether, the electrons are free to travel into and out of the tether cable creating charged clouds. As shown in the figure, the collection of electrons from a positive end plasma contactor 200 and their emission from a negative end plasma contactor 300 creates a net positive cloud 14 at the positive end plasma contactor 200 and a negative cloud 15 at the negative end plasma contactor 300 . The excess free charges migrate along the geomagnetic field lines intercepted by the tether ends until they reach the vicinity of a lower section of the ionosphere E where there are sufficient collisions with neutral particles to allow the charges to migrate across the field lines and complete the phantom circuit.
Once the current is established within the tether, the combination of the current running through the tether, the tether orbiting about the earth and the geomagnetic field of the Earth react together to create a force that acts on the tether. This force acts in a direction opposite to the movement of the tether across the magnetic field in orbit. An example of this type of electro-dynamic tether is shown in U.S. Pat. No. 6,116,544 (Forward et al.), incorporated herein by reference in its entirety. The tether consists of a wire attached to a spacecraft at one end and attached to an end mass at the other end. The tether is made of a braided aluminum or copper wire. The tether is used to slow the spacecraft down and reduce its orbit.
Another application of the tether is to generate power to either charge batteries on the spacecraft or power spacecraft subsystems. As outlined above, the orbit of the tether across the Earth's magnetic field induces a force on the electrons within the tether wire, which creates a charge separation and produces an electric potential due to Coulomb's law until the forces are balanced by current flow. When the current flow stops, there is a potential difference between one end of the tether and the other. After completing the circuit, the power provided may be used to power spacecraft substations or charge batteries. An example of such a system is shown in U.S. Pat. No. 4,923,151 (Roberts et al.), incorporated herein by reference in its entirety, with the use of a tether extended between two satellites. The tether comprises outer conductive material layers and an inner conductive material layer electrically connected to the tethered object, both separated by an insulator material.
Studies have shown that the use of a bare wire in space would substantially increase the collection of electrons as opposed to the use of conventional plasma contactors. However, a problem with bare wire plasma contactors is that in an oxygen rich environment of a low Earth orbit, the bare wire tethers of copper or aluminum would quickly oxidize and degrade, losing their electro-dynamic properties. Such greatly reduces the effective life of the tether and would require more frequent replacement. Secondly, the Earth's thermal albedo would raise the temperature of the bare wire tether to the point that its resistance would rise, thus decreasing its performance and reducing effective use of the tether.
Another problem with the prior art devices is that the wire constructions are not sufficiently flexible enough to allow a sufficient length of the tether to be wound up in a relative small space on the satellite or spacecraft orbiting a celestial body.
SUMMARY OF THE INVENTION
It is thus an object and intention of this invention to overcome these problems with the prior art devices and provide an electro-dynamic tether that can effectively increase or decrease the orbit of a satellite or power subsystems and charge batteries of a spacecraft. It is a further object to provide a tether that fits within the weight and volume constraints of the existing Small Expendable Deployer Systems (SEDS). The tether must also be strong enough to withstand the forces exerted by deployment and the tether dynamics and further to survive the space environment including atomic oxygen, temperatures and micrometeoroid/orbital debris (M/OD) to accomplish the mission duration of twenty-four hours to twenty-one days.
These and other objects are accomplished with the use of an electro-dynamic tether connected to a spacecraft or satellite comprising three sections spliced together, a non-conducting section extending away from the spacecraft, a conducting section attached to the non-conducting section and an insulating section connecting between the conducting section and the spacecraft. The non-conducting section is a flat, braided polyethylene fiber, the conducting section is a coated aluminum wire group and the insulating section is an insulated aluminum wire group. The insulating section attached to a unit within the spacecraft, which can be connected to craft subsystems, battery charges, and/or plasma contactors.
In a preferred embodiment, the length of the non-conducting section is preferably 10 km. Such length provides sufficient gravity-gradient tension to both deploy the conductive tether and to stabilize the entire system under action of electro-dynamic thrust force.
In another embodiment, the conducting section is coated with an atomic oxygen resistant conducting polymer, such as C-COR, made by Triton Systems, Inc. of Chelmsford, Mass. The conducting section of the tether collects electrons from the space plasma. The coating on the conducting section provides good surface conductivity for electron collection and improved surface optical properties for thermal control that prevents the aluminum wire from overheating.
In a further embodiment, each aluminum wire of the insulating section is over coated with a polyimide and an oxygen resistant, insulating polymer, such as TOR-BP, made by Triton Systems, Inc. of Chelmsford, Mass. The insulating section, which is closest to the spacecraft or satellite, prevents electron re-connection from the plasma contactor to the tether.
In another embodiment, the aluminum wires of the conducting and insulating sections are wrapped around a braided KEVLAR aramid fiber core. The aramid fiber core provides ample tensile strength as well as improved windability and deployability.
In a fifth embodiment, the aluminum wires in the conducting section and the insulating section are cold welded together. A cold weld provides strong bond between the wires while not damaging or oxidizing the aluminum.
BRIEF DESCRIPTION OF THE DRAWINGS
Other embodiments, features and advantages of the invention described herein will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which:
FIG. 1 is a diagram of the circuit created using a tether in orbit above the Earth;
FIG. 2 is a perspective view of the tether system according to the preferred embodiment of the present invention;
FIG. 3 is a diagram of the circuitry within a spacecraft having the tether of FIG. 2 attached thereto;
FIG. 4 is a perspective view of the connection apparatus between the tether of FIG. 2 and the spacecraft;
FIG. 5 is a blown up view of the tether according to the preferred embodiment of the present invention;
FIG. 6A is a cross section of the conducting section wire of the tether shown in FIG. 5 ; and
FIG. 6B is a cross section of the insulating section wire of the tether shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
The electro-dynamic tether 400 according to the present invention is shown in FIG. 2 . In the figure, a spacecraft 300 is orbiting the Earth 12 in the direction and speed V. A tether 400 is extended down towards the surface of the Earth from spacecraft 300 in order to provide thrust to the spacecraft, power various subsystems or charge batteries. The tether is separated into three sections, an insulating section 401 attached to spacecraft 300 , a conducting section 402 attached to the insulating section extending therefrom and a non-conducting 403 section attached to the conducting section and extending therefrom.
Circle dots 13 a and 13 b represent the magnetic field lines of the Earth moving out of the page (to the left of the direction of travel V). The horizontal lines extending from the field lines 13 a and 13 b represent the change in field strength. As is shown in FIG. 2 , spacecraft 300 is at a different field strength than the extended portion of conducting section 402 . As was discussed above with reference to FIG. 1 , the magnetic field induces the electrons to move in the direction along path C towards Earth, i.e., to the lower end of tether 400 , causing the upper end (away from Earth) of the tether to be more positive and the lower end (closer to Earth) of tether to be more negative. Conducting section 402 of tether 400 releases the electrons into space and a plasma contactor (not shown) located on spacecraft 300 draws in electrons, thus completing a circuit in a manner similar to the circuit described above with respect to FIG. 1 .
As the spacecraft orbits the Earth in direction and speed V, the combination of the movement of tether 400 in orbit, current traveling throughout tether and the magnetic field of the Earth causes a force SF to act upon the electrons in the tether in the opposite direction from the direction V according to the equations:
Force= e*E (1)
where E =(velocity of tether)×(magnetic field strength) (2)
and e =the charge moving through the tether (3)
Force SF acting on the tether, in turn slows the orbit of the spacecraft as well. Thus, by extending the tether towards the Earth in an orbit, the tether in effect produces a reverse thrust to slow spacecraft 300 down and reduce its orbit.
Tether 400 may also be used to increase the velocity of the spacecraft and thus raise its orbit by reversing the flow of the electrons in the tether. As mentioned above, the natural flow of electrons along the tether is towards Earth 12 . If a power supply is attached between the plasma contactor in the spacecraft and insulating section 401 and has a sufficient voltage to overcome the voltage supplied naturally in the tether, the electrons will travel in a reverse direction, namely the electrons will move up toward the spacecraft. Conducting section 402 will then collect electrons from the ionosphere and the plasma contactor will expel them from the spacecraft. Such arrangement effectively reverses the current in the tether, and according to equations (1), (2) and (3) above, will reverse the force acting on the tether, namely in the opposite direction of force SF and in the direction of force AF, shown in FIG. 2 . Since the force AF acts on tether 400 in the same direction as V, the velocity of the tether will be increased, and thus the velocity of spacecraft 300 will increase as well.
The tether according to the present invention further may be used as a power generator on the spacecraft. In such an arrangement as shown in FIG. 2 , a tether 400 B is extended away from a spacecraft 300 B and away from Earth, in a higher orbit. Spacecraft 300 B is traveling in direction V. Based on the principles of the tether dynamics as described in reference to FIG. 1 , the electrons will be collected by a conducting section 402 B, move down through tether 400 B, into spacecraft 300 B. The orbital velocity in this apparatus creates a motional electric field that may be determined by equation (2) above. The motional electric field provides a voltage across tether 400 B such that the current is collected by conducting section 402 B and brought into spacecraft 300 B for use by power systems and/or to charge battery systems.
The circuitry located within spacecraft 300 used to perform each of these functions is illustrated in a basic form in FIG. 3 . Depending on which function is being performed, i.e., reverse thrust, forward thrust and power generating, the electron flow will be coming in on or going out of tether 400 . A connecting apparatus 500 is used to reel in and let out tether 400 from the spacecraft. The circuit generally has a switching section 900 , which is used to complete the circuit with several systems.
If switching section 900 is connected as shown, the circuit is completed directly between tether 400 and a plasma contactor 600 , which may be a hollow cathode, an electron gun, or other apparatus for bringing in electrons or emitting them. This circuit would be used to perform a reverse thrust to slow the spacecraft down.
If switching apparatus 900 connects the circuit across to a power supply 700 that is connected to plasma contactor 600 , tether 400 would operate as a forward thruster. Namely, as outlined above, power supply 700 would provide a voltage along the circuit consisting of tether 400 , power supply 700 , plasma contactor 600 and the phantom loop that is stronger than the natural voltage occurring without the applied voltage. The electrons would be received by tether 400 , brought through the power supply and emitted from plasma contactor 600 .
If switching apparatus 900 connects across to a system substation 800 that is connected to plasma contactor 600 , then tether 400 would operate as a power generator. The electrons would travel down tether 400 as outlined above with respect to the power generator into the system substation to run various devices within the spacecraft or to charge batteries.
FIG. 4 illustrates a view of connecting apparatus 500 . Tether 400 is extended from or drawn into connecting apparatus by operation of a spool 503 . At the center of spool 503 , tether 400 emerges at end 450 and is connected to the various devices as shown in FIG. 3 . Tether 400 is guided out of the spacecraft via a system of rollers 502 and a tether guide 501 . While a specific connecting apparatus is shown here, various other apparatus obvious to a person having ordinary skill in the art that is capable of drawing in and extending out the tether would work.
The structure of tether 400 is shown with reference to FIGS. 5 , 6 A and 6 B. Tether 400 generally comprises three sections as discusses above, a non-conducting section 403 , a conducting section 402 and an insulating section 401 . Non-conducting section 403 generally comprises a length of material, preferably 10 to 15 km, of flat, polyethylene fiber braid of 13×100 denier braided 7.5 to 8 picks per inch. An example of polyethylene fiber is Dyneema fiber, produced by Western Filament of Grand Junction, Colo. It is deployed first to provide sufficient gravity-gradient tension to both deploy the conductive tether and to stabilize the entire system under action of electro-dynamic thrust force. A mass may also be connected to the distal end of the tether from the spacecraft or used in place of non-conducting section to provide the required stability.
Conducting Section
Connected to non-conducting section 403 is the conducting section 402 . This section either accepts electrons from the space plasma or emits them, depending on the particular use of tether 400 . It generally comprises a length, which can range anywhere from 0.5 to 150 km in length. Preferable lengths are between 3 km and 10 km, with a preferred length of about 4.84 km, of aluminum wire, copper wire or alloys thereof. Use of either metal is dependent on weight constraints of the tether apparatus. In a preferred embodiment, conducting section 402 comprises seven wires 412 of aluminum wires, 28 American Wire Gauge 1350-0, braided together (shown parallel in FIG. 5 for illustration purposes). The braiding may occur in any fashion known to those having ordinary skill in the art that allows for the electrons to freely move along the tether while allowing the tether to be spooled for storage. For example, there may be no braiding, a cadacus type braiding or a braiding similar to that used in the Hoyt-tether (U.S. Pat. No. 6,116,544 (Forward et al.)). To provide conducting section 402 with a strong tensile strength and the ability to be spooled onto spool 503 , the seven wire strands 412 are wrapped around a 6×380 braided high tensile but flexible polymer core, such as KEVLAR aramid fiber, produced by E. I. du Pont de Nemours and Company Corp. of Wilmington, Del.
The cross section of each wire 412 is shown in FIG. 6A . Each wire 412 comprises an aluminum wire 440 and is coated with a conductive and atomic oxygen resistant polymer coating 420 that may comprise one to three thin coatings. The conductive coating allows for electrons to freely pass through the coating. A preferable thickness F of coating 420 is between 0.34 mil and 0.36 mil, but other thicknesses are possible depending on the thickness of the aluminum wire and the particular application. Typical thickness of conductive sections is 0.3 mil to 0.4 mil. Preferably, thickness F is 0.35 mil.
For conducting section 402 , coating 420 is a polyarlene ether resin that makes the polymer coating colorless mixed along with a conductive polymer which will additionally make the conducting section highly conductive to allow electrons to enter and exit the conducting section.
The conductive polymer may be any polymer having the property of being conductive. Typical conductors are polyaniline, polythiophene, polypyrrole and polyacetlene. Polyaniline is used in the preferred embodiment. The polyaniline is rendered conductive by doping the emeraldine base which is insulating with an acid, “HA,” to create a emeraldine salt which is conducting. The conducting polyaniline may be made insulating again by undoping the emeraldine salt with ammonium hydroxide. The formulas can be written as follows.
Preferably, a combination of 13% polyanilene and 87% polyarlene ether resin is used as the coating 420 for conducting section 402 of tether 400 . Such combination and thickness provides good surface conductivity for electron collection and improved surface optical properties for thermal control that prevents the aluminum wire from overheating. Coating 420 also provides an atomic oxygen resistant coating which prevents the aluminum wires from corroding, thus increasing the efficiency and usability of the wires. The basis for this atomic resistance is discussed below under the heading for Oxygen Resistant Phosphine Co-polymers.
Insulating Section
Connected between conducting section 402 of tether 400 and spacecraft 300 , 300 B is insulating section 401 . It provides a passage of the electrons along the tether, without releasing them into the space plasma near the spacecraft and also prevents reconnection of the electrons from plasma contactor 600 in the spacecraft back into the tether (See FIG. 3 ), which could interfere with the tether electrical circuit as described above with reference to FIGS. 1 and 2 . It generally comprises a length, typically from 0.0 m in some applications where no insulating section is needed to a length of 1 km in others to avoid reconnection as outlined above. In a preferred embodiment, the length is about 214 m of aluminum or copper wire. Use of either metal is dependent on weight constraints of the tether apparatus. In the preferred embodiment, the section comprises seven wires 411 of aluminum braided together (shown parallel in FIG. 5 for illustration purposes). The braiding occurs similar to that described above with reference to conducting section 402 . For consistency between sections, the number of wires and the braiding of insulating section 401 should be similar or the same as conducting section 402 . To provide insulating section 401 with a strong tensile strength and the ability to be spooled onto spool 503 , the seven wire strands are wrapped around a 9×380 braided high tensile but flexible polymer core, such as KEVLAR aramid fiber, similar to the core of conducting section 402 .
The cross section of each wire 411 in insulating section 401 is shown in FIG. 6B . Wire 411 comprises an aluminum wire 440 and is coated with a combination of an insulating polymer and an atomic oxygen resistant polymer. A single layer of a polymer having these properties can be used. In the preferred embodiment of the invention as shown in FIG. 6B , the coating consists of a first insulating layer 421 surrounding the wire and an oxygen resistant layer 422 surrounding insulating layer 421 . The insulating polymer making up insulating layer 421 is preferably a polyimide. Insulating layer 421 preferably has a thickness E of 1.0 mil.
The oxygen resistant layer preferably comprises a polyarlene ether benzimidazole with biphenyl moieties and typically has a thickness of F of between 0.3 and 1.41 mil, but preferably has a thickness F of between 0.3 and 0.4 mil. In the preferred embodiment, the thickness is 0.35 mil. However, larger or smaller thickness may be used depending on the intended use and specific parameters of the tether. The basis for this atomic resistance is discussed below under the heading for Oxygen Resistant Phosphine Co-polymers
The layer of polyimide in insulating layer 421 provides a superior insulation with high heat resistant capabilities. In the preferred embodiment, the thickness should be such as to provide a dielectric breakdown voltage of between 5000 and 6000V, based on the electric wire structure outlined above, while being able to withstand temperatures of −98 to 88° C.
Insulating section 401 and conducting section 402 are preferably connected together via a cold weld between each wire in the sections, preformed in a manner known to those skilled in the art, such as high pressure, forced contact or electric current cold welding. The cold weld provides a strong joint between these tether sections without affecting their electrical properties. The insulating polymer and oxygen resistant layer of insulating section 401 may overlap the connection to protect the connection.
Oxygen Resistant Phosphine Co-Polymers
In the low Earth orbit, atomic oxygen are heavily present, which would quickly cause the copper or aluminum wire strands to oxidize if the wires were left bare, without any coating. Following this oxidation, the electrodynamics of the copper and aluminum wires decreases substantially.
In the oxygen resistant layers, 420 and 422 , in conducting section 402 and insulating section 401 , respectively, the polyarlene ether (COR) and the polyarlene ether benzimidazole with biphenyl moieties (TOR-BP) each have phenylphosphine oxide groups in their backbone make-up of the polymer, which gives them the property of being oxygen resistant (see formulas below). The use of
these phenyl-phosphine oxide groups in the coating for the tether in the low Earth orbit oxygen rich environment causes a layer of phosphate to form on the outer surface of the coating upon exposure to the plasma. The phosphate layer created will protect against attack by the atomic oxygen, protecting the wire from further erosion. Suitable ranges for these phenyl-phosphine moieties is greater than or equal to 75% molar ratio.
While these phosphines polymers were used in this example, other phosphine polymers could be used that have similar properties as outlined above. For example, rather than using a polyarlene ether benzimidazole having biphenyl moieties as outlined above, the co-polymer may be a polyarlene ether benzimidazole with no biphenyl moieties having the following formula.
Where Ar is
An example of a copolymer having the above formula is a product sold under the trade name TOR, by Triton Systems, Inc. of Chelmsford, Mass.
Although the present invention has been described and illustrated in detail to a specific tether design and structure, such explanation is to be clearly understood that the same is by way of illustration and example only, and is not to be taken by way of limitation. Other modifications of the above examples may be made by those having ordinary skill in the art which remain within the scope of the invention. For instance, other coatings other than those presented here can be used as long as those coating provide similar properties. Further varying lengths and width of the tether and the wires in the tether are disclosed herein; however, such lengths can be extended or shortened depending on the use and intention of the tether system. More or fewer wire strands can also be used according to this invention. Further, other coatings on the wire may be introduced in lieu of or in addition to those described herein provided they provide similar functional characteristics or have similar properties as those polymers disclosed herein. However, various other structures are possible using the invention, such as a tether with an end mass rather than the non-conducting section, or differing materials used in the non-conducting section. It should be apparent from this description that embodiments other than those described above come within the spirit and scope of the present invention. Thus, the spirit and scope of the present invention should be defined only by the terms of the claims.
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A tether system for providing thrust to or power subsystems of an artificial satellite in a low earth orbit. The tether has three main sections, an insulated section connected to the satellite, a conducting section connected to the insulating section for drawing in and releasing electrons from the space plasma and a non-conducting section for providing a tension to the other sections of the tether. An oxygen resistant coating is applied to the bare wire of the conducting section as well as the insulated wires of the insulated section that prevents breakdown during tether operations in the space plasma. The insulated and bare wire sections also surround a high tensile flexible polymer core to prevent any debris from breaking the tether during use.
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FIELD OF INVENTION
[0001] The present invention refers to the field of chemical compounds possessing the 1,2,3-triazole heterocyclic ring, their preparation and use as a medical device for tumor-related pathologies where angiogenesis is altered, i.e. pathologies having a tumor origin, tumor methastasis, osteoporosis and rheumatoid arthritis.
STATE OF THE ART
[0002] Integrins are a class of cellular receptors known to bind extracellular matrix proteins, and therefore mediate cell adhesion events. One important recognition site of a ligand for αvβ3 and αvβ5 integrins is the arginine-glycine-aspartic acid (RGD) tripeptide sequence, which is found in all peptide-based ligands identified for the vitronectin receptor integrins. Among the RGD-dependent integrins, αvβ3 and αvβ5 receptors have received increasing attention as therapeutic targets as they are expressed in various cell types and are involved in osteoporosis, arthritis, retinopathy, and tumor-related processes. The RGD recognition site can be mimicked by polypeptides that contain the RGD sequence, and αvβ3 antagonists, including RGD-containing peptides, have been successfully applied as inhibitors of blood vessel development and tumor growth. During last years, the cyclic peptide c[RGDfV] has been reported by Kessler and co-workers as a selective ligand for the αvβ3 integrin. Many different cyclic RGD-containing peptides have been reported, and in particular, the N-methylated derivative c[RGDf(Me)Val] (Cilengitide), which is actually being examined in clinical trials as an angiogenesis inhibitor for the treatment of glioblastoma. Nevertheless, there is a need for alternative drugs capable of displaying a different activity profile in order to solve potential side effects outlined in present clinical trials (Reynolds, A. R. e collab. Nat. Med. 2009, 15, 392). Moreover, new molecular probes for the diagnosis of pathologies where integrins are involved are strongly requested.
[0003] During last years, several examples of peptidomimetic integrin inhibitors containing heterocyclic nuclei have been reported (Cacciari, B.; Spalluto, G. Curr. Med. Chem. 2005, 12, 51-70), including: benzodiazepinones, piperazines, benzoazepinones, nitroaryls, isoxazolines, indazoles, phenols, and others, with the exception of triazole derivatives.
[0004] The unique molecular system containing the triazole ring is a cyclic analogue of c[RGDfV] peptide, wherein the triazole ring is a replacement for the D-Phe-Val dipeptide, which solves only in part the issues concerning the chemical stability and bioavailability (Kolb, H.; Chen, K.; Walsh, J. C.; Gangadharmath, U.; Kasi, D.; Wang, B.; Duclos, B.; Liang, Q.; Padgett, H. C.; Karimi, F. WO2008/033557). No examples of linear non-peptidic integrin antagonists containing the 1,2,3-triazole ring have been reported, so far. There has been an increasing interest in the synthesis of molecules containing the triazole nucleus since the development by Sharpless and collab. of a catalytic method using Cu(I) as catalyst with or without sodium ascorbate for the generation of 1,4-disubstituted 1,2,3-triazole compounds from an alkyne and an azide under mild and high regioselective conditions (Sharpless, B. K.; Fokin, V.; Rostovsev, V.; Green, L.; Himo, F. WO03/101972). There is a need for new high affinity αvβ3 and αvβ5 integrin ligands in the diagnostic and medical field, which do not display a peptide character, are obtained by a straightforward synthetic method, and are capable of showing an antiangiogenic activity as a consequence of their antagonistic activity towards integrins. Thus, it is evident the need for a molecule metabolically more stable than present ligands based on the RGD peptide sequence, and of convenient and easy synthetic procedures starting from commercially available precursors in few synthetic steps.
[0005] Aim of the present invention is a compound possessing the above mentioned features, such as the simple preparation from easily-synthesized precursors, even as enantiopure compounds, being of wide scope so as to allow for the generation of derivatives with different properties, and possessing a significant metabolic stability, and a high affinity towards integrins related to an in vivo anti-angiogenic activity.
SUMMARY OF THE INVENTION
[0006] The present invention refers to peptidomimetic compounds containing the 1,2,3-triazole nucleus, and possessing high affinity towards αvβ3 and αvβ5 receptors of the integrins family.
[0007] The present invention refers to compounds of formula (I)
[0000]
[0008] wherein
[0009] V is a COOH group or CONHOH;
[0010] W is a guanidino group or an isostere chosen in the group consisting of
[0000]
[0011] where M=O, NH; L=H, cycloalkyl, aryl optionally substituted, NH2, OH, SH, tyrosine, tyramine,
[0000]
[0000] and s=0-8; R9=H, NH2, CH3, CF3;
[0012] V—Y— is chosen in the group consisting of V—(CH2)p-CH(R5)-N(R4)-CO—(CH2)m-Q(R1)-(CH2)r-, V—(CH2)p-CH(R5)-N(R4)-(CH2)m-, V—(CH2)p-CH(R5)-N(R4)-CO—(CH2)m-,
[0000]
[0013] wherein Q=N, O; m e r are independently=1,2,3; p=0,1,2; if Q=N then R1=H, alkyl; if Q is O then R1 is absent; R4=H, alkyl, aryl optionally substituted, SO2aryl optionally substituted; R5=amino acid side chain, or is chosen in the group consisting of
[0000]
[0014] said rings being optionally substituted, where R6, R7 and R8 are independently chosen in the group consisting of H, alkyl, cycloalkyl; and L and s are defined as above;
[0015] W—X— is chosen in the group consisting of W—(CH2)n-, W—CO(CH2)n-,
[0000]
[0000] where n=1,2,3;
[0016] including all the possible variations of the stereogenic centers, pharmaceutically acceptable salts, and including the possible presence of one or more radioisotopes.
[0017] Surprisingly, they have been found to be potent integrin inhibitors, and in particular of integrins that recognize the Arg-Gly-Asp (RGD) peptide sequence, and more specifically of αvβ3 and αvβ5 integrins. Thus, they can be used in medicine, in particular for the preparation of diagnostic and/or therapeutics for the treatment of pathologies wherein the above-mentioned integrins are involved, particularly connected to angiogenesis, tumor initiation and growth, osteoporosis, and rheumatoid arthritis.
[0018] An aspect of the present invention deals with pharmaceutical preparations containing at least one compound of formula (I), and at least another pharmaceutically acceptable ingredient, eccipient, or diluent.
[0019] Definitions
[0020] According to the present invention within compounds of formula (I) as above defined:
[0021] The term “protecting group” means any functional group capable to preclude the atom to which it is bound to participate to an unwanted reaction or new bond formation, as usual in chemical synthesis. Preferred protecting group are those capable to inhibit the reactivity and new bond formation of oxygen, nitrogen, carboxylic acids, thiols, alcohols, amines and similar ones. Such groups, their preparation and use, are known to the state of the art, and they include, for example for the OH group: benzyl, t-butyl, acetals, esters, trialkylsilylethers; for the COOH group: methyl, t-butyl, benzyl, phenyl, allyl esters; for the NH group: t-Boc, Fmoc, Cbz, Alloc, Bn, Bz, Nosyl.
[0022] The term “amino acid side-chain” means the diverse substitution as a side chain linked to an “amino acid”. The term “amino acid” includes all the 20 proteinogenic alpha-amino acids of the L or D series, and having as “side chain”: —H for glycine; —CH3 for alanine; —CH(CH3)2 for valine; —CH2CH(CH3)2 for leucine; —CH(CH3)CH2CH3 for isoleucine; —CH2OH for serine; —CH(OH)CH3 for threonine; —CH2SH for cysteine; —CH2CH2SCH3 for methionine; —CH2-(phenyl) for phenylalanine; —CH2-(phenyl)-OH for tyrosine; —CH2-(indole) for tryptophan; —CH2COOH for aspartic acid; —CH2C(O)(NH2) for asparagine; —CH2CH2COOH for glutamic acid; —CH2CH2C(O)NH2 for glutamine; —CH2CH2CH2-N(H)C(NH2)NH for arginine; —CH2-(imidazolo) for histidine; —CH2(CH2)3NH2 for lysine, including the same amino acid side chains bearing suitable protecting groups. Moreover, the term “amino acid” includes the non-proteinogenic amino acids, such as ornithine (Orn), norleucine (Nle), norvaline (NVa), β-alanine, L or D α-phenylglicine (Phg), diaminopropionic acid, diaminobutyric acid, and all the others well-known to the state of the art of peptide chemistry.
[0023] In compounds of formula (I), as above described, the term “alkyl” means C 1-8 alkyl, C 2-8 alkenyl and C 2-8 alkynyl groups, which represent both linear and cyclic radicals, such as: methyl, ethyl, propyl, isopropyl, butyl, pentyl, hexyl, heptyl, octyl, ethenyl, propenyl, butenyl, isobutenyl, acetylenyl, propargyl, butynyl, etc . . .
[0024] The term “cycloalkyl” represents: cyclopropane, cyclobutane, cyclopentane, cycloheptane, cyclooctane, norbornane, canphane, adamantane.
[0025] The term “aryl” means the phenyl, biphenyl and naphtyl groups, all optionally substituted.
[0026] The term “heterocycle” specifically represents saturated or unsaturated heterocycles containing one or more nitrogen atoms, and more specifically: pyrrole, pyrazole, pyrrolidine, imidazole, indole, pyridine, pyrimidine, pyrazine, triazole, piperidine, all optionally substituted.
[0027] Optionally substituted rings (aryls, cycloalkyls and heterocycles) are meant to be functionalized with one or more, and preferably with one or two of the types chosen among the groups consisting of: alogens, OH, nitrile, nitro, C 1-6 alkyl, OC 1-6 alkyl, NH2, NHC 1-6 alkyl, C 1-6 alkyl-Z, OC 1-6 alkyl-Z, con Z=alogen, OH, tosylate, trifluoromethanesulfonate.
[0028] The term “alogen” represents fluorine, chlorine, bromine, iodine.
DRAWING CAPTIONS
[0029] FIG. 1 a. Inhibition curve of compound 38 for αvβ3.
[0030] FIG. 1 b. Inhibition curve of compound 38 for αvβ5.
[0031] FIG. 2 a . Inhibition curve of compound 48 for αvβ3.
[0032] FIG. 2 b . Inhibition curve of compound 48 for αvβ5.
[0033] FIG. 3 . Cellular adhesion inhibition assays of compounds 38 and 48 for the A375M melanoma cell line.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Compounds of formula (I) according to the invention can also be represented by the following formulas (Ia)-(Ib)
[0035] where X, Y, V and W are as above described.
[0036] Preferably, compounds of formula (Ia) or (Ib) are those wherein
[0037] W—X— is chosen in the group consisting of W—(CH2)n-, where n=1,2,3;
[0038] V—Y— is chosen in the group consisting of V—(CH2)p-CH(R5)-N(R4)-CO—CH2-, V—CH2-CH(R5)-N(R4)-CO—CH2-N(R1)-CH2-, V—(CH2)p-CH(R5)-N(R4)-(CH2)m-, where m e p are independently=0,1,2; R1=H, alkyl; R4=H, Me, Ph, SO2aryl optionally substituted; R5=H, para-F-Ph, para-OH-Ph;
[0039] W is chosen in the group consisting of a guanidino group,
[0000]
[0040] V is a COOH group or CONHOH.
[0041] Particularly preferred compounds are those of formula (Ia)
[0000]
[0042] wherein
[0043] n=1,2,3;
[0044] Y—COOH is chosen in the group consisting of;
[0000]
[0045] W is chosen in the group consisting of a guanidino group,
[0000]
[0046] Compounds of formula (I) as above described can be obtained starting from readily obtainable precursors, also as enantiopure molecules, and specifically from the combination of two molecules bearing an azido group and a C-terminal triple bond, respectively, by means of “click-chemistry”, according to Scheme 1.
[0000]
[0047] Specifically, compounds of formula (I) can be obtained through a process comprising a Huisgen 1,3-dipolar cycloaddition between azide J-N3 and alkyne K—C≡CH, catalyzed by copper with or without ascorbic acid, where J and K are precursors of Y—V and X—W groups.
[0048] Subsequent to the cycloaddition, the aforesaid process to achieve the final compounds of formula (I), as above described, consists of chemical manipulations of J and K functional groups to give Y—V and X—W groups, as above described. Thus, the possible insertion of the guanidino group or its isostere is taken into account, followed by final deprotection of COOH and guanidino groups or their isosteres. The process is general, and allows for the creation of a variable number of derivatives which show diversity either for the functional groups or for their relative position, as a function of the choice of the components for the 1,3-dipolar cycloaddition reaction and the catalyst type. In particular, by applying the process of Scheme 1, which involves the catalysis by copper salts, such as CuI, CuSO4, CuSO4 with Cu powder, Cu(OAc)2, or iodo(triethylphosphite)Cu, with or without sodium ascorbate, in water-t-butanol solvent mixture or in tetrahydrofuran, at room temperature or under microwave irradiation, it is possible to achieve 1,2,3-triazole-based molecules of formula (Ia), as above described, starting from alkyne K—C≡CH and azide J-N3, where K is a protected precursor of —X—W group, and J is a protected precursor of the —Y—V group. Alternatively 1,2,3-triazole-based molecules of formula (Ib), as above described, can be achieved starting from alkyne K—C≡CH and azide J-N3, where K is a protected precursor of the —Y—V group, and J is a protected precursor of the —X—W group.
[0049] After the cycloaddition, the process for preparing compounds of formula (I) consists of two or three synthetic steps depending on the type of the —X—W precursor. Specifically, if J or K are a direct protected derivative of the —X—W group (meaning that J or K already contain the guanidino group or its isostere), the process involves the 1,3-dipolar cycloaddition reaction, followed by removal of V and W protecting groups (see the synthesis of compounds 33-49 and 52-59). If J or K are indirect precursors of the —X—W group (meaning that J or K do not contain the guanidino group or its isostere, but a functional group suitable for subsequent introduction of the guanidino group or its isostere), the process consists of 1,3-dipolar cycloaddition reaction, followed by the introduction of the protected or free isostere, according to the definitions given for W, using the methods known in the state of the art. For example, this can be achieved by guanidinylation reaction between a derivative having -J=-X—NH2 and a free or protected guanidino group or its isostere (see the synthesis of compounds 50-51 and Scheme 7), or by means of a Mitsunobu reaction between a precursor having -J=-X—OH and a guanidino group or its isostere, followed by removal of the protecting groups of V and W.
[0050] The synthesis of compounds of formula (I) is significantly less complicated than that of the cyclic peptidomimetics known in the state of the art, and it is possible to achieve even large quantities of final products by means of significantly simple processes. Moreover, the 1,2,3-triazole nucleus is quite stable, as it is not easily hydrolyzed, oxidized or reduced, thus suggesting high in vivo resistance. The preparation of alkynes and azides is achieved according to synthetic methods known in the state of the art.
[0051] In order to provide few examples, selected compounds for the 1,3-dipolar cycloaddition reaction, as above described, are given in Table 1:
[0000]
TABLE 1
Representative molecules for the preparations of selected compounds of
general formula (I).
ALKYNE
1
2
3
4
5
6
7
8
9
10
AZIDE
11
12
13
14
15
16
17
18
19
20
[0052] Alkyne 6 and azide 14, as reported in Table 1, are obtained starting from β-(S)-para-F-phenylalanine methyl ester as shown in Scheme 2, which in turn is obtained from the corresponding methyl para-F-cynnamate according to methods known in the state of the art (Davies, S. G.; Ichihara, O. Tetrahedron: Asymmetry 1991, 2, 183). The reaction between β-(S)-para-F-phenylalanine methyl ester 21 and bromo-acetyl bromide in anhydrous solvent, preferably anhydrous dichloromethane, in the presence of a base, preferably triethylamine, and preferably at room temperature until reaction completion, gives the corresponding bromide derivative 22. Subsequent treatment with NaN3 in a polar aprotic anhydrous solvent, preferably DMF, at refluxing temperature until reaction completion, results in the achievement of the corresponding azide 14. The reaction between bromide 22 and N-methyl-propargylamine in a polar aprotic solvent, preferably DMF, and in the presence of a base, preferably triethylamine, at room temperature until reaction completion, gives alkyne 6. Similarly, alkyne 7 and azide 15 shown in Table 1 can be obtained starting from the corresponding β-(R)-para-F-phenylalanine methyl ester.
[0000]
[0053] Alkynes 1-3 as reported in Table 1, can be prepared by Mitsunobu reaction from the corresponding alkynol and N,N-di-Boc-guanidine in anhydrous aprotic solvent, preferably tetrahydrofuran, under microwave irradiation, preferably at 110° C., until reaction completion. Alkyne 4 as reported in Table 1, can be obtained by SN2 reaction between compound 23 (Scheme 3) and propargyl bromide. Alkyne 5 of Table 1 can be easily obtained by treating commercially available Boc-piperazine 23 with a butynol derivative, preferably butynyl mesylate, followed by Boc removal, preferably by treatment with a 1:1 TFA-dichloromethane mixture, and final guanidinylating reaction, preferably by using di-Boc-guanidinyl triflate, according to Scheme 3.
[0000]
[0054] Alkynes 8 and 9 can be obtained by reacting the common precursor 27, which is achieved by Mitsunobu reaction between commercially-available di-Boc-thiourea 26 and 4-pentynol, as reported (Delle Monache, G.; Botta, B.; Delle Monache, F.; Espinal, R.; De Bonnevaux, S. C.; De Luca, C.; Botta, M.; Corelli, F.; Carmignani, M. J. Med. Chem. 1993, 36, 2956), with tyramine or the lipoic acid derivative 28, prepared as reported (Nam, J.; Won, N.; Jin, H.; Chung, H.; Kim, S. J. Am. Chem. Soc. 2009, 131, 13639), as outlined in Scheme 4.
[0000]
[0055] Alkyne 10 is obtained by Mitsunobu reaction between di-Boc-benzimidazole and 4-pentynol.
[0056] Azide 11 is prepared as for 14 (Scheme 2) using N-phenylglycine. Azides 12 and 13 are obtained as for 14 (Scheme 2) starting from (S)- or (R)-β-phenylalanine methyl or t-butyl esters, respectively. Azide 16 can be obtained as for 14 (Scheme 2) starting from the corresponding β-(S)-para-OTIPS-phenylalanine methyl ester, obtained from the corresponding methyl para-OTIPS-cynnamate, which in turn is obtained as reported by Maier et al. (Schmauder, A.; Sibley, L. D.; Maier, M. E. Chem. Eur. J. 2010, 16, 4328), according to methods known in the state of the art (Davies, S. G.; Ichihara, O. Tetrahedron: Asymmetry 1991, 2, 183). Azide 17 is prepared from ethanolamine as showed in Scheme 5. Amine protection of ethanolamine as Boc-derivative 29 is followed by conversion to the corresponding mesylate 30, and final conversion to azide 17 by reaction with NaN3.
[0000]
[0057] Azides 18 and 19 are prepared as for 14 (Scheme 2) using methyl 3-aminopropionate or ethyl 4-aminobutyrate, respectively. Finally, azide 20 is obtained, as reported in Scheme 5, from ethanolamine by reaction with methyl bromoacetate to give 31, which is treated with tolyl-sulfonyl chloride in the presence of a base to give 32. Compound 20 is finally obtained by conversion of 32 to azide 20 by Mitsunobu reaction with DPPA (diphenylphosphorylazide).
[0058] For example, Table 2 shows compounds of formula (Ia) and (Ib) obtained according to the above-described process, comprising the Cu-catalyzed 1,3-dipolar cycloaddition reaction between an azide and an alkyne of Table 1, followed by acid-mediated hydrolysis.
[0000]
TABLE 2
Representative compounds of general formula (I).
[0059] The synthetic process of the present invention for the preparation of compounds of formula (Ia) is outlined in Scheme 6 for the preparation of compound 38 starting from azide 12a and alkyne 3 of Table 1.
[0000]
[0060] The Huisgen 1,3-dipolar cycloaddition reaction between selected azides and alkynes is carried out in equimolar amounts, in a protic solvent, preferably a 1:1 water-t-butanol mixture, or in an aprotic solvent, preferably tetrahydrofuran, in the presence of copper and ascorbic acid salts, preferably copper(II) acetate and sodium ascorbate, or without sodium ascorbate using preferably catalytic iodo(triethylphosphite)Cu, at room temperature and until reaction completion, for a maximum time of two days, or under microwave irradiation, preferably at 80° C., and until reaction completion. After treatment of the reaction mixture with a basic solution, preferably 5% aqueous NaHCO3, and further chromatographic purification, subsequent hydrolysis is achieved by treating the protected derivative with an acidic aqueous solution, preferably 3M HCl, thus giving the desired product as a hydrochloride salt after solvent evaporation.
[0061] In the case of compounds 50 and 51 of formula (Ib), the synthetic process is based on the introduction of the guanidino group subsequent to the “click chemistry” reaction. For example, the preparation of compound 50 of formula (I) consists of the Cu-catalyzed Huisgen 1,3-dipolar cycloaddition using precursors 17 and 7 of Table 1, as reported in Scheme 7. Subsequent deprotection of the adduct 61, and guanidinylation to give the protected compound 63, gives the final product 50 after acidic hydrolysis.
[0000]
[0062] In vitro competition studies, which have been carried out using αvβ3 and αvβ5 receptors, purified from human placenta by affinity chromatography, have shown a high binding affinity of 38 for both receptors, having a IC50=16.4 nM for αvβ3 and IC50=1.02 μM for αvβ5 ( FIG. 1 ). The introduction of a fluorine on the aromatic ring in para position, in analogy with a potential labelling with fluorine-18 (PET radioisotope), corresponding to compounds 48 and 49 of formula (I), has shown that the presence of the fluorine maintain the affinity towards the receptor, though with lowered potency of about an order of magnitude (compound 48: IC50=215 nM for αvβ3, and IC50=9.90 μM for αvβ5, as shown in FIG. 2 ; compound 49: IC50=101 nM for αvβ3). High binding affinity is observed for compound 55 lacking the aromatic ring (IC50=13 nM for αvβ3). Compounds 54 and 57 show inhibition towards αvβ3 with IC50=2.1 μM and 200 nM. Moreover, compound 52 displays 77% and 54% inhibition of 125I-Echistatin binding to αvβ3 at 10 μM and 1 μM concentrations, respectively. Finally, compound 59 shows inhibition towards αvβ3 with IC50=308 nM.
[0063] A series of experiments carried out using the flux cytometry technique and specific monoclonal antibodies, allowed for the setup of particular human melanoma cells characterized by an over-expression of integrin receptors. Such cells have been used to test the capability of selected compounds of formula (I) at 10, 1.0 and 0.1 μM concentrations, of inhibiting the binding between these cells and suitable substrates containing the RGD sequence, such as vitronectin, fibronectin, and osteopontin ( FIG. 3 ). The results clearly show that compound 48 significantly inhibits the binding of melanoma cells to both vitronectin and osteopontin, whereas it displays a minor effect towards the adhesion of the cells to fibronectin. Compound 48 significantly inhibits only the binding of the cells to vitronectin, whereas it shows a minor effect towards the adhesion of the cells to both osteopontin and fibronectin. Taken all together, these data demonstrate that the RGD-like molecules of formula (I) are capable to exert important biological effects also to integrin receptors associated to the plasma-membrane of tumor cells, which is a pre-requisite for their use in-vivo. Moreover, these results show that among the two selected peptidomimetics of formula (I), compound 38 displays a higher affinity for the αvβ3 integrin receptor, which recognizes the RGD sequence exposed both on vitronectin and osteopontin.
[0064] These results suggest a potential use of compounds of formula (I), as above-described, as medicaments and/or diagnostics for the treatment and/or diagnosis of pathologies where integrins are involved. Compounds of the present invention can be used as antagonists of integrin receptors, in particular of integrins that recognize the tripeptide Arg-Gly-Asp (RGD) sequence, and more specifically, of αvβ3 and αvβ5 integrins, thus resulting useful, for example, for the treatment of initiating or growing tumors (acting as anti-angiogenic agents), osteoporosis, or rheumatoid arthritis.
[0065] Compounds of formula (I) according to the present invention, when containing one or more radioisotopes, can be applied as diagnostics, or starting from compounds of formula (I) as above-described, conjugated compounds with suitable molecular probes can be obtained.
[0066] Experimental Section
[0067] General procedure (A) for the synthesis of alkynes 1-3 of Table 1. To a solution of alkyn-1-ol (1 eq) in anhydrous THF, PPh 3 (1 eq) and N,N′-di-Boc-guanidine (1 eq) are added under a nitrogen atmosphere. Successively, DIAD (1 eq) is slowly added at 0° C., then, the mixture is left reacting in a microwave synthesizer at 110° C. for 30 min. The solvent is evaporated and the crude is purified by flash chromatography (1:2 EtOAc-petr. et.), thus giving pure product.
[0068] N,N′-Di-Boc-N″-(prop-2-ynyl)-guanidine (1). Compound 1 is obtained according to general procedure A in 79% yield. (1:2 EtOAc-petr. et., Rf=0.80). 1 H NMR (CDCl 3 , 200 MHz) δ 8.46 (br, 1H), 4.22 (dd, J=4.8, 2.6 Hz, 2H), 2.26 (t, J=2.6 Hz, 1H), 1.49 (s, 18H) ppm.
[0069] N,N′-Di-Boc-N″-(but-3-ynyl)-guanidine (2). Compound 2 is obtained according to general procedure A as a white solid in 72% yield. (1:2 EtOAc-petr. et., Rf=0.80). 1 H NMR (CDCl 3 , 200 MHz) δ 9.20 (br, 1H), 4.08 (t, J=7.0 Hz, 2H), 2.52 (td, J=7.0, 2.6 Hz, 2H), 1.95 (t, J=2.6 Hz, 1H), 1.53 (s, 9H), 1.48 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 163.3 (s), 159.8 (s), 154.4 (s), 83.8 (s), 81.1 (s), 78.5 (s), 69.7 (d), 42.8 (t), 28.2 (q), 27.9 (q), 18.5 (t) ppm.
[0070] N,N′-Di-Boc-N″-(pent-4-ynyl)-guanidine (3). Compound 3 is obtained according to general procedure A as a white solid in 68% yield. (1:2 EtOAc-petr. et., Rf=0.63). 1 H NMR (CDCl 3 , 200 MHz) δ 9.30 (br, 1H), 4.00 (t, J=7.2 Hz, 2H), 2.23 (td, J=7.2, 2.2 Hz, 2H), 1.93 (t, J=2.2 Hz, 1H), 1.83 (m, 2H), 1.52 (s, 9H), 1.48 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 163.7 (s), 160.5 (s), 154.8 (s), 83.8 (s), 83.7 (s), 78.7 (s), 68.5 (d), 43.9 (t), 28.3 (q), 28.0 (q), 27.5 (t), 16.0 (t) ppm.
[0071] [t-butoxycarbonylimino-(4-prop-2-ynyl-piperazin-1-y)-methyl]-carbamic acid t-butyl ester (4). To a solution of N,N′-di-Boc-N″-trifluoromethanesulfonylguanidine (1.72 g, 4.40 mmol) in anhydrous CH 2 Cl 2 (20 mL) Et 3 N (674 μL, 4.84 mmol) and N-propargyl piperazine (600 mg, 4.84 mmol) are added. The mixture is left reacting at room temperature for 16 h, then the solvent is evaporated. The residue is taken up in EtOAc, and treated with a saturated aqueous NaHCO 3 solution and brine. Crude compound is purified by flash chromatography (2:1 EtOAc-petr. et., Rf=0.37) giving compound 4 as a yellow oil (1.01 g, 2.77 mmol) in 63% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 9.61 (br, 1H), 3.44 (m, 4H), 3.16 (d, J=2.6 Hz, 2H), 2.41 (m, 4H), 2.18 (m, 1H), 1.27 (s, 9H) ppm.
[0072] [t-butoxycarbonylimino-(4-but-3-ynyl-piperazin-1-yl)-methyl]-carbamic acid t-butyl ester (5) (Scheme 3). To a solution of 23 (1.02 g, 5.47 mmol) triethylamine (762 μL, 5.47 mmol) and NaI (23 mg, 0.153 mmol) in DMSO but-3-ynyl mesylate (810 mg, 5.47 mmol) is dropwise added. The mixture is heated at 50° C. overnight, then water is added. The aqueous phase is treated with Et 2 O, and the organic phase is washed with brine, and dried over sodium sulfate. After solvent evaporation, 4-but-3-ynyl-piperazine-1-carboxylic acid t-butyl ester (24) (1.10 g, 4.62 mmol, 84%) is obtained as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 3.38 (t, J=4.8 Hz, 4H), 2.55 (m, 2H), 2.41-2.28 (m, 6H), 1.94 (t, J=2.6 Hz, 1H), 1.40 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 154.3 (s), 82.3 (s), 79.5 (s), 69.1 (d), 56.9 (t), 52.6 (t), 43.5 (t), 28.4 (q), 16.7 (t) ppm. Compound 24 (1.10 g, 4.62 mmol) is left reacting for 16 h in the presence of a 1:1 mixture of CH 2 Cl 2 /TFA (2 mL/mmol). After solvent evaporation, the residue is taken up in MeOH, and eluted through a column containing Amberlyst A-21, thus giving pure 1-but-3-ynyl-piperazine (25) (606 mg, 4.39 mmol) in 95% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 6.98 (br, 1H), 3.06-3.01 (m, 4H), 2.62-2.55 (m, 6H), 2.38-2.29 (m, 2H), 1.96 (t, J=2.6 Hz, 1H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 82.1 (s), 69.4 (d), 56.6 (t), 50.6 (t), 44.1 (t), 16.8 (t). MS m/z 138 (M + , 7), 99 (100), 70 (48), 56 (98) ppm. To a solution of N,N′-di-Boc-N″-trifluoromethanesulfonylguanidine (1.52 g, 3.88 mmol) in anhydrous CH 2 Cl 2 (18 mL) triethylamine (595 μL, 4.27 mmol) and 25 (590 mg, 4.27 mmol) are added. The mixture is left reacting for 16 h at room temperature, and then the solvent is evaporated. The residue is taken up in EtOAc and treated with a saturated aqueous NaHCO 3 solution and brine. Crude product is purified by flash chromatography (CH 2 Cl 2 -MeOH 12:1, Rf=0.50), giving pure 5 as a white solid (1.10 g, 2.25 mmol) in 58% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 3.58 (m, 4H), 2.63-2.51 (m, 6H), 2.39-2.33 (m, 2H), 1.96 (t, J=2.6 Hz, 1H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 154.7 (s), 151.2 (s), 115.9 (s), 85.9 (s), 82.3 (s), 69.2 (d), 56.6 (t), 52.3 (t), 46.7 (t), 28.0 (q), 27.8 (q), 16.8 (t); MS m/z 380 (M + , 0.11), 160 (17), 121 (79), 57 (100) ppm.
[0073] (3S)-(2-Bromo-acetylamino)-3-(4-fluoro-phenyl)-propionic acid methyl ester [(S)-22] (Scheme 2). To a solution of compound (S)-21 (1.0 g, 5.08 mmol), prepared as reported (Davies, S. G.; Ichihara, O. Tetrahedron: Asymmetry 1991, 2, 183), and triethylamine (0.71 mL, 5.08 mmol) in anhydrous CH 2 Cl 2 (5 mL) bromoacetyl bromide (442 μL, 5.08 mmol) is dropwise added at −10° C. After 15 min at −10° C., the mixture is allowed to reach room temperature, and it is left reacting for additional 30 min. Then, water is added and the two phases are separated. The organic phase is washed with 5% HCl and brine, and it is dried over anhydrous Na 2 SO 4 . After solvent evaporation, compound (S)-22 is obtained as a yellow oil (1.40 g, 4.42 mmol) in 87% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.74 (br, 1H), 7.30-7.23 (m, 2H), 7.07-6.98 (m, 2H), 5.36 (dt, J=8.0, 5.6 Hz, 1H), 3.90 (s, 2H), 3.64 (s, 3H), 2.88 (dd, J 1 =5.6, 3.8 Hz, 2H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 171.3 (s), 164.8 (s), 162.1 (d, J CF =245 Hz), 135.5 (s), 127.8 (d, J CF =8.2 Hz), 115.6 (d, J CF =20 Hz), 52.1 (q), 49.6 (d), 39.6 (t), 29.1 (t) ppm.
[0074] (3R)-(2-Bromo-acetylamino)-3-(4-fluoro-phenyl)-propionic acid methyl ester [(R)-22]. Compound (R)-22 is prepared as described for (S)-22 starting from (R)-21 (1.0 g, 5.08 mmol). After solvent evaporation, (R)-22 is obtained as a yellow oil (1.35 g, 4.27 mmol) in 84% yield and with NMR data as for (S)-22.
[0075] (S)-3-(4-Fluoro-phenyl)-3-[2-(methyl-prop-2-ynyl-amino)-acetylamino]-propionic acid methyl ester (6) (Scheme 2). A solution of compound (S)-22 (654 mg, 2.18 mmol) in DMF (2 mL) is added at room temperature to a solution of N-methyl propargylamine (181 μL, 2.18 mmol) and triethylamine (453 μL, 3.27 mmol) in DMF (5 mL). After 1 h, the mixture is brought to 80° C. and left reacting for 16 h. Then, water is added and the organic phase is extracted with diethyl ether. Crude product is purified by flash chromatography (3:2 EtOAc-petr. et., Rf=0.50) giving pure 6 as a yellow oil (0.990 g, 3.54 mmol) in 80% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.81 (d, J=8.4 Hz, 1H), 7.26-7.18 (m, 5H), 5.43-5.34 (m, 1H), 3.55 (s, 3H), 3.28 (d, J=2.5 Hz, 2H), 3.05 (s, 2H), 2.81 (t, J=6.0 Hz, 2H), 2.30 (s, 3H), 2.19 (t, J=1.2 Hz, 1H) ppm; 13 C NMR δ 170.9 (s), 169.2 (s), 140.4 (s), 128.5 (d), 127.4 (d), 126.1 (d), 73.5 (t), 59.3 (t), 51.6 (q), 49.0 (t), 46.2 (t), 42.2 (q), 40.2 (t) ppm.
[0076] (R)-3-(4-Fluoro-phenyl)-3-[2-(methyl-prop-2-ynyl-amino)-acetylamino]-propionic acid methyl ester (7). Compound 7 is prepared as reported for 6 starting from (R)-22, with same NMR data as for 6.
[0077] N,N′-di-Boc-1-hex-4-ynyl-2-methyl-isothiourea (27) (Scheme 4). To a solution of N,N′-diBoc-2-Methyl-isothiourea 26 (500 mg, 1.72 mmol), PPh 3 (540 mg, 2.05 mmol) and pent-4-yn-1-ol (145 mg, 1.72 mmol) in anhydrous THF (20 mL) DIAD (415 ml, 2.06 mmol) is dropwise added at −10° C. Then, the mixture is left reacting in a microwave synthesizer at 50° C. for 30 min. The solvent is evaporated, and the crude is purified by flash chromatography (10:1 EtOAc-petr. et., Rf=0.33), thus giving pure N,N′-diBoc-1-Hex-4-ynyl-2-methyl-isothiourea 27 in 98% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 3.63 (t, 2H), 2.39 (s, 3H), 2.27-2.20 (m, 2H), 1.97 (t, 2H), 2.35 (t, 2H), 1.90 (t, 2H), 1.52 (s, 9H), 1.48 (s, 9H) ppm.
[0078] Alkyne 8. A solution of tyramine (200 mg, 0.637 mmol), 27 (600 mg, 1.68 mmol) and triethylamine (510 ml, 5.06 mmol) in anhydrous THF (20 mL) is left reacting in a microwave synthesizer at 100° C. for 1 h, and then the solvent is evaporated. The residue is taken up in EtOAc, and treated with brine. Crude compound is purified by flash chromatography (1:2 EtOAc-petr. et., Rf=0.42) to give compound 8 (350 mg) in 47% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.04 (d, 2H), 6.77 (d, 2H), 3.66 (t, 2H), 3.42 (t, 2H), 3.42 (t, 2H), 2.18-2.04 (m, 2H), 1.95 (t, 2H), 1.62 (t, 2H), 1.49 (s, 9H), 1.46(s, 9H).
[0079] Alkyne 9. 5-[1,2]Dithiolan-3-yl-pentanoic acid (2-amino-ethyl)-amide 28 is obtained as reported (Nam, J.; Won, N.; Jin, H.; Chung, H.; Kim, S. J. Am. Chem. Soc. 2009, 131, 13639) starting from lipoic acid (2.0 g, 9.70 mmol), 1,1-carbonyldiimidazole (200 g, 12.3 mmol), and ethylenediamine (3.5 mL, 48.4 mmol) in 80% yield. 1 H NMR (D 2 O, 200 MHz) δ 3.62-3.52 (m, 1H), 3.34-3.26 (m, 2H), 3.22-3.08 (m, 2H), 2.82 (t, 2H), 2.52-2.40 (m, 1H), 2.20 (t, 1H), 1.96-1.84 (m, 1H), 1.72-1.58 (m, 5H), 1.51-1.38 (m, 2H) ppm. A solution of 28 (787 mg, 3.17 mmol), 27 (754 mg, 2.11 mmol) and triethylamine (640 ml, 6.33 mmol) in anhydrous THF (30 mL) is left reacting in a microwave synthesizer at 100° C. for 1 h. Then, the solvent is evaporated. The residue is taken up in EtOAc, and treated with brine. Crude compound is purified by flash chromatography (30:1 CH 2 Cl 2 —CH 3 OH, Rf=0.37) giving 9 (480 mg) in 41% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 6.42 (br, 1H), 3.75-3.68 (m, 2H), 3.50-3.35 (m, 4H), 3.30-3.15 (m, 2H), 2.52-2.40 (m, 2H), 2.30-2.10 (m, 5H), 1.97 (t, 1H), 1.95-1.85 (m, 2H), 1.80-1.70 (m, 2H), 1.72-1.60 (m, 4H), 1.49 (s, 9H,), 1.45 (s, 9H) ppm.
[0080] 2-(tert-Butoxycarbonyl-pent-4-ynyl-amino)-methyl-benzoimidazole-1-carboxylic acid tert-butyl ester (10). To a solution of C-(1H-benzoimidazol-2-yl)-methylamine (200 mg, 1.0 mmol) and triethylamine (139 μL, 1 mmol) in CH 2 Cl 2 (5 mL) (Boc) 2 O (420 mg, 2 mmol) is added, and the reaction mixture is stirred at r.t. for 1 h. After solvent evaporation, the crude product is purified by flash chromatography (1:1 EtOAc-Et.petr., Rf=0.5), to give 2-(tert-butoxycarbonylamino-methyl)-benzoimidazole-1-carboxylic acid t-butyl ester as a yellow oil (246 mg, 0.71 mmol) in 71.% yield. 1 H NMR (CDCl 3 , 200 MHz) ε 7.96-7.91 (m, 1H), 7.72-7.67 (m, 1H), 7.35-7.26 (m, 2H), 5.85 (br, 1H), 4.80 (d, 2H), 1.71 (s, 9H), 1.48 (s, 9H) ppm. This intermediate (175 mg, 0.5 mmol) is dissolved in anhydrous THF (10 mL) and PPh 3 (330 mg, 0.5 mmol) and 4-pentynol (46 μL, 0.5 mmol) are added. Then, after cooling to 0° C., DIAD (100 μL, 0.5 mmol) is slowly added, and after 15 min at 0° C., the mixture is heated under microwave irradiation at 110° C. for 1 h. Following flash chromatography purification (5:1 EtOAc-petr. et.), compound 10 is obtained in 64% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.95-7.90 (m, 1H), 7.71-7.67 (m, 1H), 7.34-7.26 (m, 2H), 5.79 (d, 2H), 2.30-2.20 (m, 2H), 2.03 (s, 1H), 1.95-1.92 (m, 2H), 1.80 (t, 2H), 1.71 (s, 9H), 1.47 (s, 9H) ppm.
[0081] [(2-Azido-acetyl)-phenyl-amino]-acetic acid t-butyl ester (11). To a solution of N-phenyl-glycine methyl ester (1.65 g, 7.98 mmol) and triethylamine (1.11 mL, 7.98 mmol) in anhydrous CH 2 Cl 2 (8 mL) bromoacetyl bromide (695 μL, 7.98 mmol) is dropwise added at −10° C. After 15 min at −10° C., the mixture is allowed to reach room temperature, and it is left reacting for additional 30 min. Then, water is added and the two phases are separated. The organic phase is washed with 5% HCl and brine, and it is dried over anhydrous Na 2 SO 4 . After solvent evaporation, 2.10 g of the corresponding bromoacetyl-derivative are obtained as a brown oil (85%). 1 H NMR (CDCl 3 , 200 MHz) δ 7.41 (m, 5H), 4.23 (s, 2H), 3.67 (s, 2H), 1.42 (s, 9H) ppm. To a solution of this compound (2.10 g, 6.76 mmol) in DMF, NaN 3 (1.32 g, 20.3 mmol) is added at room temperature. After 5 min, the mixture is brought to 80° C. and left reacting for 16 h. Then, water is added and the organic phase is extracted with diethyl ether. Crude product is purified by flash chromatography (1:3 EtOAc-petr. et., Rf=0.57), thus giving 11 as a white solid (1.06 g, 3.65 mmol) in 54% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.41-7.35 (m, 5H), 4.29 (s, 2H), 3.66 (s, 2H), 1.46 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 167.4 (s), 167.3 (s), 140.9 (s), 129.9 (d), 128.8 (d), 127.7 (d), 82.1 (s), 52.2 (t), 50.6 (t), 28.1 (q) ppm; MS m/z 290 (M + , 0.2), 262 (0.7), 217 (11), 189 (1.8), 161 (7.3), 106 (30), 77 (18), 57 (100).
[0082] (3S)-(2-Azido-acetylamino)-3-phenyl-propionic acid methyl ester (12a) Compound 12a is prepared as described for 14, starting from (S)-β-phenylalanine methyl ester (1.0 g, 5.59 mmol), prepared as reported (Davies, S. G.; Ichihara, O. Tetrahedron: Asymmetry 1991, 2, 183). After solvent evaporation, the intermediate bromoacetyl-derivative is obtained as a brown oil (1.37 g, 4.97 mmol) in 89% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.72 (d, J=8 Hz, 1H), 7.37-7.24 (m, 5H), 5.38 (dt, J=8.0, 5.8 Hz, 1H), 3.87 (s, 2H), 3.62 (s, 3H), 2.90 (t, J=5.8 Hz, 2H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 171.1 (s), 164.9 (s), 139.6 (s), 128.6 (d), 127.6 (d), 126.0 (d), 51.8 (q), 50.1 (d), 39.5 (t), 28.9 (t) ppm. To a solution of this compound (1.37 g, 4.97 mmol) in DMF NaN 3 (969 mg, 14.9 mmol) is added at room temperature. After 5 min, the mixture is brought to 80° C. and left reacting for 16 h. Then, water is added and the organic phase is extracted with diethyl ether. Crude product is purified by flash chromatography (1:1 EtOAc-petr. et., Rf=0.40), giving 12a as a white solid (1.01 g, 4.12 mmol) in 83% yield. [α] 23 D −25.9 (c 1.8, CHCl 3 ). 1 H NMR (CDCl 3 , 200 MHz) δ 7.35-7.26 (m, 5H), 5.43 (dt, J=8.0, 5.8 Hz, 1H), 4.03 (s, 2H), 3.64 (s, 3H), 2.90 (t, J=5.8 Hz, 2H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 171.2 (s), 165.9 (s), 139.7 (s), 128.7 (d), 127.4 (d), 126.1 (d), 52.5 (t), 51.9 (q), 49.5 (d), 39.6 (t) ppm.
[0083] (3S)-(2-Azido-acetylamino)-3-phenyl-propionic acid t-butyl ester (12b). Compound 12b is prepared as reported for 12a starting from (S)-β-phenylalanine t-butyl ester. 1 H NMR (CDCl 3 , 200 MHz) δ 7.47 (d, J=7.8 Hz, 1H), 7.32 (m, 5H), 5.39 (dt, J=8.4, 5.8 Hz, 1H), 4.02 (s, 2H), 2.80 (pseudo t, J=6.2 Hz, 2H), 1.34 (s, 9H) ppm. [α] 23 D −18.9 (c 1.0, CHCl 3 ).
[0084] (3R)-(2-Azido-acetylamino)-3-phenyl-propionic acid methyl ester (13a). Compound 13a is prepared as reported for 12a starting from (R)-β-phenylalanine methyl ester (1.0 g, 5.59 mmol). After solvent evaporation, the intermediate bromoacetyl-derivative is obtained as a brown oil in 85% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.72 (d, J=8.0 Hz, 1H), 7.37-7.24 (m, 5H), 5.38 (dt, J=8.0, 5.8 Hz, 1H), 3.87 (s, 2H), 3.62 (s, 3H), 2.90 (t, J=5.8 Hz, 2H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 171.1 (s), 164.9 (s), 139.6 (s), 128.6 (d), 127.6 (d), 126.0 (d), 51.8 (q), 50.1 (d), 39.5 (t), 28.9 (t) ppm. Compound 13a is obtained from this intermediate compound (1.31 g, 4.75 mmol) as reported for 12a in 80% yield and with same NMR data as reported for 12a. [α] 23 D +25.0 (c 1.6, CHCl 3 ).
[0085] (3R)-(2-Azido-acetylamino)-3-phenyl-propionic acid t-butyl ester (13b). Compound 13b is prepared as reported for 12a starting from (R)-β-phenylalanine t-butyl ester, with same NMR data as reported for 13b. [α] 23 D +18.3 (c 1.0, CHCl 3 ).
[0086] (3S)-(2-Azido-acetylamino)-3-(4-fluoro-phenyl)-propionic acid methyl ester (14) (Scheme 2). To a solution of (S)-22 (1.40 g, 4.42 mmol) in DMF NaN 3 (862 mg, 13.3 mmol) is added at room temperature. After 5 min, the mixture is brought to 80° C. and left reacting for 16 h. Then, water is added and the organic phase is extracted with diethyl ether. Crude product is purified by flash chromatography (3:2 EtOAc-petr. et., Rf=0.50), giving pure 14 as a yellow oil (0.990 g, 3.54 mmol) in 80% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.46 (d, J=8.0 Hz 1H), 7.29-7.22 (m, 2H), 7.00 (td, J HF =8.8 Hz, J HH =1.4 Hz, 2H), 5.36 (dt, J=8.0, 5.6 Hz, 1H), 3.97 (s, 2H), 3.62 (s, 3H), 2.88 (pseudo t, J=5.6 Hz, 2H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 170.9 (s), 165.7 (s), 161.9 (d, J CF =245 Hz), 135.6 (s), 127.8 (d, J CF =8.2 Hz), 115.5 (d, J CF =20 Hz), 52.5 (t), 51.9 (q), 48.9 (d), 39.7 (t) ppm. [α] 23 D −22.0 (c 0.6, CHCl 3 ).
[0087] (3R)-(2-Azido-acetylamino)-3-(4-fluoro-phenyl)-propionic methyl ester (15). Compound 15 is prepared as reported for 14 starting from (R)-22 (1.35 g, 4.27 mmol). Crude product is purified by flash chromatography (3:2 EtOAc-petr. et., Rf=0.50), giving 15 as a yellow oil (0.932 g, 3.33 mmol) in 78% yield with same NMR data as reported for 14. [α] 23 D +23.4 (c 0.5, CHCl 3 ).
[0088] (3S)-(2-Azido-acetylamino)-3-(4-hydroxy-phenyl)-propionic acid methyl ester (16). Compound 16 is prepared as described for 14, starting from (R)-β-tyrosine methyl ester (1.12 g, 5.28 mmol), prepared according to literature (Davies, S. G.; Ichihara, O. Tetrahedron: Asymmetry 1991, 2, 183) from 3-(4-triisopropylsilanyloxy-phenyl)-acrylic acid methyl ester (1.0 g, 3.34 mmol), prepared as reported (Schmauder, A.; Sibley, L. D.; Maier, M. E. Chem. Eur. J. 2010, 16, 4328). After solvent evaporation, the intermediate bromoacetyl-derivative is obtained as a brown oil (0.80 g, 1.69 mmol) in 51% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.61 (d,1H), 7.20 (d, J=8.7, 2H), 6.82 (d, J=8.7, 2H), 5.32 (m,1H), 3.91 (s, 2H), 3.61 (s, 3H), 2.98-2.78 (m,2H), 1.37-1.15 (m, 3H), 1.07 (d, 18H) ppm. To a solution of this compound (0.80 g, 1.69 mmol) in DMF NaN 3 (0.33 mg, 5.07 mmol) is added at room temperature. After 5 min, the mixture is brought to 80° C., and left reacting for 16 h. Then, water is added and the organic phase is extracted with diethyl ether. Crude product is purified by flash chromatography (1:1 EtOAc-petr. et., Rf=0.40), giving 16 as a white solid (0.25 g, 0.90 mmol) in 53% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.42 (d,1H), 7.10 (d, J=8.4, 2H), 6.71 (d, J=8.4, 2H), 6.00 (br, 1H), 5.33 (m,1H), 4.02 (s, 2H), 3.64 (s, 3H), 2.98-2.79 (m, 2H) ppm.
[0089] (2-Azido-ethyl)-carbamic acid t-butyl ester (17) (Scheme 5). A solution of ethanolamine (300 μL, 4.9 mmol) in CH 3 CN (25 mL) is treated with (Boc) 2 O (1.2 g, 5.5 mmol) and DMAP (120 mg, 0.98 mmol) at room temperature for 3 h. Then, the mixture is treated with 5% KHSO 4 and brine, and dried over sodium sulfate. After solvent evaporation, pure Boc-ethanolamine 29 is obtained in 53% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 5.27 (br, 1H), 3.67 (br, 1H), 3.53 (t, J=5.1 Hz, 2H), 3.17-3.09 (m, 2H), 1.35 (s, 9H) ppm. This intermediate compound is dissolved in anhydrous CH 2 Cl 2 and Et 3 N (1.1 mL, 7.9 mmol) is added under a nitrogen atmosphere. The mixture is cooled to 0° C., MsCl (614 μL, 7.94 mmol) is dropwise added, and the mixture is left reacting at the same temperature for 20 min. Successively, 1M NaOH (10 mL) is added and the organic phase is separated. The mixture is treated with a saturated aqueous NaHCO 3 solution and with brine, and dried over sodium sulfate. After solvent evaporation, pure Boc-aminoethyl mesylate 30 (509 mg) is obtained in 64% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 5.05 (br, 1H), 4.33-4.20 (m, 2H), 3.45-3.21 (m, 2H), 3.01 (s, 3H), 1.39 (s, 9H) ppm. The resulting mesylate 30 is dissolved in DMF (5 mL), and NaN 3 (413 mg, 6.36 mmol) is added at 0° C. The mixture is heated at 80° C. for 16 h, then water is added (50 mL). The organic phase is extracted with Et 2 O (25 mL×5), and dried over sodium sulfate. After solvent evaporation, the crude product is purified by flash chromatography (1:3 EtOAc-petr. et., Rf=0.75), giving 17 (224 mg) as an oil in 61% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 4.92 (br, 1H), 3.40-3.35 (m, 2H), 3.30-3.22 (m, 2H), 1.41 (s, 9H) ppm.
[0090] 3-(2-Azido-acetylamino)-propionic acid methyl ester (18). To a solution of methyl 3-aminopropionate ester hydrochloride (1.12 g, 8.00 mmol) and triethylamine (2.2 mL (16.00 mmol) in anhydrous CH 2 Cl 2 (30 mL) bromoacetyl bromide (690 μL, 8.00 mmol) is dropwise added at −10° C. After 15 min at −10° C., the mixture is allowed to reach room temperature, and is left reacting for additional 30 min. The organic phase is washed with 4M HCl, saturated Na 2 CO 3 solution, and brine, and it is dried over anhydrous Na 2 SO 4 . After solvent evaporation, 1.02 g (4.57 mmol) of the corresponding bromoacetyl-derivative is obtained as a brown oil (57%). 1 H NMR (CDCl 3 , 200 MHz) δ 7.10 (br,1H), 3.83 (s,H), 3.75 (s, 3H), 3.57 (q, 2H), 2.57 (t, 2H) ppm. 13 C NMR (CDCl 3 , 50 MHz) δ 172.7 (s), 165.4 (s), 51.9 (t), 35.5 (t), 33.4 (t), 29.1 (q) ppm. To a solution of this compound (1.02 g, 4.57 mmol) in anhydrous DMF (12 mL) NaN 3 (900 mg, 13.71 mmol) is added. The mixture is heated at 80° C. for 16 h. Then, water (50 mL) is added and the organic phase is extracted with diethyl ether. Crude product is purified by flash chromatography (1:1 EtOAc-Et.petr., Rf=0.4) to give 18 as a white solid (340 mg, 1.82 mmol) in 40% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 6.91 (br, 1H), 3.94 (s, 3H), 3.68 (s, 3H), 3.53 (q, 2H), 2.55 (t, 2H) ppm. 13 C NMR (CDCl 3 , 50 MHz) δ 172.5 (s), 165.5 (s), 52.7 (t), 52.0 (t), 34.9 (t), 33.7 (q) ppm.
[0091] 4-(2-Azido-acetylamino)-butyric acid ethyl ester (19). Compound 19 is prepared as described for 18. Specifically, starting from ethyl 4-aminobutanoate hydrochloride (1.00 g, 7.65 mmol), triethylamine (2.1 mL, 15.30 mmol) in anhydrous CH 2 Cl 2 (26 mL) and bromoacetyl bromide (520 μL, 7.65 mmol), the corresponding bromoacetyl-derivative is obtained as a brown oil (59%). 1 H NMR (CDCl 3 , 200 MHz) δ 6.77 (br,1H), 4.11 (q, 2H), 3.84 (s, 2H), 3.32 (m, 2H), 2.35 (t, 2H), 1.94-1,78 (m, 2H), 1.23 (t, 3H) ppm. 13 C NMR (CDCl 3 , 50 MHz) δ 172.9 (s), 165.5 (s), 60.7 (t), 39.8 (t), 31.7 (t), 29.2 (t), 24.48 (t), 14.4 (q) ppm. Starting from a solution of this compound (950 mg, 3.77 mmol) in anhydrous DMF (7 mL) and NaN 3 (720 mg, 11.31 mmol), after purification by flash chromatography (1:1 EtOAc-Et.petr., Rf=0.7), 19 is obtained as a white solid (350 mg, 1.64 mmol) in 44% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 6.60 (br,1H), 4.13 (q, 2H), 3.96 (s, 2H), 3.33 (m, 2H), 2.35 (t, 2H), 1.93-1.82 (m, 2H), 1.24 (t, 3H). 13 C NMR (CDCl 3 , 50 MHz) δ 173.0.99 (s), 166.5 (s), 60.7 (t), 52.8 (t), 39.1 (t), 31.8 (t), 24.5 (t), 14.3 (q).
[0092] [(2-Azido-ethyl)-(toluene-4-sulfonyl)-amino]-acetic acid ethyl ester (20) (Scheme 5). To a solution of (2-hydroxy-ethylamino)-acetic acid ethyl ester 31 (2.8 g, 10 mmol), prepared as reported (Yoon U. C.; Kwon H. C.; Hyung T. G.; Choi K. H.; Oh S. W.; Yang S.; Zhao Z.; Mariano P. S. J. Am. Chem. Soc. 2004, 126, 1110) and triethylamine (3.95 mL, 15 mmol) in anhydrous THF (230 mL) tosyl chloride (3.63 g, 10 mmol) is dropwise added at 0° C., and the mixture is left reacting for 4 h at 0° C. Then, water and 1N HCl are added up to pH=2. The organic phase is extracted with EtOAc. Crude compound is purified by flash chromatography (1:1 EtOAc-petr. et., Rf=0.45) giving compound 32 (3.50 g) in 56% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.73 (d, 2H), 7.31 (d, 2H), 4.18 (q, 2H), 4.04 (s, 2H), 3.73 (t, 2H), 3.34 (t, 2H), 2.43 (s, 21H), 1.26 (t, 3H) ppm. To a solution of 31 (2.96 g, 9.8 mmol), PPh 3 (7.71 g, 29.4 mmol) in anhydrous THF (35 mL) a solution of DIAD (5.12 g, 29.9 mmol) and DPPA (8.09 g, 29.9 mmol) in anhydrous THF (10 mL) is dropwise added at −10° C. The mixture is left reacting at r.t. for 2 h. Then, a solution of 1N KOH is added, and the organic phase is extracted with EtOAc. Crude compound is purified by flash chromatography (1:3 EtOAc-petr. et., Rf=0.34), giving compound 20 (0.800 g) in 25% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 7.72 (d, 2H), 7.31 (d, 2H), 4.15 (s, 2H), 4.09 (q, 2H), 3.56 (t, 2H), 3.39 (t, 2H), 2.43 (s, 21H), 1.21 (t, 3H) ppm.
[0093] General procedure (B) for the Cu-catalyzed cycloaddition: to a solution of alkyne (1 eq.) and azide (1 eq.) in H 2 O/t-BuOH 1:1 (4 mL/mmol) a 0.9M sodium ascorbate solution (1 eq) and a 0.3M Cu(OAc) 2 solution (1 eq.) are added under a nitrogen atmosphere. The reaction mixture is left under stirring at room temperature for two days. The organic phase is extracted with CH 2 Cl 2 , treated with 5% NaHCO 3 and brine, and dried over sodium sulfate. After solvent evaporation, the crude product is purified by flash chromatography.
[0094] General procedure (C) for the Cu-catalyzed cycloaddition: to a solution of alkyne (1 eq.) and azide (1.2 eq.) in dry THF (6 mL/mmol) and iodo(triethylphosphite)Cu (0.1 eq.) are added under a nitrogen atmosphere. The reaction mixture is left reacting under microwave irradiation at 80° C. for 25 min. After solvent evaporation, the crude product is purified by flash chromatography.
[0095] Compound 33. Following the general procedure B, alkyne 1 (195 mg, 0.66 mmol) and azide 13b (200 mg, 0.66 mmol) in 1:1 H 2 O/t-BuOH (2.6 mL) give, after work-up and chromatographic purification (1:1 EtOAc-petr. et., Rf=0.25), protected adduct (388 mg, 64%), precursor of 33 as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 11.39 (br, 1H), 8.71 (br, 1H), 7.72 (s, 1H), 7.48 (br, 1H), 7.19 (m, 5H), 5.32 (m, 1H), 4.98 (s, 2H), 4.64 (s, 2H), 2.69 (m, 2H), 1.45 (s, 9H), 1.41 (s, 9H), 1.20 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 169.8 (s), 164.1 (s), 163.1 (s), 155.8 (s), 152.8 (s), 144.3 (s), 139.7 (s), 128.5 (d), 127.6 (d), 126.1 (d), 123.8 (d), 83.1 (s), 81.4 (s), 79.3 (s), 52.8 (t), 50.2 (d), 41.0 (t), 36.3 (t), 28.2 (q), 27.9 (q), 27.8 (q) ppm. Compound 33 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. [α] 24 D +73.2 (c 0.2, H 2 O). 1 H NMR (D 2 O, 400 MHz) δ 8.00 (s, 1H), 7.46-7.37 (m, 5H), 5.35-5.23 (m, 3H), 4.56 (s, 2H), 2.79 (m, 2H) ppm.
[0096] Compound 34. Following the general procedure B, alkyne 2 (200 mg, 0.64 mmol) and azide 13a (168 mg, 0.64 mmol) in 1:1 H 2 O/t-BuOH (2.6 mL) give, after work-up and chromatographic purification (EtOAc-petr. et. 4:1, R f =0.50), protected adduct (177 mg, 48%), precursor of 34, as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 9.24 (br, 1H), 7.68 (s, 1H), 7.30-7.17 (m, 5H), 5.38 (m, 1H), 5.02 (s, 2H), 4.17 (m, 2H), 3.58 (s, 3H), 3.06 (m, 2H), 2.81 (m, 2H), 1.48 (s, 9H), 1.47 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 170.7 (s), 164.3 (s), 163.5 (s), 160.0 (s), 154.5 (s), 145.6 (s), 139.5 (s), 128.6 (d), 127.7 (d), 125.9 (d), 123.3 (d), 84.0 (s), 78.7 (s), 52.9 (t), 51.9 (q), 50.1 (d), 44.2 (t), 39.7 (t), 28.5 (q), 28.0 (q), 25.4 (t) ppm. Compound 34 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. [α] 24 D +60.9 (c 0.3, H 2 O). 1 H NMR (D 2 O, 400 MHz) δ 7.87 (s, 1H), 7.49-7.40 (m, 5H), 5.34 (m, 1H), 5.28 (d, J=5.2 Hz, 2H), 3.53 (t, J=6.4 Hz, 2H), 3.05-3.00 (m, 4H) ppm.
[0097] Compound 35. Following the general procedure B, alkyne 3 (153 mg, 0.47 mmol) and azide 13a (124 mg, 0.47 mmol) in 1:1 H 2 O/t-BuOH (2 mL) give, after work-up and chromatographic purification (EtOAc-petr. et. 4:1, Rf=0.38), protected adduct (153 mg, 55%), precursor of 35. 1 H NMR (CDCl 3 , 200 MHz) δ 9.34 (br, 1H), 7.28-7.20 (m, 6H), 5.38 (m, 1H), 5.05 (s, 2H), 3.90 (m, 2H), 3.55 (s, 3H), 2.79 (m, 4H), 1.98 (m, 2H), 1.49 (s, 9H), 1.46 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 170.6 (s), 164.5 (s), 163.3 (s), 159.8 (s), 154.6 (s), 147.7 (s), 139.6 (s), 128.5 (d), 127.5 (d), 126.0 (d), 122.8 (d), 83.8 (s), 78.8 (s), 52.7 (t), 51.8 (q), 50.0 (d), 43.9 (t), 39.8 (t), 28.3 (q), 28.0 (q), 27.7 (t), 22.9 (t) ppm. Compound 35 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. [α] 24 D +56.9 (c 0.4, H 2 O). 1 H NMR (D 2 O, 400 MHz) δ 7.83 (s, 1H), 7.48-7.39 (m, 5H), 5.33 (pt, J=7.2 Hz, 1H), 5.26 (d, J=3.6 Hz, 2H), 3.21 (t, J=6.8, 2H), 3.00 (d, J=7.2 Hz, 2H), 2.82 (t, J=7.6 Hz, 2H), 1.97 (m, 2H) ppm.
[0098] Compound 36. Following the general procedure B, alkyne 1 (301 mg, 1.01 mmol) and azide 12b (308 mg, 1.01 mmol) in 1:1 H 2 O/t-BuOH (4 mL) give, after work-up and chromatographic purification (1:1 EtOAc-petr. et., R f =0.25), protected adduct (273 mg, 45%), precursor of 36, as a yellow oil with same NMR data as for protected 33. Compound 36 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation with same NMR data as for 33. [α] 24 D −66.3 (c 0.2, H 2 O).
[0099] Compound 37. Following the general procedure B, alkyne 2 (140 mg, 0.45 mmol) and azide 12a (118 mg, 0.45 mmol) in 1:1 H 2 O/t-BuOH (2 mL) give, after work-up and chromatographic purification (4:1 EtOAc-petr. et., Rf=0.50), protected adduct (203 mg, 55%), precursor of 37, as a yellow oil with same NMR data as for protected precursor of 34. Compound 37 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation with same NMR data as for 34. [α] 24 D −63.2 (c 0.3, H 2 O).
[0100] Compound 38 (Scheme 6). Following the general procedure B, alkyne 3 (200 mg, 0.61 mmol) and azide 12a (160 mg, 0.61 mmol) in 1:1 H 2 O/t-BuOH (2.5 mL) give, after work-up and chromatographic purification (4:1 EtOAc-petr. et., Rf=0.38), protected adduct (215 mg, 60%), precursor of 38, as a yellow oil with same NMR data as for protected precursor of 35. Compound 38 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation with same NMR data as for 35. [α] 21 D −63.5 (c 0.6, H 2 O).
[0101] Compound 39. Following the general procedure B, alkyne 4 (222 mg, 0.61 mmol) and azide 13b (186 mg, 0.61 mmol) in 1:1 H 2 O/t-BuOH (2 mL) give, after work-up and chromatographic purification (10:1 CH 2 Cl 2 /MeOH, Rf=0.47), protected adduct (201 mg, 49%), precursor of 39, as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 7.63 (s, 1H), 7.37 (br, 1H), 7.20 (m, 5H), 5.33 (m, 1H), 5.01 (s, 2H), 3.65 (s, 2H), 3.51 (m, 4H), 2.68 (m, 2H), 2.51 (m, 4H), 1.46 (s, 18H), 1.28 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 169.7 (s), 164.1 (s), 162.8 (s), 154.4 (s), 144.0 (s), 139.7 (s), 137.2 (s), 128.3 (d), 127.5 (d), 126.1 (d), 124.3 (d), 88.7 (s), 81.2 (s), 80.0 (s), 52.6 (t), 52.4 (t), 52.1 (t), 50.2 (d), 46.4 (t), 41.0 (t), 28.2 (q), 27.9 (q), 27.6 (q) ppm. Compound 39 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. [α] 24 D +49.3 (c 0.6, H 2 O). 1 H NMR (D 2 O, 400 MHz) δ 7.96 (s, 1H), 7.33-7.27 (m, 5H), 5.23 (s, 2H), 5.17 (t, J=6.8 Hz, 2H), 3.87 (s, 2H), 3.45 (m, 4H), 3.21 (m, 2H), 2.67 (m, 4H) ppm.
[0102] Compound 40. Following the general procedure B, alkyne 5 (319 mg, 0.84 mmol) and azide 13a (221 mg, 0.84 mmol) in 1:1 H 2 O/t-BuOH (3.5 mL) give, after work-up and chromatographic purification (12:1 CH 2 Cl 2 -MeOH, Rf=0.46), protected adduct (297 mg, 55%), precursor of 40, as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 7.54 (s, 1H), 7.30-7.20 (m, 5H), 5.38 (m, 1H), 5.03 (s, 2H), 3.58 (m, 4H), 3.58 (s, 3H), 2.94 (m, 2H), 2.81 (m, 2H), 2.71 (m, 2H), 2.56 (m, 4H), 1.48 (s, 18H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 170.8 (s), 164.4 (s), 162.8 (s), 154.6 (s), 146.4 (s), 139.5 (s), 137.2 (s), 128.6 (d), 127.7 (d), 126.0 (d), 122.8 (d), 88.7 (s), 81.2 (s), 57.3 (t), 52.9 (t), 52.5 (t), 52.0 (q), 50.0 (d), 46.8 (t), 39.7 (t), 28.2 (q), 23.3 (t) ppm. Compound 40 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. [α] 24 D +57.4 (c 0.3, H 2 O). 1 H NMR (D 2 O, 400 MHz) δ 7.95 (s, 1H), 7.49-7.40 (m, 5H), 5.35-5.31 (m, 3H), 3.82 (m, 4H), 3.67-3.56 (m, 6H), 3.30 (t, J=7.2 Hz, 2H), 2.99 (d, J=7.2 Hz, 2H) ppm.
[0103] Compound 41. Following the general procedure B, alkyne 4 (117 mg, 0.32 mmol) and azide 12b (98 mg, 0.32 mmol) in 1:1 H 2 O/t-BuOH (1.5 mL) give, after work-up and chromatographic purification (10:1 CH 2 Cl 2 -MeOH, Rf=0.47), protected adduct (93 mg, 43%), precursor of 41, as a yellow oil with same NMR data as for protected precursor of 39. Compound 41 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation with same NMR data as for 39. [α] 24 D −70.8 (c 0.6, H 2 O).
[0104] Compound 42. Following the general procedure B, alkyne 5 (361 mg, 0.95 mmol) and azide 12a (250 mg, 0.95 mmol) in 1:1 H 2 O/t-BuOH (4 mL) give, after work-up and chromatographic purification (12:1 CH 2 Cl 2 -MeOH, Rf=0.46), protected adduct (400 mg, 65%), precursor of 42, as a yellow oil with same NMR data as for protected precursor of 40. Compound 42 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation with same NMR data as for 40. [α] 24 D −55.2 (c 0.3, H 2 O).
[0105] Compound 43. Following the general procedure B, alkyne 1 (165 mg, 0.55 mmol) and azide 11 (160 mg, 0.55 mmol) in 1:1 H 2 O/t-BuOH (2 mL) give, after work-up and chromatographic purification (2:1 EtOAc-petr. et., Rf=0.56), protected adduct (177 mg, 55%), precursor of 43, as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 11.41 (br, 1H), 8.71 (br, 1H), 7.68 (s, 1H), 7.40 (m, 5H), 4.92 (s, 2H), 4.66 (d, J=6.0 Hz, 2H), 4.23 (s, 2H), 1.45 (s, 9H), 1.42 (s, 9H), 1.41 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 167.1 (s), 164.9 (s), 163.0 (s), 155.6 (s), 152.5 (s), 143.4 (s), 140.5 (s), 130.0 (d), 129.0 (d), 127.7 (d), 123.7 (d), 82.9 (s), 82.1 (s), 79.0 (s), 52.2 (t), 50.9 (t), 36.2 (t), 28.1 (q), 27.8 (q), 27.7 (q) ppm. MS m/z 353 (4.5), 266 (1.6), 151 (23), 106 (100), 77 (57), 57 (7). Compound 43 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 400 MHz) δ 7.88 (s, 1H), 7.55-7.47 (m, 5H), 5.23 (s, 2H), 4.51 (s, 2H), 4.49 (s, 2H) ppm.
[0106] Compound 44. Following the general procedure B, alkyne 2 (200 mg, 0.64 mmol) and azide 11 (186 mg, 0.64 mmol) in 1:1 H 2 O/t-BuOH (2.6 mL) give, after work-up and chromatographic purification (4:1 EtOAc-petr. et., Rf=0.69), protected adduct (228 mg, 59%), precursor of 44, as a white solid. 1 H NMR (CDCl 3 , 200 MHz) δ 7.62 (s, 1H), 7.44 (m, 5H), 4.91 (s, 2H), 4.27 (s, 2H), 4.18 (m, 2H), 3.02 (m, 2H), 1.48 (s, 9H), 1.46 (s, 9H), 1.44 (s, 9H) ppm; 13 C-NMR (CDCl 3 , 50 MHz) δ 167.1 (s), 165.1 (s), 163.1 (s), 160.0 (s), 154.6 (s), 143.2 (s), 140.7 (s), 130.1 (d), 129.0 (d), 127.8 (d), 123.3 (d), 83.9 (s), 82.2 (s), 78.7 (s), 52.4 (t), 50.9 (t), 44.3 (t), 28.4 (q), 28.1 (q), 28.0 (q), 25.4 (t) ppm. MS m/z 601 (M + , 0.3), 501 (0.9), 401 (3.7), 106 (11), 77 (4), 57 (49), 41 (100). Compound 44 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 400 MHz) δ 7.82 (s, 1H), 7.58-7.50 (m, 5H), 5.24 (s, 2H), 4.51 (s, 2H), 3.51 (m, 2H), 3.00 (m, 2H) ppm.
[0107] Compound 45. Following the general procedure B, alkyne 3 (197 mg, 0.61 mmol) and azide 11 (176 mg, 0.61 mmol) in 1:1 H 2 O/t-BuOH (2.4 mL) give, after work-up and chromatographic purification (4:1 EtOAc-petr. et., Rf=0.75), protected adduct (232 mg, 62%), precursor of 45, as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 9.30 (br, 2H), 7.63 (s, 1H), 7.48 (m, 5H), 4.92 (s, 2H), 4.27 (s, 2H), 3.95 (m, 2H), 2.74 (m, 2H), 1.95 (m, 2H), 1.48 (s, 9H), 1.47 (s, 9H), 1.43 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 167.0 (s), 165.1 (s), 163.4 (s), 160.4 (s), 154.7 (s), 146.3 (s), 140.6 (s), 130.7 (d), 129.0 (d), 127.8 (d), 122.7 (d), 83.7 (s), 82.1 (s), 78.5 (s), 52.3 (t), 51.0 (t), 44.1 (t), 28.3 (q), 28.1 (q), 28.0 (q), 23.0 (t), 21.8 (t) ppm. MS m/z 615 (M + , 0.2), 515 (0.5), 343 (20), 287 (15), 106 (22), 77 (9), 57 (100). Compound 45 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 400 MHz) δ 7.78 (s, 1H), 7.60-7.50 (m, 5H), 5.25 (s, 2H), 4.52 (s, 2H), 3.23 (t, J=6.8 Hz, 2H), 2.80 (t, J=7.2 Hz, 2H), 1.97 (m, 2H) ppm.
[0108] Compound 46. Following the general procedure B, alkyne 5 (372 mg, 0.98 mmol) and azide 11 (284 mg, 0.98 mmol) in 1:1 H 2 O/t-BuOH (4 mL) give, after work-up and chromatographic purification (12:1 CH 2 Cl 2 -MeOH, Rf=0.46), protected adduct (450 mg, 68%), precursor of 46, as an orange solid. 1 H NMR (CDCl 3 , 200 MHz) δ 7.59 (s, 1H), 7.45 (m, 5H), 4.94 (s, 2H), 4.28 (s, 2H), 3.62 (m, 4H), 2.90 (m, 2H), 2.70 (m, 2H), 2.57 (m, 4H), 1.48 (s, 9H), 1.47 (s, 9H), 1.44 (s, 9H) ppm. Compound 46 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 400 MHz) δ 8.01 (s, 1H), 7.53-7.34 (m, 5H), 5.2 (s, 2H), 4.44 (s, 2H), 4.07 (m, 2H), 3.75 (m, 2H), 3.65 (m, 2H), 3.57 (m, 4H), 3.25 (m, 4H) ppm.
[0109] Compound 47. Following the general procedure B, alkyne 2 (140 mg, 0.45 mmol) and azide 15 (125 mg, 0.45 mmol) in 1:1 H 2 O/t-BuOH (2.0 mL) give, after work-up and chromatographic purification (4:1 EtOAc-petr. et., Rf=0.43), protected adduct (159 mg, 60%), precursor of 47, as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 9.24 (br, 1H), 7.69 (s, 1H), 7.29-7.14 (m, 2H), 7.01-6.93 (m, 2H), 5.35 (m, 1H), 5.01 (s, 2H), 4.18 (m, 2H), 3.57 (s, 3H), 3.05 (m, 2H), 2.80 (m, 2H), 1.49 (s, 9H), 1.47 (s, 9H) ppm; 13 C NMR (CDCl 3 , 50 MHz) δ 170.5 (s), 164.3 (s), 161.6 (d, J CF =163 Hz), 159.4 (s), 154.4 (s), 145.4 (s), 135.5 (s), 127.8 (dd, J CF =8.3 Hz, 2C), 123.4 (s), 115.4 (dd, J CF =22 Hz, 2C), 84.0 (s), 78.8 (s), 52.8 (t), 51.9 (q), 49.5 (d), 44.1 (t), 39.8 (t), 28.3 (q), 28.0 (q), 25.3 (t) ppm. Compound 47 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. [α] 24 D +55.2 (c 0.5, H 2 O). 1 H NMR (D 2 O, 400 MHz) δ 7.86 (s, 1H), 7.41 (dd, J=8.8, 5.2 Hz, 2H), 7.16 (t, J=8.8 Hz, 2H), 5.31 (m, 1H), 5.26 (d, J=4.4 Hz, 2H), 3.52 (t, J=6.8 Hz, 2H), 3.04-2.97 (m, 4H) ppm.
[0110] Compound 48. Following the general procedure B, alkyne 3 (146 mg, 0.45 mmol) and azide 15 (125 mg, 0.45 mmol) in 1:1 H 2 O/t-BuOH (2.0 mL) give, after work-up and chromatographic purification (4:1 EtOAc-petr. et., Rf=0.6), protected adduct (96 mg, 37%), precursor of 48, as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 9.34 (br, 1H), 7.86 (br, 1H), 7.19-7.12 (m, 3H), 6.99-6.90 (m, 2H), 5.33 (m, 1H), 5.03 (s, 2H), 3.88 (m, 2H), 3.55 (s, 3H), 2.77 (t, 4H), 2.03 (m, 2H), 1.48 (s, 9H), 1.46 (s, 9H) ppm. Compound 48 is obtained after treatment with 3M HCl (2 mL) for 16 h at room temperature, followed by solvent evaporation. [α] 24 D +59.2 (c 0.3, H 2 O). 1 H NMR (D 2 O, 400 MHz) δ 7.81 (s, 1H), 7.42 (dd, J=8.8, 5.2 Hz, 2H), 7.17 (t, J=8.8 Hz, 2H), 5.32 (m, 1H), 5.26 (d, J=2.8 Hz, 2H), 3.22 (t, J=6.4 Hz, 2H), 3.00 (m, 2H), 2.82 (t, J=7.4 Hz, 2H), 1.98 (m, 2H) ppm.
[0111] Compound 49. Following the general procedure B, alkyne 3 (117 mg, 0.36 mmol) and azide 14 (100 mg, 0.36 mmol) in 1:1 H 2 O/t-BuOH (2.0 mL) give, after work-up and chromatographic purification (4:1 EtOAc-petr. et., Rf=0.6), protected 49 (88 mg, 34%) as a yellow oil with same NMR data as for precursor of 48. Compound 49 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation with same NMR data as for 48. [α] 24 D −56.0 (c 0.3, H 2 O).
[0112] Compound 50 (Scheme 7). Following the general procedure B, alkyne 7 (158 mg, 0.57 mmol) and azide 17 (107 mg, 0.57) in 1:1 H 2 O/t-BuOH (1 mL) give, after work-up and chromatographic purification (2:1 EtOAc-Et 2 O, Rf=0.3), adduct 61. 1 H NMR (CDCl 3 , 200 MHz) δ 8.18 (d, 1H), 7.53 (s, 1H), 7.30 (t, 2H), 7.05 (t, 2H), 5.43 (q, 1H), 5.03 (br, 1H), 4.41 (t, 2H), 3.71 (s, 2H), 3.64 (s, 3H), 3.61 (d, 2H), 3.09 (s, 2H), 2.92 (t, 2H), 2.33 (s, 3H), 1.40 (s, 9H) ppm. Successively, 61 is treated with a 1:1 TFA:CH 2 Cl 2 mixture (3.8 mL) for 2 h at room temperature, followed by solvent evaporation, thus giving compound 62 in 93% yield. 1 H NMR (D 2 O, 200 MHz) δ 8.03 (br, 1H), 7.26 (s, 1H), 7.14 (t, 2H), 6.87 (t, 2H), 5.02 (m, 1H), 4.53 (d, 2H), 4.29 (s, 3H), 3.80 (s, 2H), 3.38 (s, 2H), 3.31 (d, 2H), 2.68 (dd, 2H), 2.65 (s, 3H), 2.00 (s, 3H) ppm. To a solution of 62 (150 mg, 0.40 mmol) and triethylamine (62 μL, 0.40 mmol) in anhydrous CH 2 Cl 2 (2 mL) a solution of N,N′-di-Boc-N″-triflylguanidine (171 mg, 0.40 mmol) in anhydrous CH 2 Cl 2 (2 mL) is added, and the mixture is left reacting for 16 h at room temperature. After solvent evaporation and chromatographic purification (1:1 EtOAc-Et 2 O, Rf=0.14), compound 63 (55 mg, 0.09 mmol) is obtained in 25% yield. 1 H NMR (CDCl 3 , 200 MHz) δ 11.40 (s, 1H), 9.20 (d, 1H), 8.48 (m, 1H), 8.39 (d, 1H), 7.68 (t, 1H), 7.31 (t, 2H), 7.06 (t, 2H), 5.40 (q, 1H), 4.61 (t, 2H), 3.92 (q, 2H), 3.74 (s, 2H), 3.62 (s, 3H), 3.18 (s, 2H), 2.37 (s, 3H), 1.51 (s, 9H), 1.47 (s, 9H) ppm. Compound 50 is achieved in quantitative yield after treatment of 63 (55 mg, 0.09 mmol) with 3M HCl (1 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 8.09 (s, 1H), 7.21 (m, 2H), 6.95 (t, J=8.7 Hz, 2H), 5.10 (t, J=5.7 Hz, 1H), 4.48-4.40 (m, 6H), 3.91 (s, 2H), 3.55 (m, 2H), 2.78 (s, 3H) ppm; 13 C NMR (D 2 O, 50 MHz) d 173.5 (s), 163.6 (s), 163.2 (s), 157.3 (d, J CF =140 Hz), 135.2 (s), 134.7 (s), 127.4 (d, 2C), 127.3 (s), 114.8 (dd, J CF =11 Hz, 2C), 55.0 (d), 49.5 (q), 49.3 (t), 48.6 (t), 44.7 (t), 40.6 (t), 39.9 (t), 39.1 (t). [α] 24 D +18.6 (c 0.3, H 2 O).
[0113] Compound 51. Compound 51 is prepared according to the procedure for the synthesis of 50, starting from alkyne 6 (122 mg, 0.65 mmol) and azide 17 (180 mg, 0.65 mmol), with same NMR data as for 50. [α] 24 D +23.2 (c 0.3, H 2 O).
[0114] Compound 52. Following the general procedure C, alkyne 2 (100 mg, 0.306 mmol), azide 20 (80 mg, 0.306 mmol) and iodo(triethylphosphite)Cu (11 mg, 0.0306 mmol) in anhydrous THF (2 mL) give, after purification (2:1 EtOAc-petr. et. Rf=0.35), protected adduct as a yellow oil (140 mg, 86% yield). 1 H NMR (CDCl 3 , 200 MHz) δ 9.45 (br, 1H), 9.35 (br, 1H), 7.68 (d, 2H), 7.55 (s,1H), 7.31 (d, 2H), 4.62 (pt, 2H), 4.38 (pt, 2H), 4.13 (q, 2H), 3.83 (s, 2H), 3.68 (t, 2H), 3.02 (pt, 2H), 2.43 (s, 3H), 1.52 (s, 9H), 1.46 (s, 9H), 1.25 (t, 3H) ppm. Compound 52 is obtained after treatment with 3M HCl (3 mL) for 16 h at 30° C., followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 7.70 (s,1H), 7.44 (d, 2H), 7.24 (d, 2H), 4.44 (t, 2H), 3.98 (t, 2H), 3.67 (pt, 2H), 3.33 (t, 2H), 2.79 (t, 2H), 2.28 (s, 3H) ppm.
[0115] Compound 53. Following the general procedure C, alkyne 3 (100 mg, 0.306 mmol), azide 20 (830 mg, 0.306 mmol) and iodo(triethylphosphite)Cu (11 mg, 0.0306 mmol) in anhydrous THF (3 mL) give, after purification (2:1 EtOAc-petr. et., Rf=0.35), protected adduct as a yellow oil (140 mg, 84% yield). 1 H NMR (CDCl 3 , 200 MHz) δ 9.40 (br, 21H), 7.67 (d, 2H), 7.58 (s,1H), 7.29 (d, 2H), 4.60 (t, 2H), 4.05 (q, 2H), 3.93 (t, 2H), 3.83 (s, 2H), 3.72 (t, 2H), 2.75 (t, 2H), 2.42 (s, 3H), 1.97 (s, 3H), 1.51 (s, 9H), 1.49 (s, 9H),1.15 (t, 3H) ppm. Compound 53 is obtained after treatment with 3M HCl (5 mL) for 16 h at 30° C., followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 7.67 (s,1H)7.42 (d, 2H), 7.22 (d, 2H), 4.43 (t, 2H), 4.00 (t, 2H), 3.67 (pt, 2H), 3.04 (t, 2H), 2.57 (t, 2H), 2.28 (s, 3H), 1.76 (t, 2H) ppm. 13 C NMR (D 2 O, 50 MHz) δ 168.4 (s), 163.7 (s), 160.6 (s), 154.9 (s), 143.9 (s), 135.6 (d), 129.7 (d), 127.3 (d), 61.4 (t), 49.8(t), 49.6 (t), 48.9 (t), 44.1 (t), 28.3 (t), 28.0 (q) ppm.
[0116] Compound 54. Following the general procedure C, alkyne 3 (189 mg, 0.68 mmol), azide 16 (200 mg, 0.615 mmol) and iodo(triethylphosphite)Cu (24 mg, 0.068 mmol) in anhydrous THF (4 mL) give, after purification (5:1 EtOAc-petr. et., Rf=0.48), protected adduct as a yellow oil (88% yield). 1 H NMR (CDCl 3 , 200 MHz) δ 9.45 (br, 1H), 8.02 (br, 1H),7.35 (br, 1H), 7.62 (s,1H), 7.00 (d, 2H), 6.72 (d, 2H), 5.38-5.22 (m, 1H), 5.00 (s, 2H), 3.85 (m, 2H), 3.50 (s, 3H), 2.90-2.60 (m, 4H), 1.95 (m, 2H), 1.45 (s, 9H,), 1.39 (s, 9H) ppm. Compound 54 is obtained after treatment with 3M HCl (3 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 7.63 (s, 1H), 7.10 (d, 2H), 6.72 (d, 2H), 5.10-5.05 (m, 1H), 5.06 (s, 2H), 3.02 (t, 2H), 3.78 (d, 2H), 2.62 (t, 2H), 1.78 (m, 2H) ppm.
[0117] Compound 55. Following the general procedure B, alkine 3 (200 mg, 0.62 mmol) and azide 18 (170 mg, 0.62 mmol) in 1:1 H 2 O/t-BuOH (5 mL) give, after purification (30:1 CH 2 Cl 2 -methanol, Rf=0.7), protected adduct as a yellow oil. 1 H-NMR (CDCl 3 , 200 MHz) δ 9.34 (sb, 2H), 7.77 (s, 1H), 6.72 (sb, 1H), 4,95 (s, 2H), 3.91 (q, 2H), 3.62 (s, 3H), 3.49 (q, 2H), 2.76 (t, 2H), 2.50 (t, 2H), 2.14-1.90 (m, 2H), 1.47 (s, 9H), 1.46 (s, 9H). Compound 55 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 7.84 (s, 1H), 5.10 (s, 2H), 3.36 (t, 2H), 3.08 (t, 2H), 2.75-2.62 (m, 2H), 2.47 (t, 2H), 1.83 (t, 2H) ppm. 13 C NMR (D 2 O, 50 MHz) δ 177.8 (s), 166.9 (s), 156.7 (s), 146.0 (s), 126.1 (d), 52.9 (t), 42.2 (t), 38.9 (t), 31.0 (t), 27.0 (t), 21.0 (t) ppm.
[0118] Compound 56. Following the general procedure B, alkine 3 (200 mg, 0.62 mmol) and azide 19 (132 mg, 0.62 mmol) in 1:1 H 2 O/t-BuOH (5 mL) give, after purification (1:1 EtOAc-petr. et., Rf=0.7), protected adduct as a yellow oil. 1 H NMR (CDCl 3 , 200 MHz) δ 9.50 (sb, 1H), 7.95 (s, 1H), 5.15 (s, 2H), 4.25 (q, 2H), 4.11-4.08 (m, 2H), 3.45-3.41 (m, 2H), 2.94 (t, 2H), 2.44 (t, 2H), 2.41 (s, 1H), 2.17-2.15 (m, 2H), 1.96-1.91 (m, 2H), 1.65 (s, 9H), 1.64 (s, 9H), 1.37 (t, 3H,) ppm. Compound 56 is obtained after treatment with 3M HCl (5 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 7.92 (s, 1H), 5.14 (s, 2H), 3.15-3.04 (m, 4H), 2.71 (t, 2H), 2.20 (t, 2H), 1.85-1.78 (m, 2H), 1.68-1.61 (m, 2H) ppm. 13 C NMR (D 2 O, 50 MHz) δ 177.8 (s), 166.9 (s), 156.7 (s), 146.0 (s), 126.1 (d), 52.9 (t), 42.2 (t), 38.8 (t), 31.0 (t), 27.0 (t), 23.7 (t), 21.0 (t) ppm.
[0119] Compound 57. Following the general procedure B, alkyne 10 (73 mg, 0.26 mmol) and azide 14 (108 mg, 0.26 mmol) in H 2 O/t-BuOH 1:1 (35 mL) give, after purification (3:1 EtOAc-petr. et., Rf=0.55), protected adduct as a yellow oil (75 mg, 42% yield). 1 H NMR (CDCl 3 , 200 MHz) δ 7.85 (s, 1H), 7.72-7.45 (m, 4H), 7.22 (s, 1H), 7.22-7.15 (m, 2H), 7.00-6.96 (m, 2H), 5.25 (q, 1H), 5.05 (s, 2H), 3.95-3.85 (m, 2H), 3.56 (s, 3H), 3.83 (t, 4H), 2.04 (s, 2H,), 1.50 (s, 9H), 1.48 (s, 9H), 1.25 (t, 2H) ppm. Compound 57 is obtained after treatment with 3M HCl (3 mL) for 16 h at room temperature, followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 7.75-7.65 (m, 1H), 7.65 (s, 1H), 7.58-7.35 (m, 3H), 7.28-7.17 (m, H,), 7.05-6.91 (m, 2H), 5.16-5.08 (m, 1H), 5.07 (s, 2H), 3.05 (t, 3H), 2.81 (d, 2H), 2.66 (t, 3H), 1.84-1.70 (m, 2H). 13 C NMR (D 2 O, 50 MHz) δ 173.6 (s), 165.9 (s), 161.1 (d, J C-F =243.50), 155.8 (s), 145.9 (s), 134.9 (d, J C-F =2.75), 132.30 (s), 131.1 (s), 130.9 (d), 128.2 (d), 127.9 (d), 127.3 (d, J C-F =31.20), 126.3 (d), 124.0 (d), 114.9 (d), 114.5 (d), 113.4 (d), 51.4 (d), 49.3 (t), 39.4 (t), 38.9 (t), 26.5 (t), 20.6 (t) ppm.
[0120] Compound 58. Following the general procedure C, alkyne 9 (400 mg, 0.718 mmol), azide 12a (209 mg, 0.79 mmol) and iodo(triethylphosphite)Cu (28 mg, 0,079 mmol) in anhydrous THF (4 mL) give, after purification (5:1 CH 2 Cl 2 —CH 3 OH, Rf=0.35), protected adduct as a yellow oil (120 mg, 20% yield). 1 H NMR (CDCl 3 , 200 MHz) δ 7.52 (s, 1H), 7.38-7.18 (m, 5H), 5.43-5.37 (m, 1H), 5.03 (s, 2H),3.75-3.20 (m, 6H), 3.58 (s, 3H), 3.20-3.05 (m, 4H), 2.90-2.63 (m, 2H), 2.45-2.35 (m, 1H), 2.20-1.80 (m, 4H), 1.85-1.05 (m, 8H), 1.47 (s, 9H,), 1.43 (s, 9H) ppm. Compound 58 is obtained after treatment with 3M HCl (5 mL) for 16 h at 30° C., followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 7.67 (s, 1H), 7.34-7.18 (m, 5H), 5.18-5.12 (m, 1H), 5.09 (s, 2H), 3.75-3.70 (m, 2H), 3.30-2.95 (m, 4H), 2.90-2.75 (m, 4H), 2.75-2.60 (m, 3H), 2.30-2.00 (m, 4H), 1.95-1.80 (m, 2H), 1.50-1.25 (m, 2H),1.20-1.05 (m, 4H) ppm.
[0121] Compound 59. Following the general procedure C, alkyne 8 (280 mg, 0.69 mmol), azide 12a (182 mg, 0.69 mmol) and iodo(triethylphosphite)Cu (25 mg, 0.069 mmol) in anhydrous THF (4 mL) give, after purification (EtOAc, Rf=0.53), protected adduct as a yellow oil (364 mg, 82% yield). 1 H NMR (CDCl 3 , 200 MHz) δ 9.50 (d, 1H), 7.37 [s,1H), 7.31-7.18 (m, 5H), 6.93 (d, 2H), 6.48 (d, 2H), 5.45-5.38 (m, 1H), 5.02 (s, 2H), 3.62 (s, 3H), 3.52 (t, 2H), 3.40 (m, 2H), 3.00-2.90 (m, 2H), 2.75 (t, 2H), 2.45 (t, 2H), 1.70-1.50 (m, 2H), 1.45 (s, 9H), 1.39 (s, 9H) ppm. Compound 59 is obtained after treatment with 3M HCl (5 mL) for 16 h at 30° C., followed by solvent evaporation. 1 H NMR (D 2 O, 200 MHz) δ 7.54 (s,1H), 7.26-7.18 (m, 5H), 6.93 (d, 2H), 6.60 (d, 2H), 5.18-5.0 5 (m, 1H), 5.06 (s, 2H), 3.32 (t, 2H), 2.90 (m, 2H), 2.80 (d, 2H), 2.58 (t, 2H), 2.48 (t, 2H), 1.70-1,60 (m, 2H) ppm.
[0122] Solid-phase receptor binding assay. [ 125 I]-Echistatin, labelled according to the lactoperoxidase method and with a specific activity of 2000 Ci/mmol, and αvβ3 and αvβ5 integrins, purified from human placenta, are used for the in vitro assays. Purified αvβ3 and αvβ5 receptors are respectively diluted to 500 ng/mL and 1000 ng/mL in 20 mM Tris (pH 7.4), 150 mM NaCl, 2 mM CaCl 2 , 1 mM MgCl 2 , 1 mM MnCl 2 . An amount of the diluted receptor solutions (100 μL/well) is added to a 96-well microtiter plate (Optiplate-96 HB, PerkinElmer Life Sciences, Boston, Mass.) and incubated at 4° C. for 16 h. Then, the plate is washed once with an incubation buffer [20 mM Tris (pH 7.4), 150 mM NaCl, 2 mM CaCl 2 , 1 mM MgCl 2 , 1 mM MnCl 2 , 1% BSA] and incubated for additional 2 h at room temperature. The plate is treated twice with the same buffer, and competitive binding experiments are carried out with a fixed concentration of [ 125 I]-Echistatin (0.05 nM and 0.1 nM for αvβ3 and αvβ5 respectively) and concentrations of the test compounds ranging from 0.01 nM to 100 μM. All the assays are carried out in triplicate at a final volume of 0.2 mL, each containing the following species: 0.05 mL of [ 125 I]-Echistatina, 0.04 mL of the test compounds, and 0.11 mL of the incubation buffer. Non-specific binding is defined as the [ 125 I]-Echistatin bound in the presence of excess (1 μM) of non-labelled echistatin. After an incubation period of 3 h at room temperature, the plate is washed three times with the incubation buffer, then the radioactivity is measured in a plate counter Top-Count NXT (Perkin Elmer Life Sciences, Boston, Mass.) using 200 μL/well of scintillating liquid MicroScint-40 (PerkinElmer Life Sciences, Boston, Mass.). Data analysis. IC 50 values are determined by fitting the binding inhibition data with a non-linear regression, using the GraphPad Prism 4.0 software package (GraphPad Prism, San Diego, Calif.). Moreover, where the curves show a Hill slope significantly lower than the unit (K<−0.80), the data are further analyzed according to a two-sites model. The inhibition curves better fitted according to a two-sites model (p<0.05) rather than a single-site model are considered to be significant.
[0123] Melanoma cell line assay. The selected cell line for this study is the A375M, which are in vivo selected melanoma cells starting from A375P cells isolated from a amelanotic human melanoma. The expression of the RGD-dependent integrinic pattern, comprising αvβ3, αvβ5, α5β1 integrins, of A375M cells is determined by the flux cytometry technique (FACScanto, Becton & Dickinson) and by RT-PCR. With aim to evaluate the ability of compounds of formula (I) of binding to integrins exposed to the melanoma cells surface, the inhibition of adhesion of such cells to vitronectin, fibronectin and osteopontin are measured. A spectrophotometric evaluation of the cellular content of the culture plates used in the adhesion tests allows for the precision and the correlation of the results obtained in different experiments.
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The present invention refers to the field of chemical compounds bearing a 1,2,3-triazole ring of formula (I) and possessing guanidino and carboxylic groups or their isosteres, their preparation by Cu-catalyzed “click-chemistry”, and medical-diagnostic use in pathologies where angiogenesis is altered, for example pathologic conditions of tumor origin, tumor metastasis, osteoporosis, and rheumatoid arthritis.
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TECHNICAL FIELD
The present invention relates to a device for obtaining predetermined linear forces, and in particular to a device where the force obtained is substantially constant. These forces are primarily intended for training of the skeleton muscles, but due to its exceptional properties they can be used in various medical, technical and other applications where its features are beneficial.
BACKGROUND OF THE INVENTION
Most of the training equipment present on the market today are designed according to a few construction concepts: devices based on the movement of weights, devices comprising springs and other elastic elements, devices based on friction, actuators like clutches, brakes, fluid valves, (pneumatic, hydraulic), etc. and motor-driven devices.
In order to gain an insight into a training progression and to optimise the training result, it is extremely important to control the relevant movement parameters for muscles such as: load force, contraction speed, acceleration etc. The essential accent in this direction is to be able to exercise muscles with given load values.
When using weights, the gravitation force is used in order to obtain a load on the muscles. The mass of the weights is given and corresponds to the force of the weights during rest only. When lifting the weights during a certain time interval its mass is accelerated unavoidably. Any acceleration of a mass creates time dependent forces of inertia that are the product of the mass and the acceleration values during that time period.
From the medical, exercising and competition experience it is widely known that load variations caused by inertial force can be significant. Therefore, in order to enable some reasonably acceptable controlled training and avoid muscle and ligament injuries, lifting of weights has to be performed with as low as possible acceleration. Due to a relatively short weight lifting length, only relatively low speeds can be used in order to have a low acceleration. It will therefore be impossible during training with weights, or weight-based training equipment, to perform a movement with both arbitrary given muscle contraction loads and speeds simultaneously. Inertial force drastically restricts the freedom regarding selection of speed and acceleration in exercise. The limitation lies in the fact that instantaneous muscle power, strength or effects (product of muscle force and contraction speed) appearing during acceleration of a weight, can easily exceed a maximal tolerable value of a muscle, which value the muscle can't reach, or if reached the muscle can be injured. Consequently it is practically impossible to regularly exercise of the essential physical training magnitude i.e. the actual muscle strength.
During training with a so-called “isokinetic” machine, the problem is the reverse. In this case the speed of the muscle contraction is given, while the muscle load is arbitrarily fluctuating.
Further, weight-based training equipment has other drawbacks depending on their weight. They must therefore be placed in training facilities with robust under-carriage and should not be in movement or be swinging. Because weights during lifting can be moved only vertically, a certain orientation in space is always needed, which limits the freedom of the construction and the installation possibilities.
With friction-based equipment, a load is obtained which is dependent partly on acceleration, but particularly on speed. By continuously controlling a friction force with breaks, clutches and valves, the dependency of the movement dynamics can partly be reduced. However, the major drawback with using friction forces is that they are reactive and thereby passive, which prevents training with very favourable and desirable so called negative muscle work.
BRIEF DESCRIPTION OF THE INVENTION
The present invention has as an aim to provide a device that provides predetermined linear forces/torques, (increasing and decreasing), that gives the desired output depending on the area of application.
This is obtained with a device according to patent claim 1 . Preferable embodiments are characterised by the dependent claims.
According to one aspect of the invention it is characterised by a device for obtaining a predetermined linear force, including a first elastic force means and a force output means in the form of a non-elastic, flexible elongated member, characterised by a force transformation means arranged between said first elastic force means and the force output means, such that a pulling of the force output means creates a tension in said first elastic force means, and wherein the force transformation means is arranged and designed such that the pulling force required on the force output means decreases with the distance the force output means is pulled.
According to another aspect of the invention it is characterised in that it includes a second elastic force means and a second force output means attached to said second elastic force means, wherein the pulling force required on the second force output means increases with the distance the force output means is pulled, that the two force output means are connected to each other such as to summarise the forces, and in that the characteristics of the two elastic force means are chosen such that the pulling force is substantially constant during the pulling distance.
According to a further aspect of the invention it is characterised in that the pulling end of said first force output means is attached to a rotation means rotatable around a shaft at a distance, in that the pulling end of said second force output means is attached to said rotation means at a distance such that a torque is obtained which is constant during turning of said rotation means.
The advantages with the present invention in contrast to known devices are several. By providing a force that decreases as the output means is pulled, where the decreasing force is proportional to the pulled length, several functions may be obtained. There are several applications where it is desirable to have such a decrease as the output means is pulled out.
Further, by combining this decreasing force with a force increasing with the distance the output means is pulled, different resulting forces can be obtained. According to a preferred feature of the invention, the decreasing force and increasing force are combined such that the resulting force is a constant force, which is independent on load impulses and -speeds/accelerations.
When the output means is connected to a rotation means, a constant torque is obtained around the axis of rotation of the rotating means.
As regards training, the constant force/torque provided by the present invention gives anatomically and physiologically natural desirable combinations of muscle load forces and the derivates (speeds or accelerations) of the muscle contraction length, which combinations are preferably easily pre-set. The device according to the invention enables a controlled and regular training of a given muscle strength. Further the device according to the invention is extremely effective for training of the explosive muscle strength, which is very important for top athletes. It is accomplished by allowing the muscles to contract with a given or maximum acceleration or speed with a given muscle load. Thereby a widened area of use is obtained from rehabilitation to body-building and competition sport.
Further the present invention can provide a totally mechanical device, which can be arbitrary positioned in space and is neither bully nor heavy, but rather portable and easy to transport and further cost effective to manufacture and maintain.
These and other aspects of, and advantages with, the present invention will be apparent from the following detailed description and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the detailed description reference will be made to the accompanying drawings, of which
FIG. 1 shows schematically the principle of the present invention where a constant torque is obtained,
FIG. 2 shows a diagram over the forces acting in the present invention,
FIG. 3 shows schematically the principle of the present invention where a constant force is obtained, and
FIG. 4 shows one embodiment of a device according to the principle of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The principle according to the present invention will be described in conjunction with the device shown in FIG. 1 . It comprises an arm 10 with a length l 1 rotatably attached with one end to a shaft O 1 . The area of rotation α is within a range 0≦α≦π radians. A flexible but inelastic band 12 , hereafter named first band, is attached to the free end A of the arm. It is to be understood that the wording “flexible but inelastic” is meant to define a band or wire that is substantially free of elasticity in the longitudinal direction of the band but can be bent in the transversal direction. The band runs downwards over a pulley wheel S 1 , which pulley wheel is arranged on a horizontal plane 14 in FIG. 1 , which plane intersects the axis of rotation of the arm 10 and with the same distance between the pulley wheel and the axis of rotation as the length of the arm 1 1 =A O 1 =S 1 O 1 . The first band is attached to an elastic element Ee 1 .
When turning the arm 10 clock-wise an angle α, the portion of first band 12 which is between the pulley wheel and the attachment to the arm, has a length X 1 , and it is equal to the extension of the elastic element Ee 1 . In the band 12 an elastic force is then created according to formula
Fe 1 =K 1 ·X 1 (1)
where K 1 is the elasticity coefficient for the elastic element.
A second flexible, but inelastic, band 16 is fixated to the arm 10 at a point B between the axis of rotation O 1 and the attachment point A for the first band. The attachment point B of the arm lies on I 2 distance from the axis of rotation O 1 . It can be somewhat adjustable along the arm, for reasons that will be explained below. The second band is led via a second pulley wheel S 2 , which also is placed on the above mentioned horizontal plane with the distance l 2 from the axis of rotation O 1 of the arm (i.e. BO 1 =S 2 O 1 ), to a wheel 18 , hereafter named first wheel, where the second band is attached to the periphery of the wheel at a point D. A stop member 19 is arranged on the periphery of the first wheel to come in contact with the second pulley wheel S 2 in order to prevent the first wheel from turning anti-clockwise. Thus, the initial position of the device according to FIG. 1 is when the stop member is in contact with the second pulley wheel. Other types of stop members are of course possible in order to obtain the desired function.
In order to get the proper function of the device, the described elements must be geometrically arranged so that in any position of the arm 10 , both bands must be always in the touch (by being tangent to or by braking over) with the corresponding pulley wheels (S 1 and S 2 ). The first wheel is rotatably arranged to a shaft O 2 and has a radius R. The first wheel is so positioned that its upper peripheral surface as seen in FIG. 1 , is tangent to the above-mentioned horizontal plane 14 . During turning of the first wheel clock-wise with an angle γ, the other band is wound with a length X 2 =R·γ.
Thereby the other band 16 is tensioned with a certain force F 2 . In the initial position (γ=0) the other band is loosely tensioned with a force F 2 =±0.
During rotation of the first wheel, i.e. pulling of the second band 16 with a length X 2 the arm 10 is forced to turn clock-wise around its shaft O 1 a certain angle α. This turning means in turn that the arm 10 pulls the first band 12 a distance X 1 in that the first elastic element Ee 1 is extended. In the first band an elastic force according to equation (1) is obtained.
The forces in the first and second band 12 , 16 each create torques counteracting each other. In a stationary position these torques are equal, ie M 1 =Fe 1 ·h 1 =M 2 =F 2 ·h 2 . If Fe 1 is substituted with equation (1) one obtains:
K 1 ·X 1 ·h 1 =F 2 ·h 2 (4)
From the geometry, the following equations may be formulated:
β=α/2 (5)
h 1 =L 1 ·cos(α/2)= L 1 ·cos β (6)
h 2 =L 2 ·sin β (7)
( X 1 /2)= L 1 ·sin(α/2)= L 1 ·sin β
ie.
X 1 =2 ·L 1 ·sin(α/2)=2 ·L 1 ·sin β (8)
( BS 2 /2)= L 2 ·cos β (9)
X 2 =2 ·L 2 −BS 2 (10)
From the equations (9) and (10) is obtained:
X 2 =2 ·L 2 −2 ·L 2 ·cos β, and
cos β=(2 ·L 2 −X 2 )/(2 ·L 2 ) (11)
If cos β from equation (11) is inserted into equation (6), one obtains:
h 1 =L 1 ·(2· L 2 −X 2 )/(2 ·L 2 ) (12)
If the variables in equation (4) are substituted with equations (12), (7) and (9), one obtains:
K 1 ·2 ·L 1 ·sin β· L 1 ·(2 ·L 2 −X 2 )/2 ·L 2 =F 2 ·L 2 ·sin β.
ie
F 2 =K 1 ·L 1 2 ·(2· L 2 −X 2 )/ L 2 2 =K 1 ·( L 1 /L 2 ) 2 ·(2 ·L 2 −X 2 )=2 ·K 1 ·L 1 2 /L 2 −K 1 ·( L 1 /L 2 ) 2 ·X 2 (13)
As can be seen from equation (13) in the area of 0≦X 2 ≦2·L 2 F 2 is a linearly decreasing as X 2 becomes larger, i.e. as the second band is pulled further and further. This further provides a linearly decreasing torque around the shaft O 2 as the first wheel is turned according to M 2o2 =F 2 ·R.
A second wheel 20 is attached to the first wheel and also rotatably arranged to the shaft O 2 . The second wheel 20 has a radius r, that in the embodiment shown is smaller than the radius R of the first wheel. A third flexible but inelastic band 22 is with one end attached to the periphery of the second wheel at a point E. The other end of the third band is attached to a second flexible element Ee 3 . The second wheel is geometrically so positioned that the band 22 always is in tangent with the second wheel at the point where the band first touches the wheel surface. During clock-wise turning of the second wheel an elastic force is obtained in the third band according to
Fe 3 =K 3 ·( X 3 +X 3 (0)) (2)
where X 3 (0) is the resilience of Fe 3 during initial position (γ=0, i.e. X 3 =0), which creates the pre-tension force K 3 ·X 3 (0). The pre-tensioning is made possible because of the stop member 19 in contact with the first pulley wheel. Fe 3 is thus linearly increasing as the band 22 is pulled. A linearly increasing torque M 3 =Fe3·r is thus obtained.
The first and the second wheels 18 , 20 are used in order to summarize a linearly decreasing torque M 2o2 with a linearly increasing torque Me 3 around the shaft O 2 in a way, and for a purpose, which will be described below.
If one assumes that a torque Ms is applied to both wheels and turns them simultaneously with a certain angle γ radians clockwise, as is shown in FIG. 1 , the second band 16 is wound up on the first wheel 18 with a length X 2 =R·γ, and the third band 22 is wound up on the second wheel 20 with a length X 3 =r·γ, then the following equation is valid as:
Ms=M 3 +M 2o2 =
M s =R·F 2 +r·F 3 =R·F 2 +r·K 3 ·( X 3 +X 3 (0)) (3)
The resulting torque Ms that the forces F 2 and F 3 exert around the shaft O 2 according to equation (3) can thus be expressed as
Ms =2 ·R·K 1 ·L 1 2 /L 2 −R·K 1 ·( L 1 /L 2 ) 2 ·X 2 +r·K 3 ·( X 3 +X 3 (0))=
2 ·R·K 1 ·L 1 2 /L 2 −R·K 1 ·( L 1 /L 2 ) 2 ·X 2 +r·K 3 ·X 3 +r·K 3 ·X 3 (0)=
2 ·R·K 1 ·L 1 2 /L 2 −R·K 1 ·( L 1 /L 2 ) 2 ·R·γ+r·K 3 ·r·γ+r·K 3 ·X 3 (0)=
2 ·R·K 1 ·L 1 2 /L 2 +r·K 3 X 3 (0)+( r 2 ·K 3 −R 2 ·K 1 ·( L 1 /L 2 ) 2 )·γ (14)
In order to obtain a torque that is independent of the turning angle γ, ie constant, then
r 2 ·K 3 −R 2 ·K 1 ·( L 1 /L 2 ) 2 =0
( r/R ) 2 ·( K 3 /K 1 )=( L 1 /L 2 ) 2 , or
K 3 /K 1 =( L 1 ·R /( r·L 2 )) 2 (15)
At the prerequisite that the parameters in equation (15) fulfil the equation the constant torque will then be:
Ms= 2 ·R·K 1 ·L 1 2 /L 2 +r·K 3 ·X 3 (0) (16)
where 0≦X 3 (0)≦X 3 (0)max
The range within which the torque Ms can be set is thus
Ms min =2 ·R·K 1 ·L 1 2 /L 2
Ms max =2 ·R·K 1 L 1 2 /L 2 +r·K 3 ·X 3 (0)max
μ=( Ms max −Ms min )/ Ms min=
= r·K 3 ·X 3 (0)max/(2 ·R·K 1 ·L 1 2 /L 2 ) (17)
where μ is a given design parameter which defines the ratio between the variable part and the fixed part of the torque Ms and is intended for the dimensioning of X 3 (0)max, ie.
X 3 (0)max=(2 ·R·K 1 L 1 2 /L 2 ·μ)/( r·K 3 ) (18)
With a suitable mechanical design X 3 (0) can be varied with a desired precision. FIG. 2 shows the two torques as a function of the turning angle γ and the summation in order to obtain the constant torque Ms. As can be seen from the figure, the inclination of the two torques should be the same but with opposite signs in order to obtain the constant torque Ms. This is obtained by the suitable choice of the figuring parameters (K 3 , K 1 , L 1 , R, r and L 2 ) which satisfies the equation 15. However due to influences such as smaller deviations of the parameters of the equation 15, from the calculated values, it might be necessary to adjust one or more suitable parameters of the equation 15 in order to obtain a constant torque. This may for example be done by adjusting the attachment point B along the arm 10 somewhat.
As can be seen from FIG. 2 , and as can be noted from the above, the level of the torque Ms can be pre-set by changing the pre-tension of the elastic element Ee 3 .
A few examples of choice of dimensions:
1. If one chooses R=r and L 1 =L 2 =X 3 (0)max=L, then equation is fulfilled with K 1 =K 3 =K and
Ms=R·K·(2L+X 3 (0)), Ms min =2·R·K·L, Ms max =3·R·K·L
2. If one chooses R=r and L 1 =2·L 2 =X 3 (0)max=L then K 3 =4·K 1 =4·K, and
Ms=4·R·K·(L+X 3 (0)), Msmin=4·R·K·L, Msmax=8·R·K·L
FIG. 3 shows another summation device. Instead of a rotating wheel, a handle 30 or the like means may be employed in order to obtain a constant linear force Fs. Also here a stop member 19 is arranged in order to prevent the handle from moving beyond an initial position and to enable the pre-tensioning of the second flexible element.
Fs
=
F
2
+
F
3
=
2
·
K
1
·
L
1
2
/
L
2
-
K
1
·
(
L
1
/
L
2
)
2
·
X
2
+
K
3
·
(
X
3
+
X
3
(
0
)
)
(
19
)
Both bands are pulled simultaneously. Therefore they always pass the same distance at a time i.e.:
X 2 =X 3 =X (20)
Fs
=
2
·
K
1
·
L
1
2
/
L
2
-
K
1
·
(
L
1
/
L
2
)
2
·
X
+
K
3
·
(
X
+
X
3
(
0
)
)
=
2
·
K
1
·
L
1
2
/
L
2
-
K
1
·
(
L
1
/
L
2
)
2
·
X
+
K
3
·
X
+
K
3
·
X
3
(
0
)
)
=
2
·
K
1
·
L
1
2
/
L
2
+
K
3
·
X
3
(
0
)
)
+
(
K
3
-
K
1
·
(
L
1
/
L
2
)
2
)
·
X
(
21
)
The condition for the constant value of Fs is if the coefficient in the front of X is zero i.e.:
K 3 −K 1 ·( L 1 /L 2 ) 2 =0
Or
K 3 /K 1 =( L 1 /L 2 ) 2 (22)
Then the constant value of Fs is:
Fs= 2 ·K 1 ·L 1 2 /L 2 +K 3 ·X 3 (0)) (23)
where the value of this constant is pre-set by changing the distance of X 3 (0)).
FIG. 4 shows a practically realised and tested embodiment comprising the principle described above. The embodiment is intended as exercise equipment for training of muscles, The device comprises a base plate or a frame 50 of a rigid material. A side wall 52 is fixedly attached to the base plate. A number of guide rods 54 are attached to the side wall forming two sets of guide posts. Within each set of guide posts a compression spring is arranged, 56 , 58 , which compression springs are in contact with the side wall and a respective pressure plate 60 , 62 . The pressure plates are arranged movable along the guide rods and guided by them. To the upper pressure plate 60 as seen in FIG. 4 a pull rod 64 is attached, extending inside the spring in the longitudinal direction of the spring. A non-elastic but flexible band or wire 66 is attached to the pull rod. The band runs around a first pulley wheel 68 , which is rotatably arranged to the base plate, then around a second pulley wheel 70 , rotatably arranged to the base plate. The second pulley wheel corresponds to the wheel S 1 of FIG. 1 . The end of the band is attached to the end of an arm 72 , which arm is rotatably arranged around a shaft 74 attached to the base plate.
The arm corresponds to the arm 10 of FIG. 1 . A second non-elastic but flexible band or wire 76 is attached to the same end of the arm as band 66 . The second band runs around a third pulley wheel 78 , corresponding to the wheel S 2 of FIG. 1 , and is attached to the peripheral surface of a wheel 80 , which wheel is attached to a shaft 82 , which in turn is rotatably attached to the base plate. A stop member (not shown) is arranged to prevent the wheel 80 to rotate anti-clockwise more than the initial position shown in FIG. 4 . An exercise handle 84 , shown with broken lines in the figure, can be attached to the shaft. Drive moment is obtained by turning the handle 84 clockwise.
A third non-elastic but flexible band or wire 86 is with one end attached to the peripheral surface of the wheel. The third band runs via a fourth pulley wheel 88 around a fifth pulley wheel 90 , which is rotatably attached to a pull rod 92 arranged to the second spring 58 . The second pull rod is attached to the pressure plate 62 . The third band then runs to a fastening element 94 onto which the other end of the third band is attached. The fastening element consists of a rectangular plate or block, through which a threaded hole is arranged. A threaded shaft 96 is arranged through the hole and is rotatably supported at each end by bearings 98 . One end of the threaded shaft is protruding outside the base plate, and is provided with a handle 100 for turning the threaded shaft. When turning the handle, the pre-tension of the second spring can be adjusted as desired.
The equation 15 is satisfied by the selection of parameters as follows:
R=r, K 3 =K 1 and L 1 =L 2
Both springs are of the same length and can be equally maximally elastically compressed.
As can be understood from the above described principle of the invention, it can provide other forces/torques as a function of the turning angle.
Since the force F 2 is linearly decreasing as a function of the distance X 2 , and the turning angle γ in the embodiment of FIG. 1 , this can be used in different areas. One such area is a door-closing device. If one assumes that a door is arranged with its hinges at position O 2 , the more the door opens, is turned clock-wise in the figure, the less is the torque that tries to close the door. When closing the door, the closing force becomes stronger the more the door is closed.
With another arrangement, the principle may also be used with bows and cross-bows. If one assumes that the band 16 is a string on a bow and the bow itself is the elastic element Ee 1 the more the string is pulled the less force is required to pull it. On the other hand, when the string is released, the force driving the arrow will increase.
The force F 1 may also be used with the principle according to the present invention in order to obtain other types of torques. If the band 16 is disconnected from the arm 10 , the torque M 1 acting around the pivoting point O 1 is a sinusoidal function of the turning angle α in the area 0≦α≦π.
This may be proved in that if quantities from the equations (6) and (8) are placed in the expression for the torque M 1 (the left part of equation (4)), one obtains
M 1 =Fe 1 ·h 1 =K 1 ·X 1 ·h 1 =
= K 1 ·2 L 1 ·sin β·L 1 ·cos β= K 1 ·L 1 2 ·sin 2β=
= K 1 ·L 1 2 ·sin α (24)
This function can be used when there is a mainly sinusoidal relation between the strain on the muscle and its related joint momentum, for example the force in the biceps and the momentum on the lower arm. The momentum then creates a nearly constant muscle strain.
The embodiments of the invention as described above and shown in the drawings are to be regarded as non-limiting examples and that the invention is defined by the scope of the claims. As an example, the springs may be substituted with other elastic means such as rubber bands, gas filled pistons and the like.
One other area of use where constant force is desirable is medicine:
for example the dosage of liquids, such as syringes, where the plunger is to be pressed into the barrel of the syringe with a constant speed/force.
Or
Pulling a traumatised limb after an orthopaedic treatment, with the given force, which is independent of, displacement or jerk of the limb.
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The present invention relates to a device for obtaining a predetermined linear force, including a first elastic force means (Ee 1, 56 ) and a force output means ( 16, 76 ) in the form of a non-elastic, flexible elongated member. The invention is characterised by a force transformation means ( 10, 12, 72 ) arranged between said first elastic force means and the force output means, such that a pulling of the force output means creates a tension in said first elastic force means, and wherein the force transformation means is arranged and designed such that the pulling force required on the force output means decreases with the distance (X 2 ) the force output means is pulled.
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BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to power hand tools and more particularly to a rotary to reciprocating motion conversion attachment for the same.
[0002] Small rotary hand tools have been marketed for many years for use in carrying out woodworking and metal working tasks by hobbyists as well as commercial artisans. Such small rotary hand tools generally have a motor unit with a rotary output shaft that is adapted to be connected to a number of implements for doing such application work as grinding, polishing, drilling and sanding, among other tasks. Such hand tools are also configured to operate with accessories, such as, for example, a long sheathed cable to which a sanding implement or rotary cutting implement can be attached, a planing attachment as well as a right angle attachment that facilitates use of implements in special applications.
[0003] The drive unit of many recent models of such rotary hand tools is relatively small and lightweight and is capable of being easily used by a user. Such rotary hand tools may have a diameter less than about two inches and a length of only about six inches. The tool has a small but powerful electric motor that drives an output shaft at high speed, and a rotary implement can be typically attached to the tool's output shaft which is axially aligned with the generally cylindrical hand tool.
[0004] While most of the applications that have been discussed above are directed to applications where rotary implements are used in various ways, there are other desirable uses for such rotary hand tools if an accessory were to be attached to the hand tool that would convert the rotary motion into reciprocating motion so that cutting, sawing sanding, filing, buffing and polishing implements that reciprocate could be used. Mechanisms which convert rotary motion to reciprocating motion are known in the art, but many have one or more disadvantages in that they may not provide a sufficiently large reciprocating stroke to be efficient and effective, or they may not be sufficiently robust to have a long useful life or exhibit sufficient cutting or sawing force during operation. The mechanisms for producing a reciprocating action for a saw blade or the like generally produce a sinusoidal movement in that the duration of a stroke in one direction is equal to the duration of the stroke in the reverse direction.
[0005] For many saw blades, such as commercially available saber saw blades, the actual cutting action that is made by the blade is in a particular direction, i.e., the cutting stroke and the other movement is a return stroke which to returns the blade to the position where the next cutting stroke begins. Since the cutting action only occurs during one-half of the total length of movement of the blade, cutting action may be optimized by having the cutting stroke be of longer duration than the return stroke. This asymmetrical timing of the two strokes does not exist in known prior art rotary to reciprocating motion conversion apparatus.
SUMMARY OF THE INVENTION
[0006] A preferred embodiment of a rotary tool reciprocating motion conversion attachment for a rotary power hand tool is described which is configured to be attached to a nose portion of the hand tool housing. The attachment has a rotary drive train in a housing that is connectable to the output shaft of the hand tool, the drive train driving a barrel cam having an exterior cam groove. A cam follower rides in the cam groove and produces reciprocating motion, with the cam follower being part of a cam follower assembly to which an implement holder is attached. The preferred embodiment has a cam groove configuration which causes the implement holder to move slower during a cutting stroke and faster during a return stroke, thereby tending to optimize the operation of the implement. The preferred embodiment also includes a planetary gear set for reducing the rotational speed of the hand tool output shaft to reduce the speed of reciprocation of the attachment.
DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a side view of a preferred embodiment of the rotary to reciprocating motion conversion attachment embodying the present invention;
[0008] FIG. 2 is an exploded perspective view of the attachment shown in FIG. 1 ;
[0009] FIG. 3 is a side view of the attachment shown in FIG. 1 , with a portion of the housing removed to show the internal components thereof, and also illustrating a representing blade implement that may be driven by the attachment;
[0010] FIG. 4 is a side view of a portion of the drive train of the attachment shown in FIG. 1 , and is shown partially in section;
[0011] FIG. 5 is an exploded side view of the drive train shown in FIG. 4 ;
[0012] FIG. 6 is a top plan view of the cam follower assembly of the apparatus shown in FIG. 1 ;
[0013] FIG. 7 is a side view, partially in section, of the cam follower assembly shown in FIG. 6 ;
[0014] FIG. 8 is a front view of the cam follower assembly shown in FIG. 6 ;
[0015] FIG. 9 is a front view of the rear cam section;
[0016] FIG. 10 is a cross-section taken along the line 10 - 10 of FIG. 9 ;
[0017] FIG. 11 is a front view of the front cam section of the drive train shown in FIG. 4 ;
[0018] FIG. 12 is a cross-section taken generally along the line 12 - 12 of FIG. 11 ; and
[0019] FIG. 13 is a chart illustrating a portion of the cam groove that is defined by the front and rear cam sections when they are interconnected.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Turning now to the drawings, the attachment indicated generally at 10 , is shown as a whole in FIGS. 1-3 , with the remainder of the drawings illustrating various parts of the internal structure of the attachment. The attachment 10 is configured to be mounted on the nose portion of a high speed rotary power hand tool that is not shown in the drawings, but which is generally cylindrical in shape and has a smaller nose portion from which an output shaft extends, with the output shaft having a threaded end portion on which a chuck may be screwed on. Alternatively, a cap with an opening at the end thereof may be screwed on the shaft, with the opening being square or some other noncircular shape so that a drive coupling shaft can couple the output shaft of the hand tool to the attachment of the present invention. While not illustrated, the above described construction is known to those of ordinary skill in the art and is also disclosed in detail in U.S. Pat. No. 6,463,824 entitled Right Angle Attachment for Power Hand Tool, which is assigned to same assignee as the present invention. This patent is specifically incorporated by reference herein.
[0021] The attachment 10 has a housing, indicated generally at 12 , that is comprised of two mating sections 14 and 16 with the two sections being complementary and connected together by a number of screws 18 . The housing sections are preferably made of a plastic or plastic-like material, such as ABS or glass filled nylon. Each of the housing sections 14 and 16 has a semi-cylindrical mounting portion 20 which when the sections 14 and 16 are fit together, define a generally cylindrical configuration over which have two semi-cylindrical overflow nut pieces 22 may be placed, and which are rotatable relative to the housing 12 . A sleeve 24 is configured to snap-fit onto the coupled nut pieces 22 enabling interior threads 26 thereof to engage the outer threads of the nose portion of the rotary hand tool to which the attachment 10 is to be mounted. The sleeve 24 interconnects the overflow nut pieces 22 so that the entire structure rotates on the mounting portions 20 for screwing the attachment onto the hand tool.
[0022] The housing 12 has a number of vent openings 28 in each section 14 and 16 thereof for admitting and exhausting air from the interior of the housing 12 during operation. The housing also has a warning insert 30 that fits within a recess 32 of the housing section 16 which also has an elongated opening 34 which permits access to the interior of the housing for manipulating a set screw for securing or removing an implement such as a saw blade 36 as shown in FIG. 3 . The housing has a generally transverse front portion 38 that is slightly curved as shown and which has a raised transverse generally cylindrical portion 40 formed at the front of each section 14 , 16 of the housing which has an opening 42 through which a pivot stud 44 passes for mounting a guide foot 46 to the housing 12 .
[0023] The pivot stud 44 also passes through openings 48 on opposite sides of the guide foot 46 . The guide foot is pivotal around the pivot stud 44 and the pivot stud 44 is locked in place by an inner toothed retainer 50 . Each of the housing sections 14 and 16 also has a cut out 52 which define a single opening for the blade 36 to pass. Similarly, the guide foot 46 has an opening 54 through which the blade can extend.
[0024] With regard to the internal components of the preferred embodiment, the attachment 10 has a rotary drive train, indicated generally at 60 , and a cam follower assembly, indicated generally at 62 . As shown in FIG. 2 , the drive train 60 includes a drive coupling shaft 64 that has an annular outwardly extending flange 66 for limiting axial movement of the coupling shaft relative to a fan blade 68 that is mounted to a pinion shaft 70 that has a pinion gear 72 at its rightward end portion for engaging a planetary gear set 74 . The fan 68 has a flat circular plate portion 76 to which a number of fan blades 78 are attached or formed with the plate portion. The fan 68 is a radial fan which during rotation causes air to move outwardly in the radial direction. Because the fan 68 is positioned adjacent the vent openings 28 in the housing 12 , air from within the housing can be expelled through the vent openings 28 to cool the attachment. In this regard, the planetary gear set 74 tends to generate sufficient heat that makes it desirable for the fan 68 to provide beneficial cooling. While not specifically shown, the pinion shaft 70 is configured with a recess in its left end as shown in FIG. 2 that cooperatively engages the square cross section coupling shaft 64 so that rotation of the coupling shaft 64 will rotate the shaft 70 as well as the fan 68 . The pinion gear 72 engages components of the planetary gear set 74 .
[0025] As is best shown in FIGS. 2, 4 and 5 , the pinion shaft 70 fits within the planetary gear set 74 and particularly rides in a needle bearing 80 which is retained in an opening in a gear housing 82 of the planetary gear set 74 . The needle bearing 80 is of the type which is well known in the art and is commercially readily available. It has a number of elongated cylindrical needles that rotate within an outer cylindrical raceway. The pinion shaft 70 is therefore supported in the needle bearing 80 and the pinion gear 72 is configured to engage each of three planet gears 84 that have concentric openings so that they fit on shafts 86 that are attached to a carrier plate 88 which in turn is attached to an output shaft 90 by a press fit or other known attachment configuration, with the shaft 90 having a reduced diameter portion 92 , as well as additional reduced diameter portions 94 and 96 . The gear housing 82 has a ring gear configuration 98 on the inner surface thereof which also engages each of the planet gears 84 , it being understood that the shafts 86 and the ring gears 84 that are carried by the shafts are in a triangular arrangement relative to one another, i.e., the shafts are angularly displaced from one another by 120°.
[0026] When the planet gears 84 are mounted on the shafts 86 and the assembly is inserted into the gear housing 82 , a flat circular shim plate 100 may be inserted, with the shim plate 100 having a central opening through which the pinion shaft 70 and gear 72 may pass so that the pinion gear 72 may engage the planet gears 84 . With the illustrated configuration, the output shaft 90 of the planetary gear set 74 is reduced by a factor of 9 relative to the rotational speed of the pinion shaft 70 . This therefore reduces the rotational speed of the output relative to the input, and also proportionately increases the torque that is produced by the hand tool.
[0027] Referring to FIGS. 4 and 5 , the output shaft 90 has a bushing plate 102 that is cylindrically shaped and has an outer annular flange 104 which is sized to fit within the inside of the gear housing 82 which effectively encloses the gear set 74 . Once assembled, the rim of the gear housing 82 is preferably crimped against the outer circumference of the annular flange 104 as shown at 106 in FIG. 4 to substantially seal the interior of the housing including the carrier plate 88 and gears 84 that are located within the gear housing 82 . A bushing 108 is located within the bushing plate which is also held stationary relative to the rotating output shaft portion 90 . It should be understood that the inside diameter of the bushing 108 is sized to receive the output shaft portion 90 and firmly hold the same while permitting rotation thereof relative to the bushing 108 .
[0028] A dowel pin 110 fits within an opening 112 in the reduced diameter portion 92 of the output shaft 90 so that it extends in both directions from the shaft portion 92 . It has a length sufficient to engage recesses 118 on a rear barrel cam section 112 which has an inside diameter that is sized to receive the output shaft portion 92 in close fitting engagement. The rear barrel cam section 112 is shown in FIGS. 9 and 10 , with an inside diameter 114 having a flat portion 116 that corresponds with a flat portion of the output shaft section 92 that is not shown in detail. The corresponding flats orient the rear barrel cam section 112 in the proper angular position so that the outwardly protruding ends of the dowel pin 110 will engage the recesses 118 in the rear barrel cam section 112 . The width of the recesses 118 are slightly larger than the diameter of the dowel pin 110 so that the dowel pin will fit within the recesses 118 , but will also firmly hold the barrel cam section 112 from rotation relative to the shaft portion 92 .
[0029] A front barrel cam section 120 also fits on the shaft portion 92 immediately adjacent and in front of the rear section 112 . The front barrel cam section 120 is shown in FIGS. 11 and 12 and it has an internal opening 122 with a flat portion 124 that is provided for the same purpose as described with regard to the rear barrel cam section 112 . The front section 120 has a pair of keys 126 that fit within a pair of keyways 128 , only one of which is visible in FIG. 5 . Each of the barrel cam sections 112 and 120 has an outwardly extending flange 130 , 132 , which together with the outside diameter of barrel section 112 defines a cam groove that is indicated generally at 134 in the drawings. A ball bearing 136 appropriately sized to fit on the output shaft section 94 is supported by structural surfaces in the housing 12 so that the drive train is supported at both ends. A retaining ring 138 is friction fit on output shaft 96 and holds the components of the drive train together.
[0030] The cam groove 134 extends completely around the joined barrel sections and defines a generally sinusoidal or near sinusoidal path around the periphery. FIG. 13 illustrates a portion of the path, with the center of the path being shown and its extreme leftward position being marked as 0 . As the barrel cam sections rotate, the cam path center line moves to the right as shown in FIG. 13 to its extreme right position and then returns to the zero position upon a full revolution of the barrel cam. A chart of the path in terms of movement from its extreme left or zero position through a full 360° rotation is shown in FIG. 14 , with the amount of movement being 3.75″ of travel in the Y direction. It should be understood that the cam groove could be configured to have a greater or lesser amount of movement in the Y direction than the 0.375″ as shown, if desired. If not apparent from the foregoing description, the excursion in the Y direction is movement in the horizontal direction as oriented from FIGS. 1 and 3 which results in reciprocating movement of the blade 36 as shown in FIG. 3 .
[0031] The cam follower assembly 62 is shown in FIGS. 3, 6 , 7 and 8 and comprises an elongated plunger 140 that is slideable within a pair of supports 142 which extend transversely of the length of the plunger 140 and which have ends 144 that engage recesses 146 located in both housing sections 14 and 16 , only those in section 114 being visible in FIG. 2 . The supports 142 have a center portion that includes upper and lower sections that are sized to permit the plunger 140 to fit within them and be slideable in the left to right direction as shown in FIG. 6 . The configuration is shown in perspective in FIG. 2 of the drawings. Generally mid-way between the supports 142 is a cam follower mechanism that comprises a cylindrical needle bearing 148 that fits on a cylindrical sleeve 150 that has an enlarged head portion 152 . The sleeve 150 fits through an opening 154 in the plunger 140 . A washer 156 and a thin bronze thrust washer 158 provide a surface on which the needle bearing 148 can ride. The outer diameter of the needle bearing 148 is only slightly smaller than the width of the cam groove 134 so that very little play exists between the two components.
[0032] As the barrel cam sections 130 and 132 rotate, the cam follower defined by the needle bearing 148 will move in the horizontal direction as shown in FIGS. 6 and 7 in a reciprocating manner as is desired. At the front or right end of the plunger 140 is an implement holder, indicated generally at 160 , which is configured to receive a blade such as the saber saw blade 36 shown in FIG. 3 . The holder has a generally box-like configuration with a lower slot 162 through which the right end of the plunger 140 (as shown in FIG. 7 ) can be inserted and a dowel pin 164 is force fit into openings in both the bottom part of the holder 160 and in the end portion of the plunger 140 . Thus, the implement holder 160 is fly attached to the plunger as is desired.
[0033] The plunger also has an opening 166 in the front of the holder as shown in FIG. 8 which is configured to receive the shank end of the blade 36 . An elongated pressure pad 168 is also located in the slot 166 and generally extends from the right to the left end of the block 160 as shown in FIG. 7 . It also extends beyond the back end and has an enlarged portion 170 through which a pin 172 is force fit into an opening therein. The front end of the pressure pad 168 is preferably curved to facilitate insertion of a blade 36 into the slot 166 . The blade 36 is secured by a set screw 174 threadably engaged in a threaded hole in the holder 160 . When the set screw is tightened by an Allen wrench fitting into a recess 176 , the inner end of the set screw will contact the pressure pad 168 forcing it against the shank of the blade 36 to firmly hold it in place. It should be understood that the set screw 174 is accessible through the housing 12 by the opening 34 as shown in FIG. 1 . Also, while an Allen wrench configuration is shown, other configurations, such as a star configuration, square configuration, or even regular or Phillips screw configurations may be used.
[0034] Referring to the chart of FIG. 14 , the cam groove is configured to define a generally sinusoidal path, but it should be apparent that the movement from the 0 or extreme left position as shown in FIG. 13 represents the end of the cutting stroke which occurs when the blade 36 is pulled from the right to the left as shown in FIG. 3 . The return stroke occurs within 150° of rotation as shown in FIG. 14 and the cutting stroke occurs when the rotational angle moves from 150° through 360°.
[0035] While other near-sinusoidal paths may be used, the shape of the chart shown in FIG. 14 is defined by the following equations.
[0036] y is a function of the barrel rotation angle:
for 0° to 150°, y=4.7625
[ 1 + cos [ π 180 ( c · 180 150 + 180 ) ] ]
for 150° to 360°, y+4.7625
[ 1 + cos [ π 180 ( 180 + 180 210 ( 360 - C ) ) ] ]
where C=position angle.
[0039] Since more work is being done during the cutting stroke, the efficiency of the sawing operation is increased by causing the cutting action to occur through a greater rotational angle and the return stroke occur through a lesser rotational angle. It has been found that while a truly symmetrical distribution of the cutting and return stroke, i.e., 180° for each, will operate reasonably well, increased efficiency has been experienced when the above described asymmetrical cutting and return stroke is used.
[0040] While the chart of FIG. 14 illustrates a 150° return stroke and a 210° cutting stroke, the return stroke may be increased to extend over a larger angle if desired. However, using a larger angle return stroke will result in a reduction in operating efficiency compared to the smaller 150° return stroke. It should be understood that the lower the angle of the return stroke, the greater the stresses that are applied to the barrel cam structure. Since it is desired to make the barrel cam sections from glass filled nylon, it has been found that about 150° is the lower limit for the configuration illustrated in the drawings when the barrel cam sections are made of this material. Having a return stroke of about 150° results in acceptable stresses being applied to the barrel cam sections that will not damage them and also results in desirable operating efficiency.
[0041] While various embodiments of the present invention have been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims.
[0042] Various features of the invention are set forth in the following claims.
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A preferred embodiment of a rotary tool reciprocating motion conversion attachment for a rotary power hand tool is described which is configured to be attached to a nose portion of the hand tool housing. The attachment has a rotary drive train in a housing that is connectable to the output shaft of the hand tool, the drive train driving a barrel cam having an exterior cam groove. A cam follower rides in the cam groove and produces reciprocating motion, with the cam follower being part of a cam follower assembly to which an implement holder is attached. The preferred embodiment has a cam groove configuration which causes the implement holder to move slower during a cutting stroke and faster during a return stroke, thereby tending to optimize the operation of the cutting implement. The preferred embodiment also includes a planetary gear set for reducing the rotational speed of the hand tool output shaft to reduce the speed of reciprocation of the attachment.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 09/474,791, filed Dec. 29, 1999 now U.S. Pat. No. 6,570,764, by Intel Corporation, entitled LOW THERMAL RESISTANCE INTERFACE FOR ATTACHMENT OF THERMAL MATERIALS TO A PROCESSOR DIE.
FIELD
The embodiments disclosed herein relate to electronic devices and more particularly to the dissipation of heat generated by microprocessors.
BACKGROUND
In operation, microprocessors and other electronic devices generate heat. Excess heat can damage the device if it is not dissipated. Therefore, generally microprocessors and other heat-generating electronic devices utilize heat dissipating structures or heat sinks as a conductor to dissipate excess heat. A conventional configuration for dissipating heat from a microprocessor is to mount a heat sink of a metal material (such as aluminum or copper) over the microprocessor. Mounting a metal heat sink directly over the microprocessor is not a favored practice, because of the poor conductivity achieved by the union of the metal heat sink and the microprocessor. In addition, the surface of the heat sink material is generally comprised of micro-pores or surface roughness and the surface of the microprocessor has a crown shape. Accordingly, the union of a heat sink and the microprocessor is not uniform leading to the presence of air pockets and poor thermal conductivity. Therefore, a thermal interface material, such as thermal grease, a thermal elastomer, or a phase-change material is interposed between the microprocessor and the heat sink. The thermal interface material provides improved thermal conductivity between the processor and the heat sink. The thermal interface material tends to fill the micro-pores and therefore makes the transition between the microprocessor and the heat sink more uniform.
A microprocessor or other heat-generating electronic device generally is affixed to a printed circuit board (PCB). In the case of a microprocessor, a heat sink is usually affixed to the PCB through bolts or screws with an established gap or bond line thickness between the heat sink and the microprocessor. In portable computer applications, for example, the bond line thickness associated with conventional microprocessor packaging is approximately 5 mils±2 mils, the difference generally attributable to differences in microprocessor heights. It is desirable, in one sense, to establish a consistent bond line thickness. One way this is established is by securing the heat sink to the PCB under pressure. The amount of pressure that may be applied to heat sink affixation is limited, however, to about 20 to 100 pounds per square inch to avoid damage to the microprocessor. The amount of compression that a thermal interface material can withstand is also limited. Thermal interface material under compression tends to flow out of the gap between the heat sink and the microprocessor under compression and additionally tends to dry out with power cycling. The compressive limitation of the thermal interface material reduces the reliability of the thermal interface material.
Despite its limitations, it is desirable to use thermal interface material between a heat sink and a microprocessor or other heat-generating electronic device. What is needed is a configuration whereby thermal interface material may be utilized and the reliability issues present in prior art configurations can be avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a packaged microprocessor according to an embodiment of the invention.
FIG. 2 is a planar bottom view of the structure of FIG. 1 .
FIG. 3 is a schematic side view of a second embodiment of a heat sink according to the invention.
FIG. 4 is a planar bottom view of the structure of FIG. 3 .
FIG. 5 is a schematic side view of a portion of a heat sink over a microprocessor according to a third embodiment of the invention.
FIG. 6 is a planar bottom view of the structure of FIG. 5 .
DETAILED DESCRIPTION
The embodiments disclosed herein relate to a heat sink comprising a protuberance having a thickness defining a distance between a heat generating structure and a heat sink. In this manner, utilizing the heat sink as a heat dissipating element in conjunction with a microprocessor affixed to a printed circuit board, the protuberance defines a volume for a thermal interface material between the heat sink and a heat generating electronic device such as the microprocessor. A desired bond line thickness may be established between a heat sink and a heat generating electronic device to improve the thermal resistance of the thermal interface material and the heat sink and provide consistency of thermal resistance between packages. An apparatus incorporating such a heat sink is also described.
FIG. 1 shows a schematic side view of a packaged electronic device such as a microprocessor. In FIG. 1, microprocessor 10 (or other heat generating device) includes socket 12 that is mounted on printed circuit board 14 utilizing, for example, ball grid array 16 . Heat sink 18 is attached to printed circuit board 14 through supports 27 . Heat sink 18 is, for example, a block or plate of a metal such as aluminum or copper. Heat sink 18 is attached to printed circuit board 14 in a position that defines bond line thickness or gap 20 between bottom surface 22 of heat sink 18 and top surface 24 of microprocessor 10 . Thermal interface material 26 , such as a thermal grease, elastomer, or phase-change material, or other thermally conductive material 26 spans gap 20 and defines heat conducting path 28 from microprocessor 10 to heat sink 18 . A quantity of thermal interface material such as a thermal grease, elastomer, phase-change material or other material sufficient to fill thermal gap 20 and provide an adequate thermal path for heat generated by microprocessor 10 is shown.
In the embodiment shown in FIG. 1, heat sink 18 includes protuberances 28 defining gap 20 between heat sink 18 and microprocessor 10 . Protuberances 28 establish gap 20 at a desired fixed height. In this manner, thermal interface material 26 may be positioned between heat sink 18 and microprocessor 10 without being subject to compression that can cause squeezing out and drying of the material. Protuberances 28 also establish a consistent bond line thickness or gap 20 between different units, so that the same thermal gap is consistently established to consequently establish a consistent adequate thermal path among packaged microprocessors.
In the embodiment shown in FIG. 1, supports 27 such as pins or bolts are securely attached to heat sink 18 at the upper end and pass through four corresponding holes in printed circuit board 14 to affix heat sink 18 to printed circuit board 14 . In one embodiment, supports 27 utilize locking clips and coil spacer springs surrounding the supports to provide a consistent tension between heat sink 18 and printed circuit board 14 . This tension is not reflected against thermal interface material 26 as protuberances 28 shield thermal interface material 26 from any pressure applied by supports 27 .
FIG. 2 shows a planar bottom side view of heat sink 18 having protuberances 28 . In one embodiment, heat sink 18 is a metal such as aluminum or copper formed by a die-casting method. Protuberances 28 may also be formed according to die-casting techniques known in the art. Protuberances are formed to a height or thickness, in one embodiment, of approximately 5 mils for use with modern microprocessors and a desirable bond line thickness as known in the art. In this manner, protuberances 28 may be considered dimples in a surface of heat sink 18 . Cooling mechanism 25 such as a chain transfer mechanism as known in the art may be incorporated in heat sink 18 to dissipate heat from heat sink 18 to a fan or the environment as known in the art.
FIG. 3 shows a second embodiment of a heat sink according to the invention. In this embodiment, a surface of heat sink 180 includes protuberance 280 that is a frame having four sides extending from a surface of heat sink 180 . FIG. 4 shows a bottom planar view of the second embodiment of the invention. As shown in FIG. 4, protuberance 280 consists of a frame having four sides defining opening 285 for thermal interface material. Similar to the embodiment shown in FIGS. 1 and 2, protuberance 280 allows thermal interface material to reside in opening 285 between a microprocessor and the bottom surface of heat sink 180 without being subject to compression. Protuberance 280 of a frame, in one embodiment, is established at a bond line thickness of approximately 5 mils. In one embodiment, protuberance 280 is formed utilizing die-casting techniques along with at least the bottom surface of heat sink 180 .
It is to be appreciated that the embodiment illustrated in the figures represent, in particular, two configurations of a heat sink having a suitable protuberance or protuberances to establish a bond line thickness and allow thermal interface material to be placed between the heat sink and the microprocessor without compression. Many other configurations of protuberances, including protuberances that are not die-cast in the heat sink but are separate components may be utilized.
FIG. 5 shows still another embodiment wherein a recess is formed in the heat sink to provide a die-referenced bond line thickness between the heat sink and a microprocessor. FIG. 5 shows heat sink 380 having recess 375 over a portion of microprocessor 310 . Between heat sink 380 and microprocessor 310 in recess 375 is thermal interface material 320 such as a thermal grease. The recess defines a volume and the walls of the recess trap the thermal interface material over microprocessor 310 , inhibiting grease migration during power or temperature cycles. Heat sink 380 contacts microprocessor 310 at contact points 370 . FIG. 6 shows a planar bottom view of heat sink 380 .
In the preceding detailed description, the invention is described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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A heat sink comprises a side including a structural member defining a distance between a heat generating structure and the second side of the heat sink.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of cutting implements such as scissors. More specifically the present invention relates to a pair of scissors including a first cutting panel with a longitudinal first panel abutting face and a first panel distal segment with a first cutting edge and a first panel proximal segment configured as a first handle and a primary fixed pivot pin protruding perpendicularly from the first panel abutting face and located midway between the first panel distal segment and the first panel proximal segment, and a primary arched guide slot spaced proximally from the primary fixed pivot pin and following a path substantially defining a curve which preferably is a segment of an ellipse centered substantially at the primary fixed pivot pin; and including a second cutting panel substantially matching the size of and having substantially the mirror image shape of the first cutting panel and having a second panel abutting face placed in abutting relation to the first panel abutting face and a second panel distal segment with a longitudinal second cutting edge and a second panel proximal segment configured as a second handle and a substantially rectilinear double pivot pin slot extending substantially longitudinally between the second panel proximal and distal segments and registering with and receiving the primary fixed pivot pin which has a pin retaining head at its free end wider than the double pivot pin slot; and a floating guide pin extending through the double pivot pin slot and the primary arched guide slot with opposing pin retaining heads, having diameters greater than the widths of the double pivot pin slot and the primary arched guide slot.
The scissors cut an item placed between the first and second cutting edges by closing angularly onto the item while the first and second cutting panels inventively slide longitudinally relative to each other to enhance the cutting action. The movement of the floating guide pin along the primary arched guide slot constrains the first and second cutting edges to slide longitudinally relative to each other in a first relative direction while rotationally closing together. By the same token, this pin and slot cause the first and second cutting edges to slide back to their original positional relationship in a second relative direction.
The first cutting panel preferably has a secondary guide slot which preferably is arched and following a path substantially defining a curve which preferably is a segment of an ellipse centered substantially at the primary fixed pivot pin but may alternatively be rectilinear as long as it is angled relative to the double pivot pin slot, and the second cutting panel preferably has a fixed secondary guide pin extending substantially perpendicularly from the second cutting panel abutting face and located to register with and fit through the secondary guide slot to add structural and item cutting strength to the scissors. Either the primary guide slot or the secondary guide slot can be omitted and the scissors will function as intended and described.
2. Description of the Prior Art
There have long been pairs of scissors for cutting sheet material, cords and strings and other items. These conventional scissors include cutting blades interconnected by a pivot pin to pivot circumferentially in fixed rotational relation about the pivot pin and thereby close against and cut the item. A problem with this cutting action is that it relies entirely on compression of the converging blade edges against the item which may be of a material or of a shape which does not lend itself to easy cutting in this way.
It is thus an object of the present invention to provide a pair of scissors which combines the compression cutting action of converging cutting edges with a simultaneous sliding cutting action in which one cutting edge slides longitudinally with respect to the other.
It is another object of the present invention to provide a pair of scissors which are used and handled in the very same easy way that conventional scissors are used and handled.
It is finally an object of the present invention to provide a pair of scissors which are sturdy, reliable, and economical to manufacture.
SUMMARY OF THE INVENTION
The present invention accomplishes the above-stated objectives, as well as others, as may be determined by a fair reading and interpretation of the entire specification.
A pair of scissors is provided, including a first cutting panel with a first panel abutting face and a first panel distal segment with a first cutting edge and a first panel proximal segment configured as a first handle, and a fixed pivot pin protruding perpendicularly from the first panel abutting face and located midway between the first panel distal segment and the first panel proximal segment, and a primary arched guide slot spaced from the fixed pivot pin and following a path substantially defining a curve which preferably is a segment of an ellipse centered substantially at the fixed pivot pin; and a second cutting panel substantially matching the size of and having substantially the mirror image shape of the first cutting panel and having a second panel abutting face placed in abutting relation to the first panel abutting face and a second panel distal segment with a second cutting edge and a second panel proximal segment configured as a second handle and a substantially rectilinear double pivot pin slot extending substantially longitudinally between the second cutting panel proximal and distal segments and registering with and receiving the fixed pivot pin which has a second panel retaining structure for retaining the second cutting panel abutting face in abutting relation with the first cutting panel abutting face; and a floating guide pin extending through the double pivot pin slot and the primary arched guide slot with a floating guide pin retaining structure for retaining the floating guide pin in the double pivot pin slot and the primary arched guide slot; so that the scissors cut an item placed between the first and second cutting edges by closing angularly onto the item to be cut while the first and second cutting edges slide longitudinally relative to each other to enhance the cutting action.
The first cutting panel preferably additionally includes a secondary guide slot following a path substantially defining a curve centered substantially at the fixed pivot pin, and the second cutting panel preferably additionally includes a fixed secondary guide pin extending substantially perpendicularly from the second cutting panel abutting face and located to register with and fit through the secondary guide slot, and having a secondary guide pin head protruding at fixed secondary guide pin free end which is wider than the secondary guide slot. The curve of each of the primary guide slot and the secondary guide slot preferably is substantially a segment of an ellipse. Each of the first handle and the second handle preferably is shaped to substantially define an elliptical loop. The second handle preferably is shaped to substantially define an elliptical loop.
A pair of scissors is further provided, including a first cutting panel with a first panel abutting face and a first panel distal segment with a first cutting edge and a first panel proximal segment configured as a first handle, and a fixed pivot pin protruding perpendicularly from the first panel abutting face and located midway between the first panel distal segment and the first panel proximal segment, and a primary arched guide slot spaced proximally from the fixed pivot pin and following a path substantially defining a curve which preferably is a segment of an ellipse centered substantially at the fixed pivot pin; and a second cutting panel substantially matching the size of and having substantially the mirror image shape of the first cutting panel and having a second panel abutting face placed in abutting relation to the first panel abutting face and a second panel distal segment with a second cutting edge and a second panel proximal segment configured as a second handle and a substantially rectilinear double pivot pin slot extending substantially longitudinally between the second cutting panel proximal and distal segments and registering with and receiving the primary fixed pivot pin which has a pin retaining head at its free end wider than the double pivot pin slot; and a floating guide pin extending through the double pivot pin slot and the primary arched guide slot with opposing pin retaining heads having diameters greater than the widths of the corresponding adjacent the double pivot pin slot and the primary arched guide slot; so that the scissors cut an item placed between the first and second cutting edges by closing angularly onto the item to be cut while the first and second cutting edges slide longitudinally relative to each other to enhance the cutting action.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following discussion taken in conjunction with the following drawings, in which:
Prior Art FIG. 1 is a broken away side view of a conventional pair of scissors with the handles omitted, showing the single pivot point circular cutting edge movement which provides no sliding cutting action.
FIG. 2 is a view as in FIG. 1 of a representation of the present invention, showing the simultaneous pivoting and sliding movements of the cutting edges along a non-circular path.
FIG. 3 is a full side view of the present pair of scissors having the inventive pivoting and sliding cutting action.
FIG. 4 is an exploded side view of the scissors of FIG. 3 showing separately the first cutting panel, the floating guide pin and the second cutting panel.
FIG. 5 is a full schematic representation of the present invention, further showing the simultaneous pivoting and sliding movements of the cutting edges along a non-circular path.
FIG. 6 is the first in a series of five side views of the present scissors as shown in FIG. 3 , showing the relationships of the first and second cutting panels as the cutting edges are advanced from an open and separated relationship to close together until the first and second panel abutting faces ultimately reach maximum abutting relation.
FIG. 7 is the second in a series of five side views as described in the description of FIG. 6 .
FIG. 8 is the third in a series of five side views as described in the description of FIG. 6 .
FIG. 9 is the fourth in a series of five side views as described in the description of FIG. 6 .
FIG. 10 is the fifth in a series of five side views as described in the description of FIG. 6 .
FIG. 11 is an exploded view of a preferred pin assembly for the scissors, including the primary fixed pivot pin.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Reference is now made to the drawings, wherein like characteristics and features of the present invention shown in the various FIGURES are designated by the same reference numerals.
First Preferred Embodiment
Referring to FIGS. 1-11 , a pair of scissors 10 is disclosed including a first cutting panel 20 with a first panel abutting face 22 and a first panel distal segment 20 A with a longitudinal first cutting edge 24 and a first panel proximal segment 20 B configured as a first handle 26 and a primary fixed pivot pin 60 protruding perpendicularly from the first panel abutting face 22 and located midway between the first panel distal segment 20 A and the first panel proximal segment 20 B and a primary arched guide slot 30 spaced proximally from the primary fixed pivot pin 60 and following a path substantially defining a curve which preferably is a segment of an ellipse centered substantially at the primary fixed pivot pin 60 ; and including a second cutting panel 40 substantially matching the size of and having substantially the mirror image shape of the first cutting panel 20 and having a second panel abutting face 42 placed in abutting relation to the first panel abutting face 22 and a second panel distal segment 40 A with a longitudinal second cutting edge 44 and a second panel proximal segment 40 B configured as a second handle 46 and a substantially rectilinear double pivot pin slot 50 extending substantially longitudinally between the second panel distal and proximal segments 40 A and 40 B and registering with and receiving the primary fixed pivot pin 60 ; which has second panel retaining means in the form of a pin retaining head 62 at its free end which is wider than the double pivot slot 50 for retaining the second cutting panel abutting face in abutting relation with the first cutting panel abutting face. Scissors 10 further includes a floating guide pin 80 extending through the double pivot pin slot 50 and the primary arched guide slot 30 with floating guide pin retaining means in the form of retaining heads 82 having diameters greater than the widths of the double pivot pin slot 50 and the primary arched guide slot 30 for retaining the floating guide pin 80 in the double pivot pin slot 50 and the primary arched guide slot 30 .
The scissors 10 cut an item placed between the first and second cutting edges 24 and 44 by closing angularly onto the item while the first and second cutting panels 20 and 40 inventively slide longitudinally relative to each other to enhance the cutting action. The movement of the floating guide pin 80 along the primary arched guide slot 30 constrains the first and second cutting edges 24 and 44 to slide longitudinally relative to each other in a first relative direction while rotationally closing together. By the same token, this pin 80 and slot 30 cause the first and second cutting edges 24 and 44 to slide back to their original positional relationship in a second relative direction.
The first cutting panel 20 preferably has a secondary guide slot 70 following a path substantially defining a curve which preferably is a segment of an ellipse centered substantially at the primary fixed pivot pin 60 but may alternatively be rectilinear as long as it is angled relative to the double pivot pin slot, and the second cutting panel 40 preferably has a fixed secondary guide pin 90 extending substantially perpendicularly from the second cutting panel abutting face 42 and located to register with and fit through the secondary guide slot 70 , and having a secondary guide pin head 92 at its free end which is wider than the secondary guide slot 70 . The first handle and second handle 26 and 46 respectively preferably each are configured as an elliptical loop, such as are found on conventional scissors.
Either the primary guide slot 30 or the secondary guide slot 70 can be omitted and the scissors 10 will function as intended and described. Retaining heads 82 and guide pin head 92 are optionally rest or ride within recesses in the outward faces of first and second cutting panels 20 and 40 to be substantially flush with the outward faces. The primary arched guide slot 30 , the double pivot pin slot 50 and the secondary guide slot 70 alternatively may be grooves or channels in first and second panel abutting faces 22 and 42 , and the word slot is defined in this application to include groove or channel.
While the invention has been described, disclosed, illustrated and shown in various terms or certain embodiments or modifications which it has assumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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A pair of scissors has first and second cutting panels operationally interconnected with both pins and pin guide slot\s so that the first and second cutting edges of these panels simultaneously pivot and slide longitudinally when closing together onto an item to be cut to enhance the effectiveness of the cutting action.
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TECHNICAL FIELD
The invention relates to a remote communication system. More particularly, the invention relates to a radio frequency (RF) identification system and methods for rapidly identifying RF tags.
BACKGROUND OF THE INVENTION
Remote communication utilizing wireless equipment typically relies on radio frequency (RF) technology, which is employed in many industries. One application of RF technology is in locating, identifying, and tracking objects, such as animals, inventory, and vehicles.
RF identification (RFID) tag systems have been developed to identify, monitor, or control remote objects. As shown in FIG. 1 , a basic RFID system 10 includes an interrogator 18 and transponders (commonly called RF tags) 16 . The interrogator 18 includes a transceiver 14 and an antenna 12 . The tag 16 includes a transceiver 15 and an antenna 24 . In operation, the antenna 12 emits and receives electromagnetic radio signals generated by the transceiver 14 to activate the tag 16 , and receive signals from the tag. When the tag 16 is activated, data can be read from or written to the tag.
In some applications, the transceiver 14 and antenna 12 are components of an interrogator (or reader) 18 , which can be configured either as a hand-held or a fixed-mount device. The interrogator 18 emits the radio signals 20 in range from one inch to one hundred feet or more, depending upon its power output, the radio frequency used, and other radio frequency considerations. When an RF tag 16 passes through the electromagnetic radio waves 20 , the tag detects the signal 20 and is activated. Data encoded in the tag 16 is then transmitted by a modulated data signal 22 through an antenna 24 to the interrogator 18 for subsequent processing.
An advantage of RFID systems is the non-contact, non-line-of-sight capability of the technology. Tags can be read through a variety of substances such as snow, fog, ice, paint, dirt, and other visually and environmentally challenging conditions where bar codes or other optically-read technologies would be useless. RF tags can also be read at remarkable speeds, in most cases responding in less than one hundred milliseconds.
There are three main categories of RFID tag systems. These are systems that employ beam-powered passive tags, battery-powered semi-passive tags, and active tags. Each operates in fundamentally different ways. The invention described below in the Detailed Description can be embodied in any of these types of systems.
The beam-powered RFID tag is often referred to as a passive device because it derives the energy needed for its operation from the radio frequency energy beamed at it. The tag rectifies the field and changes the reflective characteristics of the tag itself, creating a change in reflectivity (RF cross-section) that is seen at the interrogator. A battery-powered semi-passive RFID tag operates in a similar fashion, modulating its RF cross-section in order to change its reflectivity that is seen at the interrogator to develop a communication link. Here, the battery is the only source of the tag's operational power. Finally, in the active RFID tag, both the tag and reader have transceivers to communicate and are powered by a battery.
A typical RF tag system 10 will contain at least one tag 16 and one interrogator 18 . The range of communication for such tags varies according to the transmission power of the interrogator 18 and the tag 16 . Battery-powered tags operating at 2,450 MHz have traditionally been limited to less than ten meters in range. However, devices with sufficient power can reach in excess of 100 meters in range, depending on the frequency and environmental characteristics.
Conventional RF tag systems utilize continuous wave backscatter to communicate data from the tag 16 to the interrogator 18 . More specifically, the interrogator 18 transmits a continuous-wave radio signal to the tag 16 , which modulates the signal 20 using modulated backscattering wherein the electrical characteristics of the antenna 24 are altered by a modulating signal from the tag that reflects a modulated signal 22 back to the interrogator 18 . The modulated signal 22 is encoded with information from the tag 16 . The interrogator 18 then demodulates the modulated signal 22 and decodes the information.
Conventional continuous wave backscatter RF tag systems utilizing passive (no battery) RF tags require adequate power from the signal 20 to power the internal circuitry in the tag 16 used to modulate the signal back to the interrogator 18 . While this is successful for tags that are located in close proximity to an interrogator, for example less than three meters, this may be insufficient range for some applications, for example greater than 100 meters.
A problem in RFID systems is in the rapid identification of an unknown number and identity of tags with long IDs in the field of view of the reader.
SUMMARY OF THE INVENTION
The invention provides An RFID system comprising an RFID reader configured to issue an RF command requesting that RF tags identify themselves, to issue timing information defining a plurality of timeslots; and a plurality of RF tags in selective communication with the reader, the RF tags having respective IDs, respective tags being configured to randomly select a timeslot in which to reply to the RF command, and to issue an RF reply in response to the RF command in the randomly selected timeslot, the RF reply including a frequency pattern to assist in identifying the tag but not the tag's entire ID, different tags having different frequency patterns.
Another aspect of the invention provides an RFID reader, for use with RF tags that have respective IDs, the RFID reader comprising circuitry configured to selectively provide a backscatter RF illumination field, to provide time synchronization information defining timeslots to RF tags, to issue a first RF command requesting that RF tags identify themselves, to store the identity of the timeslot where an RF reply was received by the reader from a tag, to determine if a collision occurred between RF replies, to issue a second RF command indicating the timeslot for which a reply was received from an RF tag and requesting that RF tags reply with their IDs, to receive and store IDs from RF tags, and to re-issue the first RF command response if it was determined that a collision occurred between RF replies.
Another aspect of the invention provides an RFID tag for use with a reader that is configured to issue timing signals defining timeslots, the RFID tag comprising circuitry configured to store an ID identifying the tag, to backscatter modulate an RF illumination field from a reader, to randomly select a timeslot in which to reply from a plurality of possible timeslots, to issue an RF reply in the selected timeslot, responsive to receiving a first RF command including a session identifier from the reader, the reply including a signal pattern, the signal pattern identifying the tag but not including the entire ID, the tag being further configured to issue a response to the reader including the tag's ID in response to receiving a second RF command from the reader indicating that the tag has been found by the reader, and the circuitry being further configured to ignore further receptions of the first RF command which include the session identifier responsive to receiving a third RF command from the reader confirming that the tag's ID has been received by the reader.
Yet another aspect of the invention provides an RFID communications method comprising providing an RF reader; providing a plurality of RF tags in selective communication with the reader, the RF tags having respective IDs; issuing, using an RF reader, an RF command requesting that RF tags identify themselves; issuing, using the RF reader, timing information defining a plurality of timeslots; respective tags randomly selecting a timeslot in which to reply to the RF command; and respective tags issuing an RF reply in response to the RF command, in the randomly selected timeslot, the RF reply including a frequency pattern to assist in identifying the tag but not the tag's entire ID, different tags having different frequency patterns.
Another aspect of the invention provides a method of communicating with RF tags that have respective IDs, the method comprising selectively providing a backscatter RF illumination field, including time synchronization information defining timeslots to RF tags; issuing a first RF command requesting that RF tags identify themselves; storing data identifying the timeslot where an RF reply was received from a tag; determining if a collision occurred between RF replies; issuing a second RF command indicating the timeslot for which a reply was received from an RF tag and requesting that RF tags reply with their IDs; receiving and storing IDs from RF tags; and re-issuing the first RF command response if it was determined that a collision occurred between RF replies received from tags.
Still another aspect of the invention provides a method of communicating with an RF reader that is configured to issue timing signals defining timeslots, the method comprising storing an ID; backscatter modulating an RF illumination field from the reader; randomly selecting a timeslot in which to reply from a plurality of possible timeslots; issuing an RF reply in the selected timeslot, responsive to receiving a first RF command, including a session identifier, from the reader, the reply including a signal pattern, the signal pattern identifying the tag but not including the entire ID; issuing a response to the reader including the ID in response to receiving a second RF command from the reader; and ignoring further receptions of the first RF command which include the session identifier responsive to receiving a third RF command from the reader confirming that the ID has been received by the reader.
Another aspect of the invention provides a method of using an RFID reader, comprising issuing a first RF command to an RF tag; selectively providing an RF illumination field including time synchronization pulses; monitoring for a reply during a period defined by a predetermined number of timeslots; receiving an RF reply, from a tag, including a signal pattern during the monitoring; issuing a second RF command indicating the timeslot during which a reply was received; receiving an RF reply including a tag's ID in response to the second RF command; and issuing a third RF command in response to receiving an RF reply including a tag's ID.
Still another aspect of the invention provides an RFID system comprising an RFID reader including means for issuing an RF command requesting that RF tags identify themselves, means for issuing timing information defining a plurality of timeslots, and means for monitoring a plurality of intermediate frequencies for a response; and a plurality of RF tags in selective communication with the reader, the RF tags having respective IDs, respective tags including means for randomly selecting a timeslot in which to reply to the RF command, means for randomly selecting an intermediate frequency on which to issue a reply to the RF command, and means for issuing an RF reply in response to the RF command in the randomly selected timeslot and using the randomly selected intermediate frequency, the RF reply including a frequency pattern to assist in identifying the tag but not the tag's entire ID, different tags having different frequency patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
FIG. 1 is a block diagram of a conventional RFID communication system, including a tag and reader in which the invention could be incorporated.
FIG. 2 is a block diagram of an RFID communication system, including a tag and reader, embodying various aspects of the invention.
FIGS. 3–3A provide a flowchart illustrating operation of the reader and tag in accordance with one embodiment of the invention.
FIG. 4 is a diagram illustrating communications between the reader and tag in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Attention is directed to the following commonly assigned applications, which are incorporated herein by reference: U.S. patent application Ser. No. 10/263,826 entitled “Radio Frequency Identification Device Communication Systems, Wireless Communication Devices, Backscatter Communication Methods and Radio Frequency Identification Device Communication Methods” by inventors Mike A. Hughes and Richard M. Pratt; U.S. patent application Ser. No. 10/263,809, entitled “Method of Simultaneously Reading Multiple Radio Frequency Tags, RF Tag, and RF Reader”, by inventors Emre Ertin, Richard M. Pratt, Mike A. Hughes, Kevin L. Priddy, and Wayne M. Lechelt; U.S. patent application Ser. No. 10/263,873, entitled “RFID System and Method Including Tag ID Compression”, by inventors Mike A. Hughes and Richard M. Pratt; U.S. patent application Ser. No. 10/263,940, entitled “Wireless Communication Devices, Radio Frequency Identification Devices, Backscatter Communication Device Wake-Up Methods and Radio Frequency Identification Device Wake-Up Methods”, by inventors Richard Pratt and Mike Hughes; U.S. patent application Ser. No. 10/263,997, entitled “Wireless Communication Systems, Radio Frequency Identification Devices, Methods of Enhancing a Range of Radio Frequency Device, and Wireless Communication Methods”, by inventors Richard Pratt and Steven B. Thompson; U.S. patent application Ser. No. 10/263,670, entitled “Wireless Communications Devices, Methods of Processing a Wireless Communication Signal, Wireless Communication. Synchronization Methods and a Radio Frequency Identification Device Communication Method”, by inventors Richard M. Pratt; U.S. patent application Ser. No. 10/263,656, entitled “Wireless Communications Systems, Radio Frequency Identification Devices, Wireless Communications Methods, and Radio Frequency Identification Device Communications Methods”, by inventors Richard Pratt and Steven B. Thompson; U.S. patent application Ser. No. 10/263,635, entitled “A Challenged-Based Tag Authentication Model, by inventors Mike A. Hughes” and Richard M. Pratt; U.S. patent application Ser. No. 09/589,001, filed Jun. 6, 2000, entitled “Remote Communication System and Method”, by inventors R. W. Gilbert, G. A. Anderson, K. D. Steele, and C. L. Carrender; U.S. patent application Ser. No. 09/802,408; filed Mar. 9, 2001, entitled “Multi-Level RF Identification System”; by inventors R. W. Gilbert, G. A. Anderson, and K. D. Steele; U.S. patent application Ser. No. 09/833,465, filed Apr. 11, 2001, entitled “System and Method for Controlling Remote Device”, by inventors C. L. Carrender, R. W. Gilbert, J. W. Scott, and D. Clark; U.S. patent application Ser. No. 09/588,997, filed Jun. 6, 2000, entitled “Phase Modulation in RF Tag”, by inventors R. W. Gilbert and C. L. Carrender; U.S. patent application Ser. No. 09/589,000, filed Jun. 6, 2000, entitled “Multi-Frequency Communication System and Method”, by inventors R. W. Gilbert and C. L. Carrender; U.S. patent application Ser. No. 09/588,998; filed Jun. 6, 2000, entitled “Distance/Ranging by Determination of RF Phase Delta”, by inventor C. L. Carrender; U.S. patent application Ser. No. 09/797,539, filed Feb. 28, 2001, entitled “Antenna Matching Circuit”, by inventor C. L. Carrender; U.S. patent application Ser. No. 09/833,391, filed Apr. 11, 2001, entitled “Frequency Hopping RFID Reader”, by inventor C. L. Carrender.
As shown in FIG. 2 , an embodiment of the present invention is directed to an RF communication system 30 that employs backscatter signals. The RF communication system 30 includes a reader or interrogator 32 that includes an antenna 34 through which the reader 32 can transmit an interrogation signal 36 to an RF tag 44 . The RF tag modulates the continuous wave interrogation signal 36 to produce a backscatter response signal 40 that is transmitted back to the reader 32 . The signal 40 can include an identification code stored in memory 50 , or other data. While FIG. 2 shows only two tags 44 , there would typically be multiple tags 44 in use, capable of communicating with the reader 32 .
The embodiment shown in FIG. 2 , the RF tag 44 includes an antenna 42 coupled to a modulator defined by processor 48 . The tag 44 includes a switch coupled between the antenna 42 and processor 48 . In the embodiment of FIG. 2 , the switch is included in the processor 48 . Alternatively, the switch can be a switch external to the processor 48 , such as an n-channel MOS transistor, a p-channel MOS transistor, a bi-polar transistor, or any of numerous other types of switches.
In FIG. 2 , a modulating signal from the processor 48 is input to the antenna 42 to cause the antenna to alternately reflect or not reflect. One item that can be transmitted from the tag to the reader 32 is an identification code (ID) 52 that is stored in memory 50 of the RF tag 44 . More particularly, each tag 44 includes a unique ID 52 . In one embodiment, the unique ID is a permanent ID. In another embodiment, the ID is temporary, or the tag includes both a permanent and a temporary ID. The ID is defined by a memory, or could be defined by fusible links, for example. In one embodiment, after receiving a command, the reader 32 sends a carrier wave or interrogation signal 36 that is received by the antenna 42 , and that signal is selectively reflected or not reflected back by the antenna 42 by the tag 44 shorting or not shorting dipole halves of the antenna 42 to produce portions of the response signal 40 (backscatter communications). Other communication methods are possible.
It will be appreciated that the depiction of the RF tag 44 in FIG. 2 is one embodiment only; RFID tags are well-known in the art. For example, U.S. Pat. No. 4,075,632 to Baldwin et al., which is incorporated herein by reference, discusses in detail circuit structures that could be used to produce the RF tag 44 , if modified as described below.
Similarly, the internal structures of the reader 32 are not shown in FIG. 2 . For example, the reader 32 can be the receiver described in U.S. Pat. No. 4,360,810 to Landt, which is incorporated herein by reference, modified as described below.
One aspect of the invention provides a method and apparatus to minimize the communications required to identify or discover multiple RFID tags in the reader's field of view. One aspect of the invention is particularly advantageous, for example, for the case of a significant number of unknown tags in the reader's field of view and where each tag possesses a long permanent ID number. These long identification numbers cause the tags to have a very large address space, so a linear address search of the address space is not realistic.
In the illustrated embodiment, each RFID tag has the capability to reply on any of a number of intermediate frequencies; other embodiments are possible. For example, in one embodiment, the tags can generate replies at intermediate frequencies of 16 KHz, 32 KHz, and 56 KHz. Other alternatives are possible. The method and apparatus does not require, but can benefit from, a read while write reader (reader which can send commands to one tag concurrent with reading a response from another tag). An advantage of this method is that a simple tag response is all that is required for the reader to gain information about a tag's identity. The tag does not need to present its entire ID. The tag's response can be very fast—possibly as short as a bit or symbol time. This feature allows the reader to gain important identity information about the tags within its field of view very rapidly. A TONE is any frequency or frequency pattern generated in a tag 44 that the reader 32 can recognize during a timeslot to determine that a tag 44 is responding. A timeslot is an interval controlled by the reader during which the tag responds. A simple tag response is all that is required for the reader 32 to gain information about a tag's identity—the tag does not need to present its entire ID. The reader 32 is merely looking for the presence or absence of the TONE in a time or frequency slot. In this embodiment, the multiple IF channels can still be used but instead of responding back with an entire ID, a tag responds with a tone that can be correlated to its ID.
FIG. 3 illustrates the concept for a reader 32 which cannot simultaneously read and issue commands. A discussion of the improved version of the method for an improved reader 32 design for simultaneous read/write operation appears after the discussion of FIG. 3 .
In step S 1 , the reader 32 issues a command of ENTER TAG DISCOVERY MODE and, in one embodiment, transmits a session ID.
In step S 2 , the reader 32 starts monitoring all discrete IF frequencies for presence of replies, such as in the form of On-Off Keyed modulated RF or other modulated RF.
In step S 3 , the tag 44 randomly selects a timeslot and IF frequency that it will use during the current discovery session. For example, see commonly assigned U.S. patent application, Ser. No. 10/263,809, titled “Method of Simultaneously Reading Multiple Radio Frequency Tags, RF Tag, and RF Reader”, by inventors Emre Ertin, Richard M. Pratt, Mike A. Hughes, Kevin L. Priddy, and Wayne M. Lechelt, which is incorporated herein by reference.
In step S 4 , the reader 32 issues a sequence of timing pulses (which could be, for example, the brief removal of RF illumination) to provide timeslot synchronization to the individual tags. In one embodiment, the timeslots are 100 milliseconds wide; other embodiments are possible.
In step S 5 , the tags 44 which are in communication range present a TONE or very simple modulation of their IF return frequencies during that timeslot. In one embodiment, each tag 44 uses a TONE instead of its entire identification number as described in U.S. patent application, Ser. No. 10/263,809 incorporated by reference and entitled “Method of Simultaneously Reading Multiple Radio Frequency Tags, RF Tag, and RF Reader”.
The reader 32 continues to issue timing pulses and to provide illumination until the final timeslot, and then discontinues illumination, in step S 6 .
In step S 7 , the reader 32 identifies (e.g., stores in memory) the timeslots and IF frequencies where TONEs were detected, and sends DISCOVERED YOU messages identifying the timeslots and IF frequencies where the tags' TONEs were discovered. In other words, the reader 32 transmits the timeslot and IF identifier to each discovered tag 44 . There will be cases where TONEs from multiple tags occur within the same timeslot and collide.
In step S 8 , each discovered tag 44 responds with a FOUND ME message, which contains the tag's ID (identification number).
In step S 9 , the reader 32 issues a YOU'RE DISCOVERED message to cause the tags to leave discovery mode.
More particularly, in step S 10 , the reader determines whether all tags 44 have been identified. If so, the process ends; if not, the process proceeds to step S 11 .
In step S 11 , the reader 32 will transmit another ENTER TAG DISCOVERY MODE with the same session ID, and process will repeat at step S 2 . The process is repeated until no TONES remain, meaning that all tags have been identified, and have left DISCOVERY MODE.
An embodiment similar to that of FIG. 3 is illustrated in an alternative format in FIG. 4 , to better illustrate steps performed by the reader and steps performed by the tags.
The use of timeslots alone with the tag 44 presenting a TONE (modulated IF) during a randomly chosen timeslot will allow a fast acquisition. See U.S. patent application, Ser. No. 10/263,809 incorporated above entitled “Method of Simultaneously Reading Multiple Radio Frequency Tags, RF Tag, and RF Reader”.
One embodiment involves the use of a reader which reads while writing. The use of a simultaneous read-write tag system allows overlapping the DISCOVERED YOU messages with the FOUND ME responses from the tags. This speeds up the tag acknowledgment process and thus reduces the time to identify and acknowledge large numbers of tags.
Potential applications include applications sensitive to rapidly identifying a large number of RF tags in as short a period of time as possible. To better illustrate how the tags are envisioned for usage, application areas that the inventors envisage, for example, Inventory Management, Process Monitoring, Process Control, Diagnostics, and Security.
Inventory management incorporates a wide variety of situations where RFID tags can be used. These situations include the simple inventory/locating task of critical or high value items in storage, transport, or final use locations. Speeding up the process of identifying large numbers of tagged items greatly increases the speed at which the customer's inventory management system can operate.
The addition of authentication and encryption processes to the tags requires that long messages and tag identifiers be used. Any method that reduces the time to identify a given tag will enhance system performance.
Thus, a system and method have been provided for rapidly identifying tags in a field. Collisions are also dramatically reduced as a result of using the method and apparatus of the preferred embodiment described above.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
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An RFID system comprises an RFID reader configured to issue an RF command requesting that RF tags identify themselves, and to issue timing information defining a plurality of timeslots; and a plurality of RF tags in selective communication with the reader, the RF tags having respective IDs, respective tags being configured to randomly select a timeslot in which to reply to the RF command, and to issue an RF reply in response to the RF command in the randomly selected timeslot, the RF reply including a frequency pattern to assist in identifying the tag but not the tag's entire ID, different tags having different frequency patterns.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a National Stage of International Application No. PCT/EP2012/005114, filed Dec. 12, 2012. This application claims priority to German Application No. 10 2012 000 716.7, filed Jan. 14, 2012. The entire disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The invention relates to a wind turbine having a wind gauge, and more particularly to a remote wind gauge having a mount for use on the surface of a rotating hub of a wind turbine.
BACKGROUND
[0003] Compiling and measuring predictive wind characteristics (wind velocity and/or profiles) is necessary for the economic viability of wind turbines for generating electrical energy from wind power. Knowledge of wind characteristics is necessary in particular in the area of the rotation of a rotor of the turbine caused by wind, with a rotor hub and rotor blades extending radially from the rotor axis. The rotor drives an electric generator located in a fixed machine house—also described as a gondola—that generates electrical energy that is then fed into an electrical grid.
[0004] Control mechanisms are provided in the gondola, and usually also in the rotor, with which the turbine is controlled as a function of measured or calculated wind characteristics. Both the rotor and the gondola are located on a tower.
[0005] With the increasing effective output of wind turbines, their height, and consequently that of the rotor hub, increases. Associated with this, however, the precise measurement of wind characteristics at rotor height of such facilities is associated with substantial expense.
[0006] The prior art offers several possibilities with respect to ascertaining wind characteristics. The simplest, but least exact method, is a cup anemometer. A cup anemometer is a measuring device that is mounted solidly/immovably on the fixed gondola and only measures wind characteristics there at a distance from the rotating part of the turbine. The results are, however, imprecise for predictively ascertaining or measuring in front of the hub. A cup anemometer may falsify the measurement results because the results of wind measuring devices/equipment on the gondola are strongly affected by wind turbulence caused by the rotation of the rotor blades. Vertical wind shear occurring in the area of the hub and the rotor blades is not ascertained.
[0007] Remote wind measuring instruments are known that are based on the known physical principle of the optical Doppler effect. The instrument is normally set up in front of the facility or in the primary wind direction either on the ground or on a mast (Metmast) and has a remote wind gauge that transmits beams at a specific frequency in a specific direction. Specific meteorological data, including wind characteristics, can be determined from the reflected beams in front of the facility. Doppler based installations work either on the basis of electromagnetic beams (also known as LIDAR) or on the basis of acoustic waves (also known as SODAR).
[0008] U.S. Pat. No. 6,535,158 B2 shows a remote wind measurement device that is mounted on a meteorological mast (Metmast) that is set up in front of and at a distance from a wind turbine. Signals are transmitted vertically upwards from the Metmast, wherein meteorological data, including wind characteristics in front of the wind turbine, are determined from the reflected signals that are then processed into signals for controlling the wind turbine. In addition to wind characteristics, the Doppler measuring devices/instruments also ascertain vertical wind shear, where measurements have established that the vertical wind shear varies locally and over time.
[0009] The primary advantage of a remote wind measuring instrument based on the Doppler effect lies in its ability to measure wind characteristics and profiles at a great height. In particular in very uneven country where, for example, a primary wind measuring device is in a wood, a LIDAR or SODAR system makes it possible to compare a measurement with a calculation or storage of existing wind data. Above a certain hub height, however, remote wind gauges that are mounted on a Metmast are complex and expensive if they are to measure wind characteristics at the hub height of the wind turbine.
[0010] The disadvantage of such individually deployed Doppler measuring arrays is firstly that the measurement results become less precise with increasing hub height. Secondly, with the rotation of the rotor about an axis oriented perpendicular to the axis of rotation (yaw axis), a wind gauge deployed on the ground or on a Metmast identifies increasingly less precise wind characteristics in front of the hub of the wind turbine. A measurement of the yaw error of the turbine is not possible with a stationary wind gauge. Thus, this does not provide a solution to the problem of how well an existing wind turbine can follow the wind.
[0011] In order to compensate for the disadvantage of a stationary LIDAR or SODAR array, it has already been proposed in the prior art to locate such an array using a suitable mount either inside the hub or outside on its surface in order to arrive predictively at precise measurements of the wind characteristics even with a yawing motion of the turbine.
[0012] EP 1 597 592 B1 shows, for example, a wind turbine with LIDAR equipment for measuring wind characteristics in front of the hub of the wind turbine. However, the LIDAR is mounted in the interior of the hub on a mount that is not specified in much detail, and has a line of sight that is inclined to the rotational axis of the hub in order always to scan an area in front of the hub when the hub is rotating and the turbine is rotating about the yaw axis.
[0013] The disadvantage of locating the LIDAR inside the hub, however, is the small installation space available for the LIDAR inside the narrow hub, which is packed full of several other devices. Access for maintenance and repair operations, or complete later removal and installation of the LIDAR, is possible only at considerable expense. LIDAR located inside the hub has only limited suitability for a time-limited, temporary measurement of wind characteristics, to check other wind measuring devices, or to check measured values for wind characteristics stored in advance. Furthermore, it is disadvantageous that the location of the LIDAR inside the hub allows only a very limited scanning of wind characteristics in front of the wind turbine.
[0014] Remote wind gauges that are located on the surface of a rotating rotor hub of a wind turbine, and that can ascertain, or measure, predictively the wind characteristics in front of the hub are known, for example from DE 10 2009 015 679 A1 or EP 1 770 278 A1.
[0015] Remote wind gauges on the rotating hub offer the advantage that they are maintenance-friendly and offer good accessibility. In particular, turbines can be retrofitted with a remote wind gauge at no great expense and, if need be, can also be removed at no great expense.
[0016] The precondition for locating a rotating remote wind gauge on the hub is, however, a suitable mount and an attaching fixture by means of which the remote wind gauge is fastened on the rotating hub. Increased demands are made on the mount and the attachment because of their operating location with its sometimes extreme climactic, static, dynamic and kinematic requirements.
[0017] Remote wind gauges to be used outside on the hub of the wind turbine must, therefore, be enclosed by a box-shaped protective body that has to be connected to the hub in order to protect the sensitive electronics and electrical equipment of the remote wind gauge from the effects of the climate. In the case of the remote wind gauge under consideration, it is a box-shaped component measuring about 50 cm in length, with a diameter up to 1.5 m. The hub, on the other hand, comprises a cone-shaped body with a nose-shaped spinner projecting in front of the turbine, where the rotor blades extend radially at the lateral walls of the hub. In addition, a mount for the measuring equipment is required for anchoring on the surface of the wind turbine hub. Anchoring the mount for the remote wind gauge on the surface of the hub necessitates a special type of attachment and location so that the measuring equipment can fulfill its function. The known arrangements, however, offer no guidance in this regard, since apparently locating a LIDAR or SODAR on the hub is certainly cited in the literature but has so far not been implemented technically.
[0018] On the other hand, the need exists for such a mount and type of anchoring for a remote wind gauge on the hub. This is the case, for example, when turbines are retrofitted with a remote wind gauge or are equipped only temporarily with such a measuring device, either to check the wind data from other existing measuring devices or to check calculated values that are stored as control values in the turbine control system.
[0019] It is, therefore, an object of the invention to specify a suitable method of anchoring and a suitable anchorage location for the remote wind gauge on the surface of the hub for a wind turbine.
[0020] The object is achieved by a wind turbine having a remote wind gauge with a mount. Advantageous developments of the invention are cited in the dependent claims.
[0021] The wind turbine of the invention comprises a rotor hub rotating about a rotor axis with rotor blades extending radially to the rotor axis, and a remote wind gauge attached externally on the rotor hub in a mount. The mount is oriented in such a manner that wind characteristics are ascertainable, or can be measured, at a distance in front of the hub, where the wind gauge is located between two neighboring rotor blades and in the radial direction of the rotor axis, and the mount is fastened to a respective blade flange in the area where the rotor hub is joined to the rotor blades.
[0022] The remote wind gauge with a mount for use on the surface of a rotating rotor hub of the wind turbine with rotor blades extending radially to the rotor axis of the hub, by means of which wind characteristics can be ascertained, or measured, in front of the hub, is characterized in that the mount has fastening mechanisms for a detachable connection of the mount to the hub between two neighboring rotor blades at a respective blade bearing flange of the two rotor blades.
[0023] With the invention, the remote wind gauge is located with a mount on the surface of a hub of a wind turbine between two neighboring rotor blades in such a manner that the remote wind gauge is oriented parallel to the rotor axis. This alignment of the remote wind gauge ensures that when the hub is rotating a scanning field is created in front of the hub that is almost circular and is not restricted by rotating rotor blades or a spinner located in front of the hub. Wind characteristics are thus ascertained optimally in a broad area in front of the hub that are then taken to a turbine facility control system connected to the wind gauge and can be processed into control signals for the turbine, or the measured values generated by the remote wind gauge can be compared with other measured and calculated values that are generated by other measuring devices (e.g. an anemometer located on the gondola), or have been previously stored as a calculated value in the turbine control system.
[0024] No adjustments, or only minor adjustments, to the inclination setting of the measuring device to the rotational axis of the rotor are required with the proposed position of the remote wind gauge on the hub. The attachment site of the mount for the remote wind gauge additionally offers the advantage that the problem mentioned at the beginning of the present disclosure can be solved concerning to what extent an existing wind turbine can follow the wind, or to what extent current measured wind values deviate from other measured values from other measuring devices or stored calculated values from current values. Knowledge of current values has a considerable effect on the profitability of the wind turbine.
[0025] In accordance with the invention, the attachment of the mount for the remote wind gauge is effected in the area where the rotor hub is joined to the rotor blades at a respective blade bearing flange. The hubs of wind turbines usually have flange-like extensions at the point where they join the mount at which the rotor blades are attached to a respective blade bearing flange. The proposed attachment point offers the advantage that the mount of the remote wind gauge can be located securely and without additional expense on the surface of the hub. Except at the two attachment points, the mount for the remote wind gauge has no direct point of connection to the hub of the wind turbine. In this position it can be oriented or re-adjusted always parallel to the rotor axis without great effort. Expensive retrofitting or reworking in the area of the hub is not required because either existing provisions for an attachment can be used or they can be installed without great effort in the hub flange/blade bearing flange area.
[0026] This measure simplifies the assembly, or disassembly, of the wind measuring device considerably. The remote wind gauge is always removed complete with its mount on the hub, where only the mount is connected to the hub. The remote wind gauge is expediently joined in advance to its mount in a workshop or on the ground. The complete array can then be raised by a lifting mechanism or a crane, for example, from the outside onto the hub to the attaching location and attached there. Removal is likewise carried out from outside without great effort using a lifting or crane mechanism.
[0027] Moreover, the simplified installation and removal of the entire array of remote wind gauge and mount is advantageous for maintenance and repair operations because the optics and electronics of such measuring devices, rotating in the open air under extreme climatic operating conditions, make an increased maintenance and repair cycle necessary.
[0028] The respective blade bearing flange as the joining point of a rotor blade to the hub flange to which the mount for the remote wind gauge is attached advantageously includes a threaded and/or push fit connection of the blade root to the metal flange on the hub. Bushings for lengthwise bolts are laminated into the root of the rotor blade for bolting the rotor blades to the hub flange. The lengthwise bolts are guided externally at the circumference of the hub and the rotor blades and secured with nuts.
[0029] An additional holding device with an eye to attach the mount can be installed in the connecting area with the external bolt-nut area of the blade bearing flange. The holding device can be attached subsequently, in the case of an existing wind turbine, at the studs for the installation of the remote wind gauge. Alternatively, the holding device for the mount can be attached when the turbine is constructed at the point where the blade bearing flange joins the hub flange, together with the attachment of a blade bearing flange to the hub flange.
[0030] A quite particularly advantageous holding device for the remote wind gauge mount on the hub is feasible if lifting eyes for a lifting tackle are in place with the hub that is used, with which the hub is to be attached during installation to, or removal from, a turbine house or a rotor shaft, or removed using a crane or a lifting device. These lifting eyes remain in place during operation of the wind turbine. The mount can thus be attached to the two eyes at no great expense. The wind energy plants from the General Electric Company in its GE 1.5 series with a rated output of 1.5 megawatts have such lifting eyes. These lifting eyes are attached radially to the intended axis of a blade bearing flange or rotor blade for assembly of the hub on the tower.
[0031] The connecting area of a hub flange to the appropriate rotor blade also includes an array in which a supporting sleeve is provided around the hub flange, where the sleeve has a slide rail positioned around the circumference of the hub on which a transport mount is located which slides and can be clamped on the periphery of the hub, as revealed in DE 10 2009 040 235 1 for example. Following installation of the hub to the turbine house (gondola), the transport mounts can be slid on both rails on the circumference of the hub in such manner that they are positioned radially to the axis of rotation of the rotor and thus are used as a mount for the remote wind gauge.
[0032] The optics and electronics of the remote wind gauge advantageously include a measuring system that is based on a LIDAR or SODAR system.
[0033] Such measuring systems are known and operate in accordance with the physical principle of the Doppler effect, which was mentioned at the beginning of the present disclosure. Such sensitive measuring devices have a box-shaped casing as protection, which is connected to the mount.
[0034] The mount is advantageously designed as a supporting frame that rests on an attaching plate. On both lateral longitudinal sides of the plate an attachment point can be advantageously provided on each side for the lifting eyes for the hub or for another type of attachment for the mount to the blade bearing flange, as described above.
[0035] Since the mount for the remote wind gauge is connected to the hub at only two attaching points, a mechanism is required to prevent tipping motions of the remote wind gauge. Such a mechanism is realized by an additional bearing arrangement that is positioned perpendicular to the connection of the two attaching points and towards the axis of rotation. The additional bearing arrangement includes a variable adjustment mechanism with which the inclination of the remote wind gauge to the axis of rotation of the rotor can be set. The adjusting mechanism can, for example, be configured as a foot that has an adjusting screw at its projecting end that is supported on the upper surface of the hub, whereby the inclination setting of the remote wind gauge to the rotor axis can be readjusted.
[0036] As a safety measure against damage to the rotor blades or the hub due to the remote wind gauge coming loose or falling from its mount, or to the mount coming loose from its attachment point to the hub, provision can be made for mechanical and/or electrical safety mechanisms that are connected to an emergency shut-down for the wind turbine, by means of which the rotation of the rotor blades is immediately stopped so that a loosened mount or a remote wind gauge that has become detached from its mount cannot result in damage to the rotor blade. An electrical series circuit of several safety mechanisms for the mount and/or the remote wind gauge is to be advantageously provided as an electrical safety mechanism that is linked to the emergency shut-down mechanism for the turbine configured as a safety chain.
[0037] As a further safety mechanism, the remote wind gauge can be provided with lightning protection. The mount includes for this purpose, as a lightning conductor, an electrical conductor that ensures an electrical connection of the mount to the hub during installation of the remote wind gauge on the hub. Thus the remote wind gauge is an integral part of the lightning protection for the entire turbine.
[0038] In the wind turbine in accordance with the invention, the wind gauge can be an integral part of the turbine controls, i.e. the wind characteristics measured are used directly or indirectly as control commands for the turbine. This arrangement is feasible when the remote wind gauge is installed permanently for operation on the hub.
[0039] Alternatively, the remote wind gauge can operate equally independently of the control system for the wind turbine. This method of operation is feasible when the remote wind gauge is to be installed only for a temporarily limited period on the turbine in order, for example, to perform comparative measurements with other existing wind measuring instruments on the facility to check their effectiveness. Intervention in an already existing pitch system with which the adjustment of the rotor blades about their axes is controlled, or in the turbine controls, is not necessary with this arrangement. The measured values of the remote wind gauge can be transmitted by remote querying independently of the turbine values to higher-level operations management and evaluated there according to need.
BRIEF DESCRIPTION OF DRAWINGS
[0040] Additional advantageous embodiments can be derived from one example of an embodiment that is explained in greater detail on the basis of the drawings in what follows.
[0041] FIG. 1 shows a schematic representation in a side view of a wind turbine having a remote wind gauge,
[0042] FIG. 2 shows a schematic representation in a front view of a rotor of the wind turbine,
[0043] FIG. 3 shows a side view of the remote wind gauge in a mount at its attachment point on the surface of a hub of the wind turbine,
[0044] FIG. 4 shows an alternative method of attachment to FIG. 3 , and
[0045] FIG. 5 shows a detail of the method of attachment from FIG. 3 and FIG. 4 .
DETAILED DESCRIPTION
[0046] FIG. 1 shows a wind turbine 1 that has a base 2 with an elevated tower 3 , wherein a turbine house described as a gondola 4 is located on the end of the tower facing away from the base 2 . The gondola 4 is carried rotatably on the tower 3 and can be pivoted about the axis 5 of the tower 3 (i.e., yaw axis 5 ) and can thus follow the wind direction. A rotor 6 extends away to the right from the gondola 4 that has a (rotor) axis of rotation 8 and, at the end facing away from the gondola 4 , a rotor hub 7 with three rotor blades extending radially to the rotor axis 8 that are given the reference numerals 9 , 10 and 11 . Only rotor blades 9 and 10 are visible in FIG. 1 because of the schematic method of representation. FIG. 2 shows a schematic front view of rotor 6 from which the arrangement of the rotor blades 9 , 10 and 11 can be seen. Each rotor blade 9 , 10 and 11 is normally attached offset at 120° on the circumference of the hub 7 .
[0047] It is further evident from FIG. 1 that each rotor blade 9 , 10 is mechanically coupled to a central or individual adjusting drive (pitch drive) by means of which the respective rotor blade 9 , 10 and 11 is rotated about its respective blade axis 12 , 13 and 14 . In addition, the rotor blades 9 , 10 and 11 can be turned optimally into the wind, or away from the wind using this adjusting mechanism.
[0048] The connection between a rotor blade and a metal flange on the hub 7 is made by a first blade bearing flange 21 , to which blade 9 is attached, a further blade bearing flange 22 on which blade 10 is carried, and a third blade bearing flange 23 to which blade 11 is attached. At the point of attachment to the respective rotor blade 9 , 10 or 11 , the hub 7 has a metal flange oriented radially to the rotor axis 8 described in what follows as the hub flange. Each hub flange has a bolt-nut connection to the pertinent rotor blade for the threaded connection to the hub 7 . The end of a rotor blade 9 , 10 and 11 attached to the respective blade bearing flange 21 , 22 and 23 is designated as the blade root, wherein the pertinent blade root of blade 9 bears the reference numeral 24 , the blade root of blade 10 the reference numeral 25 , and the pertinent blade root of blade 11 the reference numeral 26 .
[0049] Rotor 6 is mechanically coupled to an electric generator 15 that is located in the gondola and for the most part converts a wind force 16 acting on the individual rotor blades 9 , 10 and 11 into electrical energy. A facility control system is provided for controlled operation of the wind turbine 1 by means of which the pitch drives, and thus a suitable rotor blade angle relative to the wind force 16 , can be adjusted for energy conversion.
[0050] The most precise predictive measurement possible of wind characteristics in front of the wind turbine 1 is necessary for optimal control of the wind turbine, specifically at the height of hub 7 . Therefore, two wind gauges 18 and 19 are provided on the turbine 1 , as shown in FIG. 1 .
[0051] The first measuring device 18 is an anemometer that is located on a part of the gondola 4 facing away from the rotor 6 . Because of its location behind the rotor 6 , its measurement is affected very strongly by turbulence caused by the rotation of the rotor blades 9 , 10 and 11 .
[0052] The second measuring device, with the reference numeral 19 and attached on the surface of the hub 7 in a mount 20 (see FIG. 2 in particular), is a remote wind gauge 19 that is oriented in such a way that, using this arrangement, wind characteristics at a distance from the hub 7 can be ascertained, or measured. The remote wind gauge 19 operates in accordance with the physical “Doppler effect” and is referenced herein as “LIDAR 19 ” if it operates on the basis of laser beams. If it operates on the basis of acoustic waves, it is referenced herein as “SODAR 19 ”.
[0053] Because of its location, LIDAR technology or SODAR technology are both better suited for precisely determining wind characteristics for the turbine 1 than the anemometer 18 located on the gondola 4 . LIDAR 19 is thus suitable as a measuring device for a comparison with the anemometer 18 .
[0054] Using LIDAR 19 , the output of the turbine 1 can be improved or specific meteorological data stored in the turbine control system 17 can be checked and, if necessary, corrected with the aid of the LIDAR 19 . Using the LIDAR 19 , a check can also be performed as to how precisely the turbine 1 is following the wind force 16 .
[0055] From FIG. 2 it is particularly evident that the LIDAR 19 is positioned between two neighboring rotor blades, in this example between rotor blades 9 and 13 , and in a radial direction to the rotor axis 8 . The mount 20 is attached in the area where the rotor hub 7 attaches to the neighboring blade bearing flanges. In FIG. 2 these are blade bearing flange 21 to blade 9 and blade bearing flange 22 to blade 10 . The alignment of the LIDAR 19 is thus coaxial to the rotor axis of rotation 8 and generates an almost circular scanning field in front of the turbine 1 at the hub 7 height when rotor 6 is turning.
[0056] FIG. 3 shows in a side view the attachment of the LIDAR 19 in its mount 20 where the hub flange joins the blade bearing flange 22 . The flange 22 for the mount 20 has a holding device 27 for the mount 20 at the periphery of the blade 10 (not shown expressly in FIG. 3 ). The holding device 27 is attached by means of a screw and bolt connection to a radially projecting collar on the hub flange. Towards the opposite attaching point for the holding device 27 on the neighboring blade bearing flange, the holding device 27 has an eye for an attaching plate 28 that has an anchoring point on each of its longitudinal sides by means of which the mount 20 is attached to the LIDAR 19 on the rotor hub 7 . The mount 20 includes a cross-member 30 that is oriented in the direction of the rotor axis of rotation 8 .
[0057] The sensitive electronics and optics of the LIDAR 19 are surrounded by a protective case 31 that has a window 32 facing the scanning field (on the left in FIG. 3 ) for the emission and reception of beams. An electrical plug is integrated into the protective case 31 for the energy supply to the LIDAR 19 and for the transmission and evaluation of measurement data to the turbine control system 17 in the gondola 4 or to a separate remote control room, not shown.
[0058] The LIDAR 19 is surrounded in its mount 20 (not expressly visible in FIG. 4 ) by an electrically conductive framework 35 for lightning protection that is electrically connected to the hub 7 . The LIDAR 19 is thereby connected to the lightning protection system of the wind turbine 1 .
[0059] FIG. 4 shows an alternative attachment point for the LIDAR 19 mount on the hub 7 of the wind turbine 1 . The hub 7 has two transport or lifting eyes 36 to which lifting tackle for a crane, not shown, can be attached, by means of which the hub 7 can be connected to the rotor 6 when the turbine 1 is constructed. The two lifting eyes 36 were attached previously to the circumference of the hub 7 when it was assembled. They may be integral parts of the hub flange and remain on the circumference of the respective blade bearing flange even after assembly. Lifting eyes 36 may be set radially to the rotor axis of rotation 8 . The lifting tackle of the crane can be attached later during replacement or disassembly of the hub 7 to the two lifting eyes 36 . The attaching plate 28 with the mount and the LIDAR 19 can thus be fastened detachably to the lifting eyes 36 .
[0060] FIG. 5 shows a variable adjustment device 37 for the carrier 30 of the mount 20 . The device 37 includes an additional adjustable foot 38 located perpendicular to the attaching plate 28 and at the two attachment sites and supported on the hub 7 surface. Adjustment screws 39 are provided at the projecting end of the foot 38 by means of which the angle of inclination of the carrier 30 , and thus of the LIDAR 19 to the rotor axis 8 , can be adjusted.
[0061] The invention was described using the example of the LIDAR 19 arranged in a mount that is secured in a specially installed or integral lifting or locating eye of the hub 7 . It is part of the scope of disclosure of the invention to use remote wind gauges that are based on another physical effect for the registration and/or measurement of meteorological data. The attachment of the mount in accordance with the invention for the remote wind gauge on the hub 7 can also be used with other types of locating devices in which a sleeve is positioned in the area of the hub flange on the circumference on which a runner with an adjustable locating device is positioned that can also be used both as a lifting device and as a holding device for the remote wind gauge.
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The invention relates to a wind turbine comprising a rotor hub ( 7 ) rotating about a rotor axis ( 8 ), rotor blades ( 9, 10, 11 ) extending radially with respect to the rotor axis ( 8 ) at the same angular spacing relative to one another, and a remote wind gauge ( 19 ) that is fastened externally on the surface of the hub ( 7 ) in a mounting ( 20 ) and oriented such that wind characteristics at a distance in front of the hub ( 7 ) can be ascertained or measured, wherein the remote wind gauge ( 19 ) is arranged between two neighbouring rotor blades ( 9, 10 ) and in the radial direction of the rotor axis ( 8 ) and the mounting ( 20 ) is fastened to a respective blade bearing flange ( 21, 22 ) in the region of the connection of the rotor hub ( 7 ) to the rotor blades ( 9, 10 ), such that the remote wind gauge ( 19 ) can be retrofitted to the wind turbine ( 1 ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to cameras, such as movie cameras and, particularly, to circuits for preventing faulty operation when the battery voltage falls.
2. Description of the Prior Art
Cameras with circuits for preventing faulty operation due to a drop in the battery voltage are known. Such circuits are used in the circuitry for controlling the operation of a cine camera and constructed in the form of a warning circuit using an indicator, such as an LED, that lights upon the fall of the battery voltage, or a switching circuit that responds to the fall of the battery voltage and cuts off the electrical power supply. Such conventional error preventing, i.e., faulty operation preventing, circuits are rendered effective just as soon as the battery voltage drops below the satisfactory operating level. This may result in a serious disadvantage, namely the circuit may respond with a warning or cut off the control when the effective voltage of the battery is only temporarily lowered, for example, due to a sudden increase of the load current. Specifically, the operation of a cine camera begins by supplying electrical power to the diaphragm control circuit and, after the diaphragm control is stabilized, proceeds to drive the film motor. Supplying a large current to the diaphragm control circuit temporarily lowers the battery voltage. A conventional circuit tends to cut off the electrical power supply in response to the temporary lowering of the battery voltage. Thus, even when the battery voltage recovers the satisfactory exposure operating level, the motor is no longer supplied with electrical power.
Another disadvantage of conventional circuits is that the error preventing operation occurring when the battery voltage falls is effected by merely opening the power switch to terminate the application of electric power supplied to all the circuit portions, so that the camera control circuit stops controlling the operation of the camera even in the middle of a cycle during the pulldown operation of the claw. In other words, for example, in the sequence control circuit of a sound motion picture camera, the actuation of release initiates an exposure not directly but through various control members driven in sequence according to a predetermined program. To terminate 20 the exposure, the camera must be stopped according to a given sequence, or otherwise the rotary shutter would be left open. Accordingly, if the drop in battery voltage occurs during an exposure, it is then necessary to extend application of the electrical power supply until the concurrent exposure terminating sequence has been completed. Alternately, when a drop is detected at the time the release is actuated, the electrical power supplied to the shutter control circuit should be instantly cut off, because the exposure aperture is still closed.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a circuit for preventing faulty operation of a camera when the voltage of an electrical power source is temporarily lowered, while permitting the voltage to be checked accurately so that when a voltage drop continues, a deactuating signal is produced to stop the camera from further operation.
Another object of the present invention is to provide a circuit for preventing faulty operation of a cine camera by controlling the stoppage of electrical power in accordance with 15 the operating phase of a camera cycle in which the voltage drop is detected in such a manner that the operation of the camera is stopped.
The various features of the invention are pointed out in the claims. Other objects and advantages of the present 20 invention will become apparent from the following detailed description of embodiments when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a cine camera embodying the invention and incorporating an error preventing circuit;
FIG. 2 is an electrical circuit diagram illustrating a sequence control circuit of the cine camera in FIG. 1 and embodying features of the invention;
FIG. 3 is an electrical circuit diagram showing the details of the circuit of FIG. 2;
FIGS. 4a to 4p are voltage timing diagrams illustrating the manner in which the sequence control circuit of FIGS. 2 and 3 may operate;
FIG. 5 is a graph showing the operation of the comparator COM of FIG. 2;
FIG. 6 is a diagram of another example of the timer circuit of FIG. 3;
FIG. 7 is a diagram of an example of the diaphragm control circuit of FIG. 2.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows the outline of construction and arrangement of the main parts of a cine camera embodying the invention. Here, camera body 1 encloses a film drive motor 2. In the body, a gear 3 fixedly mounted on the rotary shaft of the motor 2 meshes with a gear 4 and forms a two-stage gear arrangement with a gear 5. A rotary shaft 6 in the two-stage arrangement has a worm gear 7 fixedly mounted thereon. A gear 9 meshing with the worm gear 7 drives a gear 10 which is connected to a takeup shaft 8 through a friction mechanism. The takeup shaft 8 carries a takeup pawl 8-1 arranged to engage a takeup spool of a film cartridge when the film cartridge is loaded into a cartridge chamber in the camera body.
A gear 11 meshes with the gear 5, and is connected to a shutter blade 12. The shutter blade 12 rotates in response to rotation of the gear 11. The camera further contains a capstan motor 13, a pulley 14 fixed to a rotary shaft 15 of the capstan motor 13, a motion transmission belt 16 trained between the pulley 15 and a pulley of a flywheel 17, a capstan shaft 18, a pinch roller 19, a sound recording magnetic head 20, and an electromagnet 21 for controlling movement of a stopper member 22. The stopper member 22 is arranged opposite an engagement groove provided in the gear 5 so as selectively to engage the engagement groove and inhibit rotation of the above described gear 5, and upon retraction from the engagement groove allows rotation of the gear 5. The shutter blade 12 is constructed so that when the gear 4 is latched by the stopper member 22 engaging the engagement groove, the exposure aperture is fully closed. A compression spring 23 urges the stopper member 22 away from the gear 5. Also included are a trigger lever 24, a relay lens 25, a prism 26 for light measurement, and a photo-sensitive element 27 whose output is utilized in determining the size of the aperture of diaphragm member 29. The output of element 27 also drives a diaphragm control circuit 28 including a meter or the like.
FIG. 2 shows one embodiment of the faulty operation preventing circuit according to the present invention applied to a sequence control circuit of the cine camera. An electrical power source or battery E energizes the circuit through an electrical power source switch SM, and partially through an electrical power supply control transistor Q6 whose emitter is connected to the switch SM and whose collector is connected to an input terminal Vint of a regulator circuit REG. Shunting the emitter-base path of the transistor Q6 is a resistor R1. The base of the transistor Q6 is connected through a resistor R2 and diodes D1, D3 to two switches S1, S2. The switch S1 is turned on by the first step of a release lever 24 of FIG. 1, and the switch S2 is a switch that is closed by the second step of the release lever 24. A capacitor C1 is connected between the collector of the transistor Q6 and the negative terminal of the battery E, so that even after the power supply control transistor Q6 is turned off, the circuit is capable of supplying power.
Resistors R3 and R4 connected in series to each other to form a battery voltage detecting resistor circuit is connected parallel to the capacitor C1 to produce an output proportional to the actual voltage of the battery E. The output at the junction of resistors R3 and R4 is applied to a negative input terminal of a comparator COM. The regulator circuit REG is constructed, for example, of a Zener diode Z, a resistor RZ and a transistor QZ, and is responsive to a voltage Vint applied to the input terminal Vint and produces a voltage Voutv appearing at an output terminal VoutT, as shown in FIG. 5. A capacitor C2 connected in series with a resistor R5 forms a power-up clear circuit therewith. The output terminal of the power-up clear circuit is connected to an input terminal Ic of an integrated circuit (IC) operation control circuit CIR.
A resistor R6 is connected through a diode D2 to the switch S1. The junction of the resistor R6 and the diode D2 is connected to an input terminal I1 of the circuit CIR. A resistor R7 is connected through a diode D4 to the switch S2. The junction point of the resistor R7 and the diode D4 is connected to an input terminal I2 of the circuit CIR. Two resistors R8 and R9 form a voltage divider for dividing the output voltage Voutv of the regulator circuit REG to form a reference voltage COMV1. The comparator COM has an output terminal connected to an input terminal I3 of the circuit CIR. The threshold level for inverting the comparator COM is preadjusted to a voltage Vth somewhat higher than the lower operating level of the control circuit CIR.
A transistor Q1 has its base connected through a resistor R14 to an output terminal O1 of the circuit CIR and its collector connected to a diaphragm control circuit 28 which controls the diaphragm on the basis of the brightness of an object being photographed. Thus, the transistor Q1 serves to control the power to the diaphragm control circuit 28. The latter, as shown in FIG. 7, is composed of a constant voltage circuit CVC, a photosensitive element Pr and a meter M whose pointer is translated into the diaphragm aperture.
A transistor Q2 has its base connected through a resistor R13 to an output terminal O2 of the circuit CIR and its collector connected to a capstan motor control circuit CM known in the art of synchronous sound recording cine cameras. A transistor Q3 has its base connected through a resistor R12 to an output terminal O3 of the circuit CIR and its collector connected to a film motor control circuit FM. A transistor Q4 has its base connected through a resistor R11 to an output terminal O4 of the circuit CIR and its collector connected to the electromagnet 21 controlling the operation of the stopper member so that the shutter is latched in the exposure aperture closing position.
A light-emitting diode LED connected through a resistor R15 to an output terminal Oo of the circuit CIR emits light when the battery voltage falls to inform the operator of the fact that the battery is no longer usable. A transistor Q5 has its collector connected to the base of the transistor Q6 and its base connected to an output terminal O2 of the circuit CIR. The transistor Q5 serves to control the power through the transistor Q6.
FIG. 3 shows details of a preferred embodiment of the control circuit CIR of FIG. 2. Here, a pulse generator OSC produces a clock pulse train CP. A D-type flip-flop FF1 has a D input connected through an inverter NT2 to the input terminal I2 and has an output terminal Q connected to the D input terminal of a D-type flip-flop FF2 and to one of the inputs of an exclusive OR gate ER1. The second flip-flop FF2 has an output terminal Q connected to the other input of the exclusive OR gate ER1. Said flip-flops FF1, FF2 and exclusive OR gate ER1 constitute a pulse forming circuit for producing a pulse which actuates sequence control operation for initiation and termination of an exposure.
An OR gate OR1 connects a reset terminal R of a counter COUNT1 to the output of the exclusive OR gate ER1 and to the input terminal Ic. Hence, the counter COUNT1 is reset by a pulse from said gate ER1 or the power-up clear pulse from the input terminal Ic. An inverter NT3 has an input connected to an output terminal Qn of the counter COUNT1 and a terminal connected to one input of an AND gate AN1. Thus, the AND gate AN1 is gated off by a high signal from the output terminal Qn of the counter COUNT1, to terminate the duration of the counting operation for the clock pulses CP entering the AND gate AN1. During the counting operation, the counter COUNT1 first produces a high signal at an output terminal Ql, and then at output terminal Qk, Qm, Qn, in sequence. An AND gate AN3 receives one input from the output terminal Qk of the counter COUNT1 and at the other input from the output terminal Q of the flip-flop FF2. The AND gate AN3 applies its output to the clock terminal C of a D-type flip-flop FF3 and produces a signal which sets the flip-flop FF3.
An AND gate AN4 receives one input from the output terminal Ql of the counter COUNT1 and another input from the Q output terminal of the flip-flop FF2. The AND gate AN4 applies its output through an OR gate OR5 to the reset terminal R of a D-type flip-flop FF5 and produces a signal for resetting said flip-flop FF5. An AND gate AN5 is connected at one input to the output terminal Qm of the counter COUNT1 and at the other input to the Q output of the flip-flop FF2. The output of the AND gate AN5 is connected to the clock terminal C of a D-type flip-flop FF4 and produces a signal for setting said flip-flop FF4. An AND gate AN5 is connected at one input to the output Qn of counter COUNT1 and at the other input to the Q output of the flip-flop FF2. The output of the AND gate AN6 is connected through an OR gate OR3 to the reset terminal R of a flip-flop FF5 and produces a signal for resetting said flip-flop FF5.
A NAND gate NA1 has its input terminal connected to the input terminal I1 and the Q output terminal of the flip-flop FF3 and its output terminal connected to the output terminal O1 of the circuit CIR. A counter COUNT2 has a reset terminal R connected through an OR gate OR2 to the input terminal Ic and the output of a NOR gate NR1, and thus is reset by a high signal from the OR gate OR2. The clock input terminal C of said counter COUNT2 receives signals from an output of an AND gate AN2, one of whose inputs is connected to an inverter NT1 and the other of whose inputs is connected to the abovedescribed pulse oscillator OSC. The counter COUNT2 starts to count when the battery voltage drops, and serves as a timer circuit for producing a high signal from an output terminal Qt after a predetermined time interval. A buffer amplifier BUF1 is connected to the output terminal Qt of the counter COUNT2.
The operation of the circuitry of the cine camera of FIGS. 1 to 3 will become clearer when referring to FIGS. 4a to 4p and 5. In normal operation, an operator first closes the power switch SM, and then depresses the release lever 24. At the first step of the release action, as the release lever 24 is depressed, the switch S1, at the time t 1 shown in FIG. 4a, is turned on. This then turns on the transistor Q6 which applies the voltage of the battery E to the input terminal Vint of the regulator circuit REG. If it is assumed that the actual voltage of the battery E is sufficiently high, the regulator circuit REG produces an output in the form of a regulated voltage Voutc appearing at the output terminal VoutT. This output voltage renders the sequence control circuit CIR operative.
Since the switch S1 is now closed, a low signal (hereinafter referred to as "0" or a low signal) is applied to the input terminal I1. Since the switch S2 is not yet closed, a high signal (hereinafter referred to as "1" or a high signal) is applied to the input terminal I2. The input terminal Ic receives a signal pulse from the power-up clear circuit, and the input terminal I3 receives the output signal of the comparator COM.
As mentioned above, since the battery E has a sufficiently high voltage, the constant voltage COMV1 at the positive input terminal of the comparator COM is exceeded by the voltage COMV2 on the negative input terminal. This causes the comparator COM to produce a "0" signal which is applied to the input terminal I3. Because the input terminal I1 receives a "0" signal as mentioned, the NAND gate NA1 produces a "1" signal which appears at the output terminal O1. This turns on the transistor Q1 and renders the diaphragm control circuit 28 of known construction operative. Adjustment of the size of the diaphragm aperture opening according to the object brightness is now initiated.
At the time t 1 , the power-up clear circuit produces a single pulse which appears at the input terminal Ic. The flip-flops FF3-FF5 remain reset and produce "0" signals at the output terminals Q. The resulting lows at the outputs 02-04 keep the transistor Q2-Q4 in the nonconductive state. Also, the pulse from the power-up clear circuit occurring at the time t 1 is transmitted through the OR gate OR2 to the counter COUNT2 at its reset terminal R, and the counter is thus reset. For this reason, at the time t 1 , the counter COUNT2 produces a "0" signal.
The NOR gate NR1 receives the "0" signal from the counter COUNT2 and also a "0" signal, shown in FIG. 4e, from the input terminal I3 to produce a "1" signal. For this reason, the counter COUNT2 continues to be reset and, therefore, the output of the counter COUNT2 is maintained at "0", so that the light-emitting diode LED is left de-energized. Until the first step or stage, only the diaphragm control circuit 28 is rendered operative.
Upon further depression of the release lever to a second step, the switch S2 is turned on. At the time t 2 at which the switch S2 is closed, the circuit CIR receives a "0" at its input terminal I2. This low is then inverted by the inverter NT2 of FIG. 3 and applied to the D terminal of the flip-flop FF1. Then, the flip-flop FF1 produces a "1" signal in synchronism with the clock pulse CP from the oscillator OSC as shown in FIG. 4l, and this signal is directed to the D input terminal of the flip-flop FF2. For this reason, the flip-flop FF2 is set one clock pulse later, after the flip-flop FF1 has been set and produces a "1" signal as shown in FIG. 4m. This causes the exclusive OR gate ER1 to produce a signal pulse as shown in FIG. 4n which is applied to the reset terminal R of the counter COUNT1.
When the counter COUNT1 is reset, its output terminals Qk, Ql, Qm and Qn produce "0" signals. The "0" output at Qn, after having been inverted to a "1" signal by the inverter NT3 is applied to the AND gate AN1 at one input thereof. Thus, the AND gate AN1 is gated on from a time t 3 onward at which the counter COUNT1 was reset, and the clock pulses from the oscillator OSC are passed through the AND gate AN1 to the clock terminal C of the counter COUNT1.
When the number of clock pulses counted by the counter COUNT1 has reached a predetermined value, a "1" signal is produced at the output Q1. Then, when the counter COUNT1 has advanced an additional predetermined number of clock pulses, the output terminal Qk produces a "1" signal which is applied to the AND gate AN3 at one input thereof. Since the other input of the AND gate AN3 is connected to the output terminal Q of the flip-flop FF2, and the output Q is "1" as shown in FIG. 4m, the AND gate AN3 produces a "1" signal. For this reason, the flip-flop FF3 is set at a predetermined time interval T1 from the time t 3 at which the counter COUNT1 starts to count, and produces a "1" signal from the output terminal Q.
At the time t 4 after the predetermined time interval T1 from the time t 3 , a "1" signal appears at the output terminal O2 of the circuit CIR as shown in FIG. 4h. This turns on the transistor Q2 to render the capstan motor control circuit CM operative. Thus, the capstan motor 13 of FIG. 1 starts to rotate.
When the counter COUNT1 has counted more pulses, a "1" signal is produced at the output terminal Qm of the counter COUNT1. This high is fed to one input of the AND gate AN5 whose other input is connected to the Q high output of the set flip-flop FF2. Thus, AND gate AN5 produces a "1" signal in response to the "1" signal from the output terminal Qm of the counter COUNT1. The "1" signal from the AND gate AN5 sets the flip-flop FF4 to produce an output Q of "1" level. Therefore, after the elapse of an additional predetermined time T2 from the time t 4 at which the counter COUNT1 produces a "1" at the output Qk, that is, at a time t 5 , a "1" signal is produced at the output terminal O3 of the circuit CIR as shown in FIG. 4i. This causes the transistor Q3 to conduct and render the film motor drive control circuit FM operative. The film motor 2 now starts to rotate and drive the film transporting mechanism and rotary shutter.
Since the actuation of the film motor drive control circuit FM is delayed from the actuation of the capstan motor by the time interval T2, even when a slack loop of film in the loaded cartridge amounts to several frames of film, advancement of the film is always initiated from a condition in which this slack loop of several frames is removed. From the time t 5 onward, motion pictures with sound accompaniment are being taken on the sound film.
Even after the time t 5 , the counter COUNT1 advances until a predetermined number of additional pulses have been counted at a time t 6 (after a time t 3 from the start of counting operation by the counter COUNT1) to produce a "1" signal at an output Qn as shown in FIG. 4p. Then, responsive to the signal, the inverter NT3 produces a "0" signal which is applied to the input terminal of the AND gate AN1. Thus, the counting operation of the counter COUNT1 is terminated, and the control scheme of the circuit CIR for initiation of the exposure has been fulfilled.
During termination of the motion picture taking operation, the circuit CIR operates as follows. Assuming that the operator removes his finger from the release lever at a time T 7 , the switch S2 is then turned off as shown in FIG. 4b, and the input at the terminal I2 is changed to "1" as shown in FIG. 4d. Therefore, the inverter NT2 of FIG. 3 produces a "0" signal which is applied to the D input terminal of the flip-flop FF1. The flip-flop FF1 is then reset by the clock pulse CP to produce a "0" signal as shown in FIG. 1. Therefore, in a manner similar to that described, the flip-flop FF2 is reset one clock pulse later to produce a "0" signal at a time t 8 . Then, the exclusive OR gate ER1 produces a single pulse whose duration is equal to one period of clock pulses as shown in FIG. 4n. This pulse is fed through the OR gate OR1 to the reset input R of the counter COUNT1 so that the counter COUNT1 is now reset.
Accordingly, at the time point t 7 , the output Qn of the counter COUNT1 is changed from "1" to "0" as shown in FIG. 4p. This causes the AND gate AN1 to be gated on again, and therefore, causes the counter COUNT1 to start counting clock pulses again. Also in this case, the flip-flop FF2 is reset at the time t 8 as shown in FIG. 4m to produce at the output Q, a "1" which is applied through the OR gat OR4 to the reset terminal R of the flip-flop FF4. Therefore, the flip-flop FF4 is reset at the time t 8 causing the circuit CIR to produce a "0" signal at the output terminal O3, and therefore, causes the transistor Q3 to be turned off. Thus, the power supply to the film motor control circuit FM is cut off to stop further movement of the film.
On the other hand, the Q output of the flip-flop FF2 is fed to the clock terminal C of the flip-flop FF5. Hence the flip-flop FF5 is set at the time t 8 , causing the circuit CIR to produce a "1" signal at its output terminal O4, and therefore, causes the transistor Q4 to turn on and energize the electromagnet 21.
The energized electromagnet 21 moves the stopper member 22 toward the gear 5 against the force of the spring 23. When the stopper member 22 engages the groove of the gear 5, the gear 5 is stopped and does not rotate further. Thus, the shutter blade 21 is latched in the exposure aperture in the fully closed position.
After the shutter is closed in this way, as the counter COUNT1 advances, its output terminal Q1 produces a "1" signal. At this time, because the flip-flop FF2 is reset, and the flip-flop FF2 produces a "1" at the output Q, the AND gate AN4 responds to and produces a "1" signal. The flip-flop FF5 is now reset by said "1" signal from the OR gate OR5, causing the circuit CIR to produce a "0" signal at its output terminal O4. This turns off the transistor Q4 which de-energizes the electromagnet 21, so that the stopper member 22 is returned to its initial position.
After that, as the counter COUNT1 advances, the outputs Qk, Qm and Qn of the counter COUNT1 change to "1" signals in sequence. Since, at this time, the flip-flop FF2 is reset, the output of the circuit CIR is not changed by the "1" signal from the terminals Qk and Qm. At a time t 9 at which the output Qn changes to "1", that is, when a time interval T3, from the start of counting operation by the counter COUNT1 has passed, the AND gate AN6 produces a "1" signal in response to the output Qn of "1",25 and this "1" signal is applied through the OR gate OR3 to the flip-flop FF3. Therefore, at the time t 9 , the flip-flop FF3 is reset, causing the circuit CIR to produce a "0" signal at the output terminal O2, and causes the transistor Q2 to turn off. Thus, the power supply to the capstan motor control circuit is cut off to stop the motor from further rotation. It is to be understood that the stoppage of the capstan motor is effected in the predetermined time interval T3 from the time the film motor is stopped. This insures that even when the film was slack, upt to several frames, at the time the film motor was stopped, the film is set to the normal state where the length of looped film between the exposure aperture and the sound head is minimized when the exposure operation is terminated. This is so because the prolonged rotation of the capstan motor feeds the part of the film which is slack. At this time, the flip-flop FF3 also produces a "1" at output Q. If the switch S1 is concurrently off and, therefore, the input at the terminal I1 is "1", the NAND gate NA1 produces a "0" signal for the first time. This causes the circuit CIR to produce a "0" signal at the output terminal O1. Hence the transistor Q1 is turned off, with the resultant deactuation of the diaphragm control circuit 28. Thus, the continuous succession of frame exposures is terminated.
It is to be noted that since the NAND gate NA1 continues to produce a "1" signal, until the flip-flop FF3 is reset, even when the switch S1 is turned off, the diaphragm control circuit 28 is maintained in the operative condition until the scheme of sequential operation has been fulfilled. As described, the normal exposure operation is put into practice in the aforementioned sequence of various steps, provided that the voltage of the battery E is above the critical level.
If the battery voltage falls below the predetermined voltage Vth, the system operates as follows. It is assumed that an exposure is initiated by the ordinary sequence, and the circuit CIR produces "1" levels at outputs O1, O2 and O3 to actuate the diaphragm control circuit 28, capstan motor control circuit CM and the film motor control circuit FM for normal sound motion picture type operation. Now, the voltage of the battery E drops to such degree that the voltage Vinv applied to the input terminal Vint of the regulator circuit REG is lowered below the reference voltage Vth (FIG. 5). In this state, as shown by dashed lines, the input voltage COMV2 of the comparator COM becomes lower than COMV1, so that the comparator produces a "1" signal which is then applied to the circuit CIR at input terminal I3. Therefore, the NOR gate NR1 produces a "0" signal which is then applied to the counter COUNT2 at the reset terminal R. Hence, the counter COUNT2 is no longer reset.
The clock pulses CP are then passed through the AND gate AN2 to the clock terminal C of the counter COUNT2. The counter COUNT2 then starts to count the pulses CP. At a predetermined time, from the start of the counting operation, the counter COUNT2 changes its output Qt to "1" which, after having passed through the buffer amplifier BUF1 appears at the output terminal Oo. Thus, the light-emitting diode LED is lit to inform the operator that the battery voltage has fallen below a satisfactory operating level.
The "1" signal produced from the output terminal Qt of the counter COUNT2 is also applied to the reset terminal of the flip-flop FF1. Thus, the aforementioned procedure, after the time t 7 of FIG. 4 repeats itself, so that the shutter blade is latched in the exposure aperture closed position to terminate the exposure operation. It is to be understood that even when the battery voltage drops during an exposure, electric power to all circuits is not instantaneously stopped. Rather, after the exposure terminating operation has been completed in the ordinary sequence, the power supplied to all the circuits is cut off, thereby preventing the shutter blade from being latched in a position where the exposure aperture is left partially or completely open.
On the other hand, assuming that the battery E recovers and reaches the threshold level between the moment the counter COUNT2 starts to count and the time the counter COUNT2 produces a "1" signal at output Qt, the comparator COM then produces a "0" signal without delay. This resets the counter COUNT2 with the "1" signal of the NOR gate NR1. The flip-flop FF1 is then not reset, but remains in the set condition, permitting the aforementioned exposure cycle to continue. It will be appreciated that accidental or temporary drop in battery voltage does not affect the normal exposure nor, for example, does a sudden increase in the current load. The normal exposure cycle is terminated only when a continuous drop in battery voltage occurs.
Alternatively, the battery voltage may drop below the reference voltage Vth before actuation of the release. In that case, closure of the switch S1 by depressing the release to its first step, which turns on the transistor Q6 and which then turns on electrical power to the regulator circuit REG results in production of a "1" signal at the comparator COM. Thereafter, the counter COUNT2 starts to count and, after the predetermined time, produces a "1" signal at the output terminal Qt. Therefore, the flip-flop FF1 is maintained in the reset state so that even when the switch SW2 is turned on at the second step of the release, the flip-flop FF1 is not set, but remains in the reset state. Hence, the sequential actuation after the time t 2 of FIG. 4 does not occur, and only the diaphragm control circuit 28 is actuated. Thus, the otherwise resulting faulty operation due to the drop in voltage is prevented.
It should be noted that even in this case, when the battery recovers its normal voltage before the end of the time interval from the start of the counting operation of the counter COUNT2 to the "1" at the output Qt, that is, before the second step of the release has been effected, the counter COUNT2 is immediately reset so that the output Qt remains "0". Upon occurrence of the second step or stage of release, the exposure initiating sequence starts to operate. It will be appreciated that even when the battery voltage has dropped for a short time due to a large current for driving the diaphragm control circuit 28, the initiation of the exposure operation follows, provided that the threshold level for the battery voltage recovers before the second stage of the release. Thus, the correction for faulty operation due to the temporary drop of the battery voltage at the time of actuation of the diaphragm control circuit is inhibited. A voltage drop beyond the predetermined time produces the needed cut off.
FIG. 6 shows another example of the timer circuit comprising the counter COUNT2, AND gate AN2 and inverter NT2 of FIG. 3. The circuit here includes the comparator COM of FIG. 2, a resistor RR, and a capacitor C6. The capacitor C6 and the resistor RR form an integrating circuit which is actuated when the output of the comparator COM changes to "1". A D-type flip-flop FF has its D input terminal connected to the output terminal of the integrating circuit upon the output of said integrating circuit reaching a predetermined voltage to set the flip-flop FF2 in synchronism with the clock pulse CP applied to the clock terminal CL thereof and to produce a "1" signal from the output terminal Qt thereof. With such a construction, therefore, when the battery voltage drops below the predetermined level, the "1" signal from the input terminal I3 is integrated. If the battery voltage does not reach the normal voltage level during the predetermined time, the output terminal Qt produces a "1" signal. If, during this time interval, the normal battery voltage is regained, the charge so far stored on the capacitor C6 is discharged through the diode D6, thus the capacitor C6 is reset to effect an equivalent result to that of the timer of FIG. 3. The diaphragm control circuit 28 of FIG. 2 appears in FIG. 7.
As has been described in detail, the faulty operation preventing circuit of the present invention cuts off the electrical power supply to the various circuit portions in time-displaced relationship to each other which differ depending upon whether or not the release signal is present, when the drop in battery voltage lasts for a longer time than the predetermined time. This makes it possible to operate the cine camera with high reliability despite the temporary change of the battery voltage and to insure that the successive control of power supply to the various circuit portions facilitates minimal occurrences of faulty operation.
While embodiments of the present invention have been described in detail, it will be evident that the invention may be embodied otherwise without departing from its spirit and scope.
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In the camera disclosed, an error preventing circuit responds to a drop in the electrical power source or battery and deactivates the camera control elements in the same sequence as that used when the camera release operation ends. According to an embodiment, the error preventing circuit also prevents the start sequence from beginning in response to a low source voltage. This assures satisfactory control over initiation and termination of each camera operating cycle and assures proper stopping when the battery voltage falls below the satisfactory operating level.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The invention generally relates to the field of artificial aquatic plants and sea life, and more particularly, to reproductions of aquarium life formed from translucent memory retaining polymers, and methods for reproducing the same.
[0003] 2. Background Information
[0004] Aquatic environments, such as aquariums, fish tanks, vivariums, or other aquatic displays, often contain any of an assortment of plants, shrubbery, and sea life as part of their landscape. These landscape displays can serve many uses, from beautifying the aquatic scenery to providing a stimulus for fish and other sea or amphibious creatures that inhabit the aquatic environment.
[0005] Live plants, such as sea weed, are often used in aquariums for a number of reasons. They are soft and provide a good stimulus for fish or other inhabitants, as fish will often play and interact with the plants. Also, live plants tend to gently sway and wave with the water as the water circulates within the aquarium. This motion by the live plants makes the overall appearance of the aquarium more pleasing, as well as providing a better stimulus for fish.
[0006] Similarly, live sea life is often used to beautify the landscape of an aquarium. Popular forms of sea life used in aquariums include sea anemones, corals, scallops, clams, sea cucumbers, and sea apples. These forms of sea life are particularly engaging because of their vibrant and luminous colors.
[0007] Unfortunately, there are a number of drawbacks associated with the use of live plants and live sea life in aquariums. Regarding live plants specifically, the environmental conditions necessary to allow live plants to thrive also tend to promote the growth of algae in the aquarium. This algae must either be treated chemically, physically cleaned, or hopefully eaten by the fish or other sea creatures living in the aquarium. Otherwise the water can become polluted and any glass walls in the aquarium tend to then become dirty. The growth of algae often requires the owner or care taker of the aquarium to change the water more frequently than may otherwise be necessary. Another drawback to live plants is that they require a lot of care. The proper lighting conditions, water hardness, and water temperature are all required to enable most live plants to thrive in an aquatic environment.
[0008] Some of the drawbacks to using live sea life are similar to those of live plants. Like live plants, live sea life must also have the proper lighting conditions, water hardness, and water temperature to thrive. Other drawbacks include the tendency of the live sea life to move about the landscape and reposition themselves in locations that are not ideal for viewing. For instance, sea anemones tend to move to the front of an aquarium and plant themselves against the smooth surface of the front pane of glass.
[0009] The common drawbacks of live aquarium life, namely their need for particular environmental conditions, can also present further problems. Since fish inhabiting an aquarium also require certain environmental conditions, problems can arise when the environmental conditions required by the live plants and sea life conflict with the environmental conditions required by the fish. Aquarium life must be found that can coexist in the same environment as required by the fish, and finding such plants and sea life can be a costly trial and error exercise. And in the case of live plants, once the proper plants are found, another problem that often arises is that the fish or other sea creatures will often feed on them. Thus, there are many drawbacks associated with the use of live plants and sea life in such aquatic environments.
[0010] Artificial plants are another option for use in aquariums. These plants are typically made from rigid plastics and do not suffer from the drawbacks of live plants, such as the accompanying algae growth, requiring certain lighting conditions, water hardness levels, and water temperature levels, and potentially being eaten by sea creatures inhabiting the aquarium. Unfortunately, known artificial plants are not as visually appealing as live plants due to their color, texture, and rigidity. Artificial plants tend to look artificial. Furthermore, known artificial plants do not add nearly the same level of beauty that the color and luminescence of sea life can provide to an aquarium. Accordingly, improved forms of artificial aquarium plants and life are desirable.
SUMMARY
[0011] The drawbacks and limitations of known live and artificial plants and sea life have been substantially improved upon by the present invention.
[0012] According to an embodiment of the invention, an article for use in an aquatic environment comprises a translucent polymer material that is configured to substantially resemble a form of aquarium life. In another embodiment of the invention, a translucent polymer material comprises a highly pliable polymer material capable of substantially retaining its shape. In further embodiments of the invention, a form of aquarium life that a translucent polymer material is configured to substantially resemble can be that of a sea anemone, a sea plant, a sea weed, live coral, a scallop, a clam, a sea cucumber, a sea apple, or a jellyfish.
[0013] These and other aspects of the invention will be more apparent in view of the following detailed description of the exemplary embodiments and the accompanying drawings thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 illustrates a reproduction of a live sea anemone according to an embodiment of the invention.
[0015] [0015]FIG. 2 illustrates a reproduction of a live coral according to an embodiment of the invention.
[0016] [0016]FIG. 3 illustrates a reproduction of a live clam according to an embodiment of the invention.
[0017] [0017]FIG. 4 illustrates a reproduction of a sea cucumber according to an embodiment of the invention.
[0018] [0018]FIG. 5 illustrates a reproduction of a sea apple according to an embodiment of the invention.
[0019] [0019]FIG. 6 illustrates a reproduction of an electric scallop according to an embodiment of the invention.
[0020] [0020]FIG. 7 is a flowchart illustrating a method for creating a reproduction of aquarium life using an injection-molding process in accordance with one aspect of the invention.
[0021] [0021]FIG. 8 is a flowchart illustrating a method for creating a reproduction of aquarium life using a curable polymer in accordance with one aspect of the invention.
[0022] [0022]FIG. 9 is a flowchart illustrating a method for creating a reproduction of aquarium life using an extrusion process in accordance with one aspect of the invention.
[0023] [0023]FIG. 10 is a flowchart illustrating a method for creating a reproduction of aquarium life using a blow molding process in accordance with one aspect of the invention.
[0024] [0024]FIG. 11 is a flowchart illustrating a method for creating a reproduction of aquarium life using a reactive polymer process in accordance with one aspect of the invention.
[0025] In the drawings, like features are typically labeled with the same reference numbers across the various drawings.
DETAILED DESCRIPTION
[0026] In one aspect, an embodiment of the invention comprises reproductions of a variety of forms of aquarium life that are made from translucent materials, and in particular, translucent, highly pliable polymers. The term “aquarium life” as used herein generally refers to plant life and sea life that can be added to an aquarium, or any other aquatic environment, for any intended use including, for example, the beautification of its landscape.
[0027] [0027]FIG. 1 illustrates a reproduction 100 of a sea anemone. Sea anemone reproduction 100 comprises a body 102 and a plurality of tentacles 104 . As will be described below, body 102 and tentacles 104 may be formed, in one embodiment, from a translucent and pliable polymer material.
[0028] [0028]FIG. 2 illustrates a reproduction 200 of a coral. Coral reproduction 200 comprises primarily a body 202 . Body 202 may also be formed, in one embodiment, from a translucent and pliable polymer material, as is described below.
[0029] [0029]FIG. 3 illustrates a reproduction 300 of a clam. Like sea anemone reproduction 100 and coral reproduction 200 above, clam reproduction 300 also comprises primarily a body 302 that may be formed, in one embodiment, from a translucent and pliable polymer material.
[0030] [0030]FIG. 4 illustrates a reproduction 400 of a sea cucumber, which comprises a body 402 and branches 404 . Both body 402 and branches 404 may be formed, in one embodiment, from a translucent and pliable polymer material.
[0031] [0031]FIG. 5 illustrates a reproduction 500 of a sea apple, which comprises a body 502 and branches 404 . Branches 404 for sea cucumber reproduction 400 and sea apple reproduction 500 can, in some embodiments, be either similar or identical. Again, both body 502 and branches 404 of sea apple reproduction 500 may be formed, in one embodiment, from a translucent and pliable polymer material.
[0032] [0032]FIG. 6 illustrates a reproduction 600 of an electric scallop. Electric scallop reproduction 600 comprises a body 602 and tentacles 104 . Tentacles 104 in FIG. 6 may, in some embodiments, be either similar or identical to tentacles 104 of sea anemone reproduction 100 of FIG. 1. As with the other reproductions of FIGS. 1 - 5 , body 602 and tentacles 104 of electric scallop reproduction 600 may, in one embodiment of FIGS. 1 - 5 , be formed from a translucent and pliable polymer material.
[0033] In should be noted that all of the above forms of sea life come in a variety of different sizes, shapes, and colors. Also, the size, shape, color, and number of tentacles 104 and branches 404 may vary widely in various embodiments without departing from the scope of the invention. Moreover, the precise species or types of sea life reproduced need not be among those illustrated in FIGS. 1 - 6 , and those of ordinary skill in the art will understand that there are many types of sea life which can be reproduced, including for example known sea life, without departing from the scope of the present invention. FIGS. 1 to 6 are merely representative examples of some of the variations that can be made, and should not be interpreted as limitations on the invention.
[0034] As mentioned above, an artificial reproduction of aquarium life in accordance with one embodiment of the invention may be formed from one or more polymer materials. The term polymer as used herein refers to any type of plastic, polyisoprene, silicone, fluorosilicone, rubber, or any resilient or elastic material, or any blend thereof, manmade or natural, and refers to any materials that have characteristics or traits similar to those specified below. The polymer materials chosen for use in forming reproductions of aquarium life must have a plurality of the following characteristics. One characteristic is that the polymer materials must be translucent. The use of a translucent polymer material allows dyes and pigments to be added to the polymer so that artificial aquarium life can be created that is colorful and lifelike, and that is a more accurate reproduction of actual aquarium life than can be made with conventional plastics.
[0035] The use of certain dyes or pigments, when added to a translucent polymer, can create fleshy tones that are associated with sea life such as, but not limited to, clams, scallops, jellyfish, nudibranchs, and sea anemones. For instance, some of these colors include, but are not limited to, muted shades of red, pink, orange, and brown. In some instances, the dyes or pigments can be used primarily in the interior portions of the sea life reproductions, while the exterior portions of the sea life reproductions remain translucent. This can provide the translucent-fleshy appearance that is often seen in these forms of sea life. Also, many forms of sea life, such as sea anemones, scallops, and jellyfish, have translucent features (e.g. tentacles 104 ) which can be reproduced using a translucent material.
[0036] Different colors can also be used to reproduce other forms of sea life, such as (but not limited to) sea cucumbers and sea apples. Some of these colors include, but are not limited to, blues, whites, reds, and purples. Even brighter colors, including but not limited to vibrant reds, blues, purples, yellows, a variety of fluorescent colors, and even glow-in-the-dark dyes, can be used in translucent polymers to reproduce still other forms of sea life, such as some types of live corals. In corals, the translucent, color-filled polymers can also be applied over a rigid interior structure that can be formed from a stiffer polymer or other material, thereby more truthfully reproducing live corals. In both of these instances, the exterior portions of the sea life reproductions can hold the dyes or pigments because the reproductions of sea cucumbers, sea apples, and corals often require a solid-fleshy, rather than a translucent-fleshy, type of appearance.
[0037] Another characteristic for the polymer materials is that they be either waterproof or able to endure long periods in an aquatic environment without substantially degrading. For instance, sponges are not considered to be waterproof but nevertheless thrive in aquatic environments. Many polymers are waterproof, and other polymers that are open-celled can survive underwater indefinitely.
[0038] Yet another characteristic for the polymers within the scope of the invention is that they be highly pliable or resilient or elastic. In other words, the polymers should have a soft and flexible texture. For instance, in one embodiment a polymer that has a supple feel to it and that is very malleable is preferred. Highly pliable polymers are beneficial because aquarium life such as plants and sea anemones tend to gently sway with any currents moving through an aquatic environment. Any reproductions of these forms of aquarium life made in accordance with embodiments of the invention should be able to move in a similar fashion. The use of soft, flexible, and pliable polymers can satisfy this requirement. For other reproductions of sea life, such as clams or scallops for instance, less pliable and indeed very rigid polymers can be used as these forms of sea life do not necessarily sway or move in currents underwater.
[0039] Regarding the polymers used in reproductions of aquarium life such as plants and anemones, the level of pliability can vary greatly. In aquarium life reproductions where movement is not necessary or desired, polymers with less pliability can be utilized. In aquarium life reproductions where it may be desirable for the aquarium life to sway with water currents or movements, then polymers with higher levels of pliability can be used. Polymers that have an almost gelatinous yet solid texture, much like a solid gel, are candidates for these forms of pliable aquarium life. An example of a polymer with these properties is sold under the brand name Plasti-Goop® by ToyMax, Inc. The Plasti-Goop® polymer is used in the Creepy Crawlers™ Bug Maker also sold by ToyMax, Inc.
[0040] Polymers used in the invention are able to retain their shape and are resilient enough to withstand typical stresses they may encounter in an aquatic environment. Such stresses may often include interactions with fish or other live sea creatures. The polymers should have a “memory” characteristic that allows them to substantially regain their original form after they have been subjected to stresses or strains from the aquatic environment.
[0041] Those of ordinary skill in the art will understand that any of numerous polymers can be used within the scope of the invention. Thermoplastics and elastomers are available that can provide the necessary properties. Some specific polymers that can be used include, but are not limited to, silicone, latex, polyethylene, polypropylene, polystyrene, polyurethane, polyvinyl chloride, and memory gels. It should be noted that thermoplastics or elastomers other than the ones previously mentioned can also be used, as long as a plurality of the properties mentioned above are satisfied. Since all of these polymers are available in different formulations, and since the different formulations will have varying characteristics that are dependent on factors such as density and chemical additives, those of ordinary skill will understand that specific formulations of each polymer may be suitable for use in the invention. For example, certain formulations of polyurethanes produce flexible foams that can be used in the invention to form reproductions of moving aquarium life, while other formulations of polyurethanes produce rigid foams that may not be suitable for some embodiments of the invention. Similarly, those of ordinary skill will understand that other polymers listed above will have certain formulations that yield the correct properties that make them candidates for use in the invention.
[0042] The artificial reproductions of aquarium life constructed according to embodiments of the invention can be formed by several different methods. The specific method used will primarily be determined by which polymer is chosen in making the reproduction. Some thermoplastic resins and elastomers, such as polypropylene, polystyrene, and polyurethane, can be formed using an injection-molding process. In such a process, melted polymer material is forcefully injected into a mold of the aquarium life being reproduced. The mold shapes the plastic into the desired form, and is generally comprised of two machined-aluminum or machined-stainless steel halves that are brought together before the polymer is injected. The polymer then cools and solidifies within the mold, and the aquarium life reproduction can then be removed.
[0043] [0043]FIG. 7 is a flowchart describing a typical injection-molding process for use with some aspects of the invention. At step 700 , the injection-molding process typically begins with a plasticating unit that melts a translucent polymer material into a liquid form. The polymer may be available in a pellet form for this process. A screw within the plasticating unit may shear the polymer pellets as they are heated. At step 702 , a clamping unit brings the two halves of the mold together and holds the mold closed during the injection process. At step 704 , a nozzle of the injection unit is coupled to one or more holes in the mold through which the melted polymer can enter the mold. At step 706 , the injection unit delivers melted polymer into the mold. Since most polymers tends to contract as they solidify, the injection molding machine will force extra polymer into the mold. This aids in causing the polymer to fill out the mold cavity when the polymer solidifies. At step 708 , the mold is cooled to cause the polymer to solidify. Finally at step 710 , the two halves of the mold are opened and one or more aquarium life reproductions can be removed. Those of ordinary skill will understand that the invention is not limited to the precise injection molding process utilized, and that variations in an injection molding process which are known may be used.
[0044] Different additives can be added to a polymer before or during the injection-molding process. For instance, in some embodiments of the invention, dyes or pigments can be added to a polymer melt prior to the polymer being injected into the mold. In other embodiments, dyes or pigments can be injected into a mold either before, during, or after the polymer melt is injected. The addition of dyes in these different manners can create a variety of desirable designs and effects. Swirls, dispersions, or explosions of color within the polymer can be created using such techniques. Also, the introduction of dyes into the mold either during or after the polymer injection can help create a translucent exterior with a colorful interior, if such an effect is desired. Those of ordinary skill will understand that addition of dyes or other additives may be accomplished in any of a variety of known methods and the invention is not limited by the specific method utilized.
[0045] According to another embodiment of the invention, a translucent curable polymer can be used to form reproductions of aquarium life. Examples of curable polymers include certain silicones and polyurethanes, as well as the Plasti-Goop® material described above. FIG. 8 is a flowchart describing a typical curable polymer molding process. Beginning at step 800 , two halves of a mold are brought together. At step 802 , the curable polymer is introduced into the mold. At step 804 , the mold is heated to cause the polymer to cure and solidify. At step 806 the mold is cooled, and finally at step 808 the mold is opened and one or more aquarium life reproductions can be removed. As with an injection-molding process, dyes and pigments can be introduced into the curable polymer at different stages of the process to create colors or effects in the translucent polymer. Those of ordinary skill will understand that a curable polymer may be accomplished in any of a variety of known methods, and the invention is not limited by the specific method utilized.
[0046] According to yet another embodiment of the invention, an extrusion process can be used to form reproductions of aquarium life. An extrusion process is particularly suited for forming certain reproductions of plant life, as well as for forming tentacles 104 or branches 404 of sea anemone reproductions 100 , scallop reproductions 600 , and sea apple reproductions 500 . FIG. 9 is a flowchart describing a typical extrusion process. At step 900 , similar to an injectionmolding process described with reference to FIG. 7, an extrusion process may begin with a plasticating unit that melts a translucent polymer material into a liquid form. A screw within the plasticating unit may shear the polymer pellets as they are heated. At step 902 , the melted polymer is forced through a heated die which extrudes the polymer into long strands. These strands can take on various forms according to the die used, including fibers, cylinders, and films. At step 904 , the extruded polymer may be cooled to solidify the polymer in its extruded form. The cooling may typically be done by extruding the polymer directly into a bin or trough of water, which almost immediately solidifies the polymer. Finally at step 906 , the extruded polymer may be cut and used to create tentacles 104 , branches 404 , or certain forms of plant life. Those of ordinary skill will understand that a polymer material may be extruded in any of a variety of known methods, and the invention is not limited by the specific method utilized.
[0047] A blow molding process can be utilized in still another embodiment of the invention. FIG. 10 is a flowchart detailing a blow molding process. Starting at step 1000 , the polymer material is melted using a device such as the plasticating unit described above. At step 1002 , a clamping unit brings the two halves of the mold together and holds the mold closed during the injection process. At step 1004 , a nozzle of the injection unit is coupled to one or more holes in the mold through which the melted polymer can enter the mold. At step 1006 , the injection unit delivers melted polymer into the mold. Next at step 1008 , air is injected into the mold to cause the melted polymer to coat the interior walls of the mold. This air is generally heated prior to being delivered into the mold to prevent the polymer from beginning to solidify. At step 1010 , the mold is cooled to solidify the polymer. Then at step 1012 , the clamping unit opens the mold and the blow-molded polymer is removed. The resulting structure may be a hollow, translucent polymer shell in the shape of the mold. This technique can be used to form one or more hollow reproductions of aquarium life. The hollow cavities within the reproductions can be left empty, or they can be filled with a liquid or solid to create a desired color, texture, density, or other effect. For instance, a hollow shell can be filled with a colorful gel to give the reproduction a gelatinous feel. Or a translucent hollow shell can be used as a skin to be placed over another reproduction of aquarium life to create a translucent-fleshy look. Those of ordinary skill will understand that a polymer material may be blow molded in any of a variety of known methods, and the invention is not limited by the specific method utilized.
[0048] According to another embodiment of the invention, reproductions of aquarium life can be formed using reactive polymers. For instance, certain polymers such as polyurethanes can be formed by reacting two components, for example an isocyanate and a polyol. FIG. 11 is a flowchart describing a reactive polymer process. At step 1100 , the two or more components intended to react and form a polymer are introduced into a mold and allowed to react. At step 1102 the components react to form a polymer material, and at step 1104 the resulting polymer material fills the volume of the mold. Catalysts may be added to aid in the reaction, including but not limited to heat and other chemicals or compounds. Blowing agents can also be added to help the polymer fill the entire mold. At step 1106 , the polymer is allowed to solidify. Additional processes may be performed to aid in the polymer solidification, such as cooling the mold. Finally at step 1108 , the mold is opened and one or more aquarium life reproductions are removed. In an additional step, dyes or pigments can be added before, during, or after the reactive process, depending on the specific reactive process chosen. Those of ordinary skill will appreciate that reactive polymers may be used in any of a variety of molding processes, and the invention is not limited by the specific reactive polymers or specific method utilized.
[0049] In still further embodiments, blocks or sheets of polymeric material can be cut, carved, or otherwise shaped into aquarium life reproductions. Dyes and/or other additives can be added to the polymeric material before or after it is shaped into reproductions.
[0050] One or more additives other than dyes and pigments can also be used in any of the above embodiments, either alone or in combination with the dyes and pigments. For instance, nibble inhibitors can be used with a polymer to prevent or discourage fish and other live sea creatures from attempting to eat or chew on the reproductions of aquarium life. Other additives can also be added to make the reproductions inedible. In addition, any of the above mentioned colors and dyes, including fluorescent and glow-in-the-dark dyes and pigments, can be used in any of the above mentioned reproductions of aquarium life.
[0051] As discussed above, the invention provides at least one or more advantages to using reproductions of aquarium life formed from a translucent polymer material. Reproductions may be stationary or may be fixed to inhibit movement to undesirable locations within an aquarium. Reproductions may be colorful and may add beauty to an aquarium landscape. Reproductions can accomplish other functions that real sea life cannot, such as glow-in-the-dark. In some embodiments, reproductions can contain nibble-inhibiting additives. In other embodiments, reproductions do not promote the growth of algae.
[0052] While various embodiments of the invention have been shown and described, it will be apparent to those of ordinary skill in the art that numerous alterations may be made without departing from the scope of the invention or inventive concepts presented herein. Persons of ordinary skill will appreciate that changes can be made to dimensions, sizing, relative dimensions, materials, blends of materials, combinations of materials, spatial and angular relationships of and between components, and manufacturing processes and other commercial or industrial techniques, all without departing from the scope of the invention. Also, those of ordinary skill will understand that the various components and sub-assemblies described with respect to alternate embodiments may be rearranged, substituted, or combined with each other and that various process steps and sub-processes described above with respect to alternate embodiments may be rearranged, substituted, or combined with each other, all without departing from the scope of the invention. Thus, the invention is not to be limited except in accordance with the following claims and their equivalents.
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An article for use in an aquatic environment comprises a translucent polymer material that is configured to reproduce a form of aquarium life. In embodiments of the invention, the translucent polymer material comprises a highly pliable polymer material capable of substantially retaining its shape, such as, but not limited to, thermoplastics, rubbers, silicones, and Plastigoop®. In further embodiments of the invention, the form of aquarium life that the translucent polymer material is configured to reproduce can be a sea anemone, a sea plant, a sea weed, live coral, a scallop, a clam, a sea cucumber, a sea apple, a nudibranch, or a jellyfish. In another aspect of the invention, a process for reproducing articles configured to reproduce aquarium life comprises processing an appropriate polymer material, and in other embodiments, further processing one or more additives, such as dyes, whereby an article reproducing one or more types of aquarium life is formed.
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FIELD OF THE INVENTION
The invention relates to extending performance life of and overall utility of plasma arc furnaces.
BACKGROUND OF THE INVENTION
Plasma arc furnaces are used in many industrial applications such as melting and heating masses of metal in the production of alloys. They are also used to heat and melt some industrial wastes in order to consolidate these wastes. Such an application of a plasma arc furnace is described in U.S. Pat. No. 5,731,564, issued Mar. 24, 1998 (Kujawa et al.).
Plasma torches used in these applications have metallic electrodes which are cooled with de-ionized water. These water cooled electrodes are the most vulnerable part of a plasma torch. Plasma arcs are initiated on these electrodes and the arc initiation regions are subject to relatively rapid erosion and wear. If erosion occurs at some concentrated area of the electrode, a leak will develop from the water cooling system. This type of failure causes very serious problems in a plasma arc furnace. It requires a shut-down of the furnace and a cooling of the entire system of molten materials and furnace. Only after cooling, can such a furnace be opened to gain access to the electrode so that it can be replaced. Electrode failures of this type result in shutdowns of furnaces which last for a number of days.
In prior art furnaces, it is necessary to break containment in order to change an electrode. If the furnace is being used to treat waste material containing toxic elements such as mercury, there is a need to perform expensive and complex purging operations before containment of the furnace is broken.
An electrode failure in prior art furnaces produces an even more severe problem when the waste materials being treated are radioactive. A cooling water leak into molten radioactive material produces vast amounts of radioactive steam which must be contained and treated. Additionally, there is a risk of an actual explosion. The risks associated with a possible leak has heretofore kept this form of plasma arc furnace waste treatment from being widely applied to radioactive materials.
This concern about cooling water leakage has produced frustration among those who seek effective methods for treating radioactive waste. A plasma arc furnace has a capability of treating waste in a highly contained environment. Additionally, plasma arc furnaces provide a method of reducing a great volume of waste into very compact and chemically stable rock-like objects. If the risk of cooling water leakage were to be eliminated, plasma arc furnaces would become a principal and very effective tool in the treatment of radioactive waste.
But even outside of the narrow field of radioactive waste treatment there is a need to eliminate the risk of cooling water leaks. Because such risks exist, normal operating procedures for plasma arc furnaces dictate that these furnaces be shut down periodically so that the electrodes can be replaced on a prophylactic basis. Because the life of an electrode is not entirely predictable, the interval of operation of a furnace between shutdowns is made relatively short. These shutdowns undermine the overall efficiency of plasma arc furnaces. Loss of efficiency appears to be a major factor in discouraging widespread acceptance of an otherwise promising furnace technology.
It is a goal of the present invention to provide a design for a plasma arc furnace with a reduced risk of cooling water leakage.
It is a further goal of the present invention to provide a plasma arc furnace which can be operated for long intervals without a need for shutdowns associated with torch electrode failure.
It is a still further goal of the present invention to provide a plasma arc furnace on which containment can be maintained while torch electrodes are replaced.
SUMMARY OF THE INVENTION
The present invention is directed to a plasma arc furnace which comprises a containment vessel and a plasma arc torch with a replaceable electrode. The plasma arc torch has a portion thereof extending through a wall of the containment vessel and outside the vessel. The plasma arc torch is configured so that the electrode can be replaced by removal through the portion of the torch extending outside of the containment vessel.
Viewed from another aspect, the present invention is directed to a plasma torch having improved operational life. The torch comprises a water-cooled body having a nozzle at one end thereof. An electrically conductive refractory electrode is inserted in the torch body. The electrode has an internal cylindrical surface formed therein upon which plasma arc initiation occurs. Plasma gas is introduced to the internal cylindrical surface. The electrode is electrically insulated from the torch body.
Viewed from still another aspect, the present invention is directed an electrode for a plasma arc torch. The electrode comprises a cylindrical rod of conductive refractory with a power attachment point at a first end thereof and a cylindrical opening formed in a second end, opposite the first end. The opening is coaxial with the rod. The rod has a length along its axis sufficient to accommodate replacement of the electrode within a torch by engagement with the first end.
The invention will be better understood from the following detailed description taken in consideration with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic cross-sectional view of a plasma arc furnace constructed in accordance with the prior art;
FIG.2 is a cross-sectional view of a plasma arc torch constructed in accordance with the present invention; and
FIG. 3 is a schematic cross-sectional a plasma arc furnace constructed in accordance with the present invention.
The drawings are not necessarily to scale.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is shown a cross-sectional view of plasma arc waste treatment furnace 10, constructed in accordance with the prior art. The furnace 10 comprises a chamber 12, a melting hearth 14, a material introduction port 16, a material removal port 18, an offgas port 20 and a plasma torch 22.
The prior art plasma torch 22 has a water cooled metallic electrode (not shown). Because of the nature of this water cooled electrode, the prior art torch 22 is provided with a multiplicity of connection members which are shown schematically in FIG. 1. The torch 22 is provided with eight connections, designated 24 through 38, respectively. Connection 24 is used to connect de-ionized water as a power ram cooling return. Connection 26 is for use as a torch gas supply. Connection 28 is used to connect de-ionized water as a nozzle cooling return. Connection 30 is used to connect de-ionized water as a torch body cooling return. Connection 32 is used to connect de-ionized water as a power ram cooling supply. Connection 34 is used to connect de-ionized water as a nozzle cooling supply. Connection 36 is used to connect de-ionized water as a torch body cooling supply. Connection 38 is for use as an electrical power supply.
The prior art torch 22, has a water-cooled hollow metallic electrode which must be replaced frequently. Water cooled hollow electrodes erode during use. In order to avoid risk of leakage of cooling water into the furnace 10, the hollow electrodes are replaced after a specified amount of running time, typically 50 to 100 hours.
The presence of the many torch connections 24 through 38, described above, has an effect on the manner in which the water cooled electrodes are replaced. With this large collection of connections, the torch 22 effectively becomes an integral part of the chamber 12. In other words, it is impracticably to remove the torch from the chamber because of the difficulty of removing and replacing the connections described above. Consequently, prior art furnaces are constructed with specialized removal systems for torches. These specialized removal mechanisms are designed to move a torch without making disconnections. However, when these mechanisms are used, they require a substantial opening in the wall of the furnace. For example, a dome of the furnace might be lifted and tilted to gain access to an output end of the prior art torch. Prior art electrodes are extracted from an output end 40 of the torch 22.
This complex method of replacing the water-cooled electrode produces some undesirable operating limits on the furnace 10. First of all, the period of operation of the furnace 10 is limited to the length of time between changes of the electrode. Secondly, there is a significant loss of operating time associated with each change of electrode. The furnace 10 must be allowed to cool before an electrode can be changed. After an electrode is replaced, the furnace 10, must be allowed to reach its full operating temperature. This cooling and re-heating can consume 15 to 24 hours. In the context of electrode life which can be as short as 30 hours, the time needed for electrode replacement is problematic.
Referring now to FIG. 2, there is shown a plasma arc torch 42 constructed in accordance with the present invention. The torch 42 comprises a water-cooled torch body 46, a nozzle 48, a torch gas injection ring 50, an insulating support 52 and a refractory electrode 54. The electrode 54 is a cylinder of conductive refractory material such as conductive ceramic, silicon carbide, molybdenum disilicide, graphite, tungsten, or hafnium. At an output end 58, the electrode 54 is provided with a cylindrical opening 60. This cylindrical opening 60 functions as an arc initiation chamber. At an input end 62, the refractory electrode 54 is connected to electrical power at a connection 64.
Referring now to FIG. 3, there is shown a cross-sectional view of a plasma-arc waste treatment furnace 70 constructed in accordance with the present invention. The furnace 70 comprises a chamber 72, a melting hearth 74, a material introduction port 76, a material removal port 78, an offgas port 80 and the inventive plasma torch 44 of FIG. 3.
It can be seen in FIG. 3 that the electrode 54 of the torch 44 is accessible from outside the chamber 72. This illustrates one important feature of the present invention. The electrode 54 can be removed from the torch 44 without gaining access to the inside of the chamber 72. Thus the electrode can be replaced without a need to cool down the furnace 70. Indeed, the electrode 54 can be replaced without a need to even break containment of the furnace 70. This capability is provided through use of a slideable shutter 82 which can be closed when the electrode 54 is withdrawn. Employment of the shutter 82 provides for an opportunity to replace the electrode 54 without exposing the contents of the furnace 70 to the atmosphere surrounding the furnace 70.
It can be seen that the electrode 54 has no water or gas connections. It is connected only to electrical power at the connection 64. All other water and gas connections needed for operation of the torch 44 are made at the torch body 46. There is no need to extract the torch body 46 from the furnace 70 during an electrode replacement. Thus there is no need to cope with the complexity of water and gas connections.
Ease of replacement of the electrode 54 is only one of many advantages features of the present invention. An additional advantageous feature is that the torch 44 does not need to be cooled with de-ionized water. The electrode 54 is electrically insulated from the torch body with the insulating support 52 which is constructed from a high temperature polymer capable of withstanding temperatures of about 1000 F. In the prior art, metallic electrodes were placed at high electrical potentials and could only be water-cooled if the water was non-conductive, i.e., de-ionized. Supplying de-ionized water in large enough quantities to provide requisite cooling for waste treatment operations is costly and cumbersome. It is particularly cumbersome in circumstances where the waste treatment furnaces are operated at remote field locations which do not have sophisticated water de-ionization facilities.
Another valuable feature of the present invention is that the electrode 54 has a substantially higher operating life as compared with hollow metallic electrodes of the prior art. This higher operating life results from various characteristics of the electrode 54 and its mode of operation.
First of all, the electrode 54 can be operated at extremely high temperatures without concern for melting of its surface. The material molybdenum disilicide, for example can tolerate temperature of up to 3200 F. without adverse effects. This allows the electrode 54 to be operated without cooling. Consequently, the walls of the electrode 54 can be made much thicker than the walls of the prior-art, water-cooled metallic electrode. There is no need to accommodate heat transfer to cooling water with a thin wall. Thick electrode walls provide for longer operating life simply because there is more material which can erode before an electrode is worn out.
Secondly, the refractory electrode 54 runs hotter than prior art metallic electrodes. This results in an arc attachment point moving more readily around the surface of the arc initiation chamber 60 of FIG. 2. When the surface temperature of the arc initiation chamber 60 is uniformly high, a plasma arc can be easily moved to various points on the surface. Indeed, the arc initiation point is continuously moved through motion of gas that flows through the gas injection ring 50. (For further details of the mechanism of arc movement, refer to U.S. patent application Ser. No. 09/137,5599, pending [Cashell et. Al.] which is incorporated herein by reference). Because the arc initiation point moves around the entire hot surface of the chamber 60, there is an advantageous distribution of arc erosion across the entire surface. When arc erosion is distributed uniformly, overall life of the electrode 54 is improved. Typical failures of prior art electrodes occurred when arc erosion became concentrated in a small area.
Through use of conductive refractory as a material for the electrode 54, concern for arc erosion can be virtually set aside. In this context, it becomes practical to operate the torch 44 with straight polarity (i.e. with the electrode 54 as a cathode). This mode of operation has heretofore not been available for use in prior art plasma arc waste treatment furnaces.
Prior art furnaces have employed reverse polarity (electrode as an anode) because reverse polarity reduces arc erosion. Straight polarity is known to provide improved heat transfer and more efficient melting. But this advantageous mode of operation has not been used in prior art systems that employ metallic water cooled electrodes. In the prior art, the disadvantages of shortened electrode life have outweighed the advantages of more efficient melting.
The inventive furnace 70 can be readily operated with straight polarity with all of the attendant improvements in melting efficiency. This can be done without jeopardizing overall efficiency of the furnace 70. The electrode 54 can be operated for a long period of time (up to about 1000 hours) in a reverse polarity mode without a need for replacement. The additional arc erosion associated with straight polarity operation reduces this replacement interval, but the reduction is very modest. With straight polarity operation, the replacement interval for the refractory electrode 54 is about 950 hours, a period which is only a few percent lower than the reverse polarity interval.
When all of the advantageous features of the refractory electrode are combined, the inventive furnace 70 can be seen to represent a substantial improvement over the prior art.
It is to be appreciated and understood that the specific embodiments of the invention are merely illustrative of the general principles of the invention. Various modifications may be made by those skilled in the art which are consistent with the principles set forth. For example there are numerous conductive refractory substances which can be employed as material for the electrode 54.
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A plasma arc waste treatment furnace is equipped with a plasma arc torch having an electrode formed from a conductive refractory material. The refractory electrode can be operated at very high temperatures and does not need to be water-cooled. This eliminates a need for de-ionized water used in prior art furnaces. Arc erosion takes place very slowly and this results in long operating intervals of the furnace between shutdowns needed for electrode replacement. The electrode can be successfully operated as a cathode and this mode of operation improves melting efficiency.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This Continuation-in-Part application claims the benefit of the Design patent application Ser. No. 29/199,299 filed on Feb. 13, 2004.
FIELD OF THE INVENTION
[0002] This invention relates generally to equipment used in the carving and artistic shaping of wax candles and sculptures and, more specifically, to heated knives and saws used in the carving and artistic shaping of wax candles and sculptures.
BACKGROUND OF THE INVENTION
[0003] In recent years, candles have seen a resurgence in popularity. While once used for lighting purposes, candles now provide decoration and pleasing aromas to a person's home, office or other area. The use of candles as decoration has led to a demand for more artistic and aesthetically sculpted candles. Indeed, many candles will be utilized solely as decoration, never to be lit.
[0004] The need for equipment to make these artistic candles has grown with the demand for the candles themselves. However, current candle carving and sculpting tools often do not provide an easy way to aesthetically cut the waxy candle material without marring the surface of the candle itself Hot cutting tools of the prior art often consist of closed loops, which make the carving of details within the candle nearly impossible.
[0005] Thus, there remains a need in the art for a candle sculpting tool that can easily and aesthetically slice through waxy candle material, and still be able to carve intricate details as well.
DESCRIPTION OF THE PRIOR ART
[0006] U.S. Pat. No. 6,434,836, issued to Olivares, discloses an electric knife that runs on a battery or by use of a corded power converter. The handle housing has an electric reciprocating motor activated by a power button located on the handle of the knife. Different sizes and shapes of knife blades, dependent on the task, can be inserted into a locking slot in the front of the motorized head, and only released by a heavy-duty lock knife release button. The motorized head is powered directly by an electric motor located directly behind it in the handle.
[0007] U.S. Pat. No. 6,754,967, issued to Lovell et al., discloses a saw blade that is connected to a hand held driver for reciprocating the saw blade to perform a cut. A bit holder and a blade holder is used to provide connection between the saw blade and the handle of the hand held driver. The bit holder includes a connecting mechanism for connecting the bit holder to the hand held driver. The blade holder provides a connection between the saw blade and the bit holder. The blade holder includes a holder body and a hex-shaped shank extending rearwardly from the holder body. The shank further includes a first holding mechanism for coupling the holder to the bit holder at the rear end and a second holding mechanism for coupling the saw blade to the holder at the forward end.
[0008] U.S. Pat. No. 3,679,958, issued to Chambers, discloses a battery operated electric knife having an elongated housing defining the knife handle and enclosing an electric motor and batter unit. A pair of charging contacts are mounted entirely within the elongated housing with access openings thereto below the motor. A charging and storage stand are provided shaped to receive the knife handle in only one predetermined position, whereby said housing for the electric knife may be resiliently clamped in assembled relationship with the charging unit. An improved permanent magnet rotor is employed having an outer field member comprising a resilient cylindrical shell with a slit there.
SUMMARY OF THE INVENTION
[0009] Briefly described, the present invention is a novel modeling tool for the cutting and sculpting of wax, plastic, foam, and the like. The tool has a handle with a heated blade attached thereto, the blade having a serrated edge. The tip of the heated blade is contoured like a chisel, to facilitate gouging and cutting within confined areas.
[0010] The candle sculpting tool generally consists of a hollow, insulated handle containing a heating element and a temperature regulator switch. The heating element is connected to a blade extending from one end of the handle. The heating element is typically a poor conductor, which will become hot upon current flowing through it. To prevent overheating of the heating element, there is a thermal switch that shuts off the current when the heating element gets to a pre-set temperature. A power supply is connected to the thermal switch, to provide power to the heating element. An on-off switch connects the power supply to the thermal switch.
[0011] A blade is connected to the heating element, such that heat is transferred to the blade as current is passed through the heating element. The blade is preferably serrated to facilitate ease of cutting through a variety of substrates. The tip of the blade can be beveled to form a chisel in order to ease cutting and trimming in confined spaces.
OBJECTS OF THE INVENTION
[0012] It is one object of the current invention to provide an improved modeling tool for the cutting and sculpting of wax, plastic, foam, and the like.
[0013] It is another object of the current invention to provide an improved modeling tool for the cutting and sculpting of wax, plastic, foam, and the like, wherein the tool has a heated blade.
[0014] It is another object of the current invention to provide an improved modeling tool with a heated blade for the cutting and sculpting of wax, plastic, foam, and the like, wherein the blade has a chisel end to facilitate gouging and cutting within confined areas.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above-mentioned and other features and objects of the invention will become more readily apparent and the invention itself will be better understood by reference to the following detailed description taken in conjunction with the accompanying drawings, wherein:
[0016] FIG. 1 is a perspective view of the sculpting tool.
[0017] FIG. 2 is a cross-sectional view of the handle of the sculpting tool of FIG. 1 .
[0018] FIG. 3 is an enlargement of the serrated edge of the sculpting tool of FIG. 1 .
DETAILED DESCRIPTION
[0019] Referring to FIG. 1 , the sculpting tool 10 consists broadly of a handle 20 , a power supply 30 , and a blade 40 .
[0020] The handle 20 can be made from any material, or made into any shape known in the art. Attached externally to the handle is a power toggle switch 22 . Switch 22 is preferably located in an ergonomically comfortable position on the handle, proximate to where a user's thumb would rest when grasping the handle. Switch 22 can be any type of switch known in the art, such as a rocker switch, a slider switch, a depressible button, or the like, and the selection of the switch type is not limiting of the invention. The switch is toggled between an “on” setting, and an “off” setting, in order to supply or interrupt the flow of current between the power supply 30 and the regulator switch 24 .
[0021] Referring now to FIG. 2 , regulator switch 24 and heating element 26 are located within the handle 20 . Regulator switch 24 is provided to control the temperature of the heating element. When the regulator switch 24 reaches a predetermined temperature, the switch disconnects, preventing further flow of current to the heating element. The type regulator switch used is non-limiting, and the invention encompasses all types of switches known in the art. Preferably, however, the switch is a bimetallic type switch.
[0022] Regulator switch 24 is coupled between a heating element 26 , and a power source 30 . The heating element is preferably a heating coil, and can made from any material known in the art. The heating element 26 is attached to the blade 40 , either directly or indirectly, which extends from one end of the handle 20 .
[0023] Insulation 28 may be provided within the handle to prevent destruction or marring of the handle itself.
[0024] Power source 30 can be either a direct current source, such as a battery, or an alternating current source, such as provided by an electrical plug. Further, the power source could be some combination of the above, such that the handle 20 has an internal rechargeable battery, and an external docking station (not shown) that would plug into an electrical socket.
[0025] Blade 40 is attached to the heating element 26 , and extends outward from the handle 20 . The blade can be made of any material known in the art capable of withstanding the elevated temperatures present when the blade is heated. Preferred materials include stainless steel, and chrome or nickel plated materials. The blade is normally between 6 to 7 inches in length, although this should not be seen as limiting. A longer or shorter blade could be used, depending on the specific application desired.
[0026] The blade 40 preferably has one serrated edge 42 . Serrations are typically provided in a range of from about 16 to about 18 teeth per inch. It has been found that this range provides a smooth cut at a very fast pace, allowing the user to trim large amounts of material, or make small precise decorative cuts with the same instrument. While the blade is shown as having Japanese-type serrations, American-type serrations can also be used. That is, the serrations can be oriented so that the cut is performed on either the push or the pull of the sculpting tool.
[0027] The tip of the blade 40 is beveled to form a chisel tip 44 . The chisel tip 44 facilitates plunge cuts into materials. Furthermore, it also allows the user to trim small amounts of material from confined spaces, allowing the user to create more intricate detail in the carved material
[0028] In use, the user turns the power toggle switch 22 to the “on” position. Current then flows from the power source 30 , to the heating element 26 . The resistance of the heating element 26 causes it to heat as current passes through it. When the heating element reaches a predetermined maximum temperature, the regulator switch 24 temporarily interrupts the current flow to the heating element, and allows it to cool. When the heating element reaches a predetermined minimum temperature, the regulator switch 24 reconnects the flow of current to the heating element 26 , and the cycle repeats.
[0029] Heat is transferred from the heating element 26 to the blade 40 . A user can then use the sculpting tool to easily sculpt and cut heat sensitive materials, such as candle wax, foam blocks and the like.
SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION
[0030] From the foregoing, it is readily apparent that I have invented a novel modeling tool with a heated blade for the cutting and sculpting of wax, plastic, foam, and the like, wherein the blade has a chisel end to facilitate gouging and cutting within confined areas. It is further apparent that the invented sculpting tool can comprise a heating element within the handle, and that the handle is internally insulated to prevent transfer of heat to the surface of the handle where it could cause injury to the operator. Further, it is apparent that the heated blade of the invented sculpting tool is provided with serrations thereon to cleanly and quickly cut through a variety of heat sensitive materials.
[0031] It is to be understood that the foregoing description and specific embodiments are merely illustrative of the best mode of the invention and the principles thereof, and that various modifications and additions may be made to the apparatus by those skilled in the art, without departing from the spirit and scope of this invention. Accordingly, it is intended to embrace all such alternatives, modifications, and variations. The present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.
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A heated sculpting tool for the sculpting and grooming of candles, foam materials, and the like. The sculpting tool has a handle that contains a power source and a heating element. A serrated blade having a chiseled tip extends outwardly from the handle. Heat is passed from the heating element to the blade. A temperature regulator is provided to maintain blade temperature in the optimal functioning range.
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This application is based on PCT/US97/05406 filed May 2, 1997, which is based on provisional application 60/038,954 filed May 3, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods for feeding monogastric animals, and more particularly to methods employing one or more hemicellulases, such as mannanase, that decrease the feed to gain, or increase the weight gain of animals fed a low caloric diet containing the enzyme.
2. Background
The world population continues to grow, but land for food production is finite. J. E. Cohen, Discover 17: 42-47, (1996). In order to keep up with the growing food demand, improvements in the utilization of food resources will be needed to maintain the current living standards. One approach to improved efficiency has been to enhance the digestion of feeds by the inclusion of enzymes. Chesson, A., Supplementary enzymes to improve the utilization of pig and poultry diets, pp 71-89, In Haresign, W. and D. J. A. Cole (eds), Recent Advances in Animal Nutrition--1987, Butterworths, London. Enzymatically aided digestion not only yields more meat per pound of feed, but also reduces the volume of manure and the disposal cost.
Four types of enzymes have been clearly recognized in the marketplace for their value in animal feeds. In diets that contain wheat, rye or triticale, the enzyme xylanase (endo-1,4-β-D-xylanohydrolase, E.C. 3.2.1.8) has been shown to be beneficial. Pettersson et al., British Journal of Nutrition 62: 139-149, 1989). Wheat, rye and the wheat/rye hybrid triticale contain large amounts of the non-starch polysaccharide arabinoxylan in the endosperm cell wall. The arabinoxylan is not digested by monogastric animals, but is hydrolyzed by microbial xylanase.
A second example of an enzyme with widespread use in feeds is β-glucanase [cellulase, endo-1,4-β-D-glucan 4-glucanohydrolase E.C. 3.2.1.4; or endo-1,3-(1,3;1,4)-β-D-glucan 3(4)-glucanohydrolase E.C. 3.2.1.6] that has been shown to be especially beneficial in diets containing barley and oats. Rotter et al., Nutrition Reports International 39: 107-120 (1989). As well as interfering with digestion, the glucan causes wet sticky manure that induces breast blisters on poultry. In practice, xylanase and β-glucanase are applied together since arabinoxylan and glucan are both present in the cereal grains. Pettersson et al., Animal Production 51: 201-20 (1990).
The use of enzymes that cleave phosphorus from phytic acid (myo-inositol hexakisphosphate) is a third example of the beneficial use of enzymes in animal feed. Simons et al., British Journal of Nutrition 64: 525-540 (1990). In monogastric animals the phosphate is not released from phytic acid during digestion but is released in the manure through microbial action. Phytic acid has a significant content in typical feeds. Phosphate run-off becomes a problem during manure disposal by causing eutrophication of nearby rivers, lakes or bays. Incorporation of phytase lowers the phosphate content in the manure and significantly decreases the need to add phosphate salts to diets.
Mannanase is another enzyme that has gained commercial use in corn and soybean based diets. The decreased feed to gain, or increased weight gain, of monogastric animals fed a diet containing mannanase was unexpected in a diet based on corn. Until the discovery that bacterial endo-1,4-β-D-mannanase (E.C. 3.2.1.78, also known as mannan endo-1,4-β-mannosidase, see McCleary, B. V., β-D-Mannanase, Methods in Enzymology 160: 596-609, 1988) increases feed efficiency in corn-soybean diets, enzymes were infrequently used in poultry or swine feeds grown on corn-soy diets. U.S. Pat. No. 5,429,828, incorporated herein by reference, teaches a method of improving the energy efficiency of hemicellulose-containing animal feed by means of adding a hemicellulase, specifically mannanase, to the diet.
The positive effect of adding endo-1,4-β-D-mannanase on feeding efficiency was unexpected in a diet based on corn. In barley or oats that contain mixed-linked glucan, or wheat, rye and triticale that contain arabinoxylan, the anti-nutritive polymer represents a large percentage of the seed endosperm. In contrast, there is only a very minor content of polymers based on 1-4-β-D-mannan in the common corn based diets. The main source of galactomannan in a typical corn based diet is the soybean meal (added primarily as a source of protein). Based on total sugar analysis and the percentage of non-starch polysaccharides, soybean meal could contain on the order of 1.3% mannan. Thus, a diet with 30% soybean meal would have only about 0.4% mannan polymer. The added energy that would be derived from complete digestion of this small percent of the diet cannot account for the large improvement seen in feed conversion and weight gain.
In many areas of the world, diet rations containing low metabolizable energy content are utilized. Diet rations in these countries are not supplemented with fat. As a consequence, there is a need to increase the energy efficiency for utilization of low fat diets. In developing or developed countries supplemental concentrated fat is being eliminated from the diet for health reasons. In addition, there are a surprising number of problems associated with the addition of concentrated fat to diet rations to increase the metabolizable energy (ME) content of the feed (Rouse, R. H., Fat quality, the confusing world of feed fats, pp 55-63 In: Proceedings of the 1994 Maryland Nutrition Conference, March 24-25, Baltimore, Md., University of Maryland Feed Industry Council, College Park, Md.).
Oxidation of unsaturated fatty acids in fat is known to lead to the formation of peroxides and free radicals. This in turn leads to the oxidation of feed nutrients and vitamins. There is also evidence available that indicates that high fat diets can lead to ventricular failure and/or ascites problems in broiler chickens (Mullins, T. M. and W. W. Saylor, Effects of a high fat diet on growth, right ventricular hypertrophy, right ventricular failure, and ascities formation in broiler chickens, Abstract 25, p 11, Southern Poultry Science Society, 16 th Annual Meeting, Jan. 16-17, 1995, Atlanta, Ga.). Some sources of animal feed fat include restaurant waste fat that has been partially hydrogenated to create un-natural fatty acids with trans double bonds that can interfere with fertility, fatty acid metabolism and the energy value of the feed (Rouse, supra). Another issue is the presence of free fatty acids in commercial fats that can have adverse effects on production and may have an antimicrobial effect in the chicken gut (Rouse, supra). Blended fats are also frequently contaminated with PCBs, pesticide residues, heavy metals, and gossypol from cotton seed oil soapstock (Rouse, supra). Feed mill managers have to be vigilant about all these issues. It is well known that ingested fat (and materials dissolved in it like PCB) can be directly incorporated into the fat of the animal that consumes it and this may present important health risks. In addition, the fat in the animal rations can influence the taste of the meat. For example, more than 1% fish oil in chicken diets will cause a distinct fish-type odor in the meat or eggs (Lesson, S., and J. D. Summers, Chapter 2: Ingredient evaluation and diet formulation, (In) Commercial Poultry Nutrition, University Books, Guelph, Ontario, 1991). The effect of high fat content (especially animal fat) on product taste is another issue that some producers are beginning to pay close attention to. The ability to avoid the use of fat and still obtain the same productivity is of general interest.
There is a continuing need for higher efficiency in food production and the urgency of providing solutions will only increase with time. The use of high energy diets which include several percent of fat to promote efficient animal growth is not always possible or desirable due to the high cost of fat or vegetable oils, or limited amounts of available animal fat in some of the most highly populated parts of the world (for example in China and India). There is a basic inefficiency in using the available fat in feed. For example, in the chemical and soap industries the fat could have more value. Finally, there are a number of health issues and problems associated with the incorporation of exogenous concentrated fats in animal diets. These issues are a further indication that a reduced fat, reduced calorie, animal feed diet that maintains high feeding efficiency is urgently needed.
A need therefore exists for a method to increase the efficiency with which monogastric animals utilize feed rations that contain a low metabolizable energy content. Likewise, a need exists for a food ration that can be utilized efficiently by monogastic animals without addition of fat.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method to increase the efficiency with which monogastric animals utilize feed rations that contain a low metabolizable energy content.
It is a further object of this invention to provide a method to increase the efficiency with which monogastic animals utilize feed rations which contain no added concentrated fat.
These and other objects are achieved, in accordance with one embodiment of the present invention by the provision of a feed composition comprising (a) a legume seed meal; (b) essential amino acids and (c) and a hemicellulase enzyme, wherein said feed composition has a total metabolizable energy content of less than 3086 Kcal/Kg.
Another embodiment of the invention is a feed composition comprising (a) a soybean meal; (b) essential amino acids and (c) and a hemicellulase enzyme, wherein said feed composition has a total metabolizable energy content of less than 3086 Kcal/Kg.
Another embodiment of the invention is a feed composition comprising (a) a soybean meal; (b) essential amino acids and (c) and a mannanase, such as endo-1,4-β-D-mannanase, wherein said feed composition has a total metabolizable energy content of less than 3086 Kcal/Kg.
Yet another embodiment of the invention is a feed composition comprising (a) a soybean meal; (b) essential amino acids and (c) and a mannanase, such as endo-1,4-β-D-mannanase, wherein said feed composition has a total metabolizable energy content of less than 3086 Kcal/Kg and contains essentially no added concentrated fat.
Another embodiment of the invention is a feed composition comprising (a) a soybean meal; (b) essential amino acids and (c) and a mannanase, such as endo-1,4-β-D-mannanase, wherein said feed composition has a total metabolizable energy content of less than 3086 Kcal/Kg and contains less than 2% added concentrated fat.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a Pump Flow Diagram--Dual Head--for Feed Mill endo-1,4-β-D-mannanase application according to the present invention.
FIG. 2 shows an example of Successful Enzyme Application at a Feed Mill Producing up to 50 Tons of Pelleted Feed per Hour according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Any hemicellulase, including any mannanase, and more specifically endo-1,4-β-D-mannanase, that is effective in decreasing feed to gain, or increased weight gain, of an animal that consumes a low fat diet can be utilized in the present invention. As an example, one preferred enzyme source is Bacillus lentus (ATCC 5045) endo-1,4-β-D-mannanase (Fodge and Anderson, supra; Fodge, Anderson, and Pettey supra) manufactured as a product with the trade name Hemicell®.
When assessing the value added by the enzyme, a "Point" system is frequently used that is the sum of "weight" points (P w ) and "feed conversion, FC" points (P FC ) The FC is calculated by dividing the weight of feed consumed by the live weight. The two types of points are defined as follows:
P.sub.W =(Weight.sub.TEST -Weight.sub.CONTROL)/0.06 lb. (at 45 days)
P.sub.FC =(FC.sub.CONTROL -FC.sub.TEST)/0.01
In most of the scientific tests conducted in the United States, improvements of roughly 5 to 8 points (see Table 2) were observed in chickens, and comparable results were observed with both turkeys and hogs (data not shown). However, occasionally, dramatically better improvement upon endo-1,4-β-D-mannanase application was observed (Rue, J. R., H. R. Zhang, Z. C. Liang, T. Li and F. R. Meng, Application of endo-1,4-β-D-mannanase in Feed Industry, Zhongguo Siliao (China Feed) 24: 19-21, 1995).
Experiments were conducted in four different locations in China by one of the inventors. Averaging the results from four-tests, there was an improvement of 24.6 points upon endo-1,4-β-D-mannanase use. The data of Rue et al. are summarized in Table 1. The differences between the diets used in the Chinese tests and the typical U.S. diets were examined. Based on the differences, we undertook some carefully controlled scientific trials to investigate the cause of the greater β-mannanase impact. The unexpected result was that fat content, and/or the kilocalorie content of the ration, was key to enhancing the endo-1,4-β-D-mannanase effect as further described below.
TABLE 1______________________________________The Effect of endo-1, 4-β-D-mannanase in Chicken Broiler Pen Trialsin China (Rue, R. J., et al., 1995) Average Feed to Total Chickens Testing Weight Gain PointsLocation in Trial Period Increase Decrease P.sub.W + P.sub.FC______________________________________Beijing 2,000 52 days 0.472 0.17 24.8Qungdao, 2,400 56 days 0.419 0.30 36.9ShangtunProvinceLenyun Harabor, 4,700 29 days 0.220 0.09 12.7Kiangsu ProvinceWeifang, 4.000 49 days 0.417 0.17 23.9ShangtunProvince______________________________________
The mannanase concentration is adjusted to 1000 MU/liter as determined by a reducing sugar assay. The enzyme concentration can also be determined, for example, with a viscosity assay or a blue dye based assay. Generally the blue dye assay is used as a rapid assay to monitor the progress of fermentations, and the reducing sugar assay is used for quality control assays of the final product and feed samples. The final product has a pH adjusted to between 7.0 and 7.5 and the enzyme solution is stabilized against secondary microbial growth by the addition of 150 g/Liter sodium chloride. In this form, the enzyme is very stable and is maintained at ambient temperatures until use.
The enzyme product is preferably applied to feed in two ways. In a first method, the enzyme is dried onto soybean grits (20-80 mesh, Archer Daniels Midland) using a Glatt Air fluidized bed drier at an enzyme concentration of 100 MU per pound. The final moisture content of the dried enzyme product is preferably maintained to less than 8%. This product is added when the feed is formulated and is blended at a rate of one pound of endo-1,4-β-D-mannanase dry product per 2000 pounds of feed. The dry product method is generally used when the mixed feed is not heated to high temperature (e.g. less than 160° F.) during processing for formation into pellets.
A recent trend in feed manufacture is the use of very high temperatures in feed pelleters and/or feed expanders and extruders. Therefore, in many instances the endo-1,4-β-D-mannanase enzyme liquid product may be sprayed onto pre-formed feed pellets at a rate of 100 Mu/ton. At a location in the feed production line downstream from a pellet cooler, falling feed is preferably spread into a wide but shallow depth flow by means of a cone or plate in the pipe or duct just before the area where the enzyme is sprayed on. Thus, about 100 ml of liquid endo1,4-β-D-mannanase per ton of feed is continuously diluted with water using a dual head pump and sprayed through a nozzle at moderate pressure in a uniform pattern onto the falling feed stream. Alternatively, the diluted enzyme is dropped onto a spinning disk which in turn sprays the enzyme onto a curtain of feed passing around the disk by the so-called roto-coater method.
Yet a third method is to spray the enzyme into a pellet mixing device usually located after some other liquid feed component has been applied such as fat or vitamins. The amount of moisture added to the feed in this process is insignificant so that the enzyme is immediately absorbed and the added moisture does not promote microbial growth or erode pellet structure. After enzyme addition, the feed passes through a mixer to make sure uniform distribution of the enzyme in the feed is obtained. Machinery that maintains a uniform flow rate of feed past the spray is preferred.
In a most preferred mode of the spraying process, either a flow meter device as manufactured by Milltronics, Arlington Tx., that provides for adjustment of the spraying rate based on feed flow rate, or a roto-coater device as manufactured by APEC (Automated Process Equipment Corporation), Lake Odessa, Mich. is utilized (Stemler, T., Extending feed processing past the pellet mill, Feed Management 45: 4, 1994). The coefficient of variation for enzyme level in the feed should be 15% or less in a preferred case. Application of more than the target amount of 100 MU enzyme per ton of feed is not deleterious, but likely provides little or no added benefit. A more detailed description of a preferred mode of enzyme application and the equipment set up for use at a high temperature feed pelleting mill is given in Example 3 below.
A large number of animal feeding pen trials and full scale field trials have been conducted with endo-1,4-β-D-mannanase as described above. In cases where tests are properly conducted with enough repetitions to yield statistically significant results, and where the enzyme was uniformly applied at the proper level, and other common pitfalls such as non-uniform feeds were avoided, the data generally support increased feed efficiency with incorporation of mannanase into the feed. Six pen trial chicken feeding experiments are summarized in Table 2. Studies were also conducted with turkeys, and hogs of various breeds, with various feed compositions and geographical locations. Occasionally, tests worked much better than expected as in the Rue et al. supra, test in China (Table 1). Examining the differences in these tests that were out of the ordinary led to the current invention.
TABLE 2______________________________________β-Mannanase Performance in USA-Type Diets Containing48%-Protein Soyabean MealImprovements Feed/GainDate Term Weight Points Comment______________________________________Feb. 1990 46 days 0.042 0.27 8.7 7 repetitions/group, S.sup.1Sept. 1990 46 days 0.042 0.13 6.4 9 repetitions/group, SDec. 1990 46 days 0.068 0.086 8.2 8 repetitions/group, SOct. 1991 45 days 0.053 0.078 6.6 7 repetitions/group, SOct. 1991 45 days 0.064 0.142 8.7 7 repetitions/group, SSept. 1993 39 days 0.037 0.103 5.4 7 repetitions/group, all males, SAverages 0.049 0.099 7.4______________________________________ .sup.1 S statistically significant (P > 0.05)
TABLE 3______________________________________Comparison of Major components Typical U.S. Broiler Chicken Rationsand the Diets Used by Rue et al., in China______________________________________Typical U.S. Broiler Ration Starter Grower WithdrawalIngredients 0-21 days 22-35 days 36-43 days______________________________________Corn 57.42% 61.20% 63.85%SBM 48 27.40% 23.80% 21.31%Bakery by-product 2.00% 5.25% 6.00%Fat 3.56% 3.11% 2.92%Poultry meal 6.00% 3.00% 3.00%Composition% of NRC lysine 100% 100% 118%Crude protein 22.5% 19.0% 18.5%β-mannan 0.336% 0.292% 0.261%ME (Dcal/Kg) 3,146 3,190 3,234______________________________________Typical China Broiler Ration 1-14 days 15-45 days 49 day -Ingredients diet diet market diet______________________________________Corn 62% 60% 73%SBM 44 33% 26% 22.5%Fish meal 2% 2% 1.5%Composition% of NRC lysine 110 108 126Crude protein 23% 21% 19%β-mannan 0.6% 0.475% 0.411%ME (Kcal/Kg) 2,950 3,000 3,050______________________________________
Table 3 compares the composition of a typical highly optimized U.S. chicken broiler diet with the diets used in the Rue, R. J., et al., 1995 study (Table 1). Both diets are corn-soybean based, but there are some differences. Little or no concentrated fat was added to the Chinese diets and the ME (metabolizable energy) averaged about 6.3% higher in the U.S. diets. Another observation is that the Chinese diet used a 44% protein soybean meal (SBM 44) whereas the US diets used 48% soybean meal (SBM 48). The higher protein percent means there is less fiber in the meal derived from the soybean hulls. Because soybean hulls are rich in mannan (Whistler, R. L. and J. Saarnio, Galactomannan from soybean hulls, J. Am. Chem Soc. 79: 6055-6057), the calculated percentage for the amount of galactomannan in the two formulations is on average about 66% more for the Chinese diet, although in both cases quite low. The crude protein levels were similar, but the lysine content in the Chinese diets is significantly higher based on the National Research Council (NRC) recommended level. The U.S. diet in Table 3 would have overall about 4.7% excess lysine on a blended basis, but the Chinese diet has about 13.8% excess lysine compared to the NRC recommendation on a blended basis. Using well designed and carefully conducted chicken growth pen trial experiments, the effects of fat (higher energy diets, Diet B) with endo-1,4-β-D-mannanase were assessed keeping the mannan content low and constant. The details of the feeding experiment are described in Example 1, infra.
The diets used in the feeding trial in Example 1 (described in detail in Example 2) are summarized in Table 4. Diet A had about 3% less fat than diet B in each of the three phases of growth (starter, grower and finisher), but diet A would be approximately 85 Kcal/Kg greater than a typical Chinese broiler diet. The amount of crude protein in the two diets was kept the same and the levels of soybean protein added were very close. The amounts of lysine and other essential amino acids, vitamins and minerals were as close to identical as practical. Diet A had more corn added to make up for the deletion of concentrated fat. This is beneficial because corn costs significantly less than fat. Each diet was tested both with and without endo-1,4-β-D-mannanase.
TABLE 4______________________________________Basic Composition of Diets in theControlled Pen Trial of Example 4 Starter Grower Withdrawal 0-21 days 22-35 days 36-43 days______________________________________Diet AKey IngredientsCorn 62.40% 68.40% 71.40%SBM 48 31.10% 25.00% 21.40%Added Fat 0.73% 1.10% 1.86%Composition% of NRC lysine 113% 108% 124%Lysine crude 22.00% 19.50% 18.00%Protein 3,008.5 3,085.6 3,162.7ME (Dcal/Kg)Diet BKey IngredientsCorn 58.60% 64.60% 67.60%SBM 48 31.70% 25.60% 22.00%Added fat 3.86% 4.19% 4.99%Composition% of NRC lysine 109 104 121Crude protein 22.00% 19.50% 18.00%ME (Kcal/Kg) 3,151.7 3,228.9 3,306.0______________________________________
enzyme in 8 pens with 70 birds per pen. The test was ended at 45 days.
The result of the trial is summarized in Table 5. Using both types of feed there was a highly statistically significant (P<0.05) improvement upon the inclusion of the endo-1,4-β-D-mannanase enzyme. However, the improvement seen by inclusion of endo-1,4-β-D-mannanase in diet A was more than a two fold better than the improvement seen in diet B upon enzyme addition. When examining the Kcal required to produce a pound of bird live weight, the Kcal/live pound decreased by 40 in diet B, but decreased by 91 in diet A. Perhaps most important is the comparison between diet B without enzyme and the lower fat diet A with enzyme. The feed conversions and weights were not statistically different comparing those two cases, but the kcal per live pound decreased by 131 in diet A plus β-mannanase. This data demonstrates it is possible to eliminate 3% fat from diets reducing the Kcal content by about 143 Kcal/Kg without the degradation of performance, if an effective endo-1,4-β-D-mannanase is added at 100 MU/ton as defined.
Due to the high cost of concentrated fat as currently used in the industry, the economic benefit of using diet A plus enzyme is very significant. This surprising result was not anticipated. It is believed that the higher mannan content in SBM 44 is a significant difference between the typical U.S. and Chinese diet that caused the mannanase enzyme to have a greater impact in the Chinese diet. These unexpected results show that fat is also of key importance and that endo-1,4-β-D-mannanase is actually improving the energy level of the feed much more than previously recognized. In order to obtain the full benefit of the Kilocalorie increase in ME upon mannanase use, essential amino acid levels should preferably be adjusted upwards accordingly so they do not become limiting.
TABLE 5______________________________________Summary of endo-1,4-β-D-mannanase EnzymeEffect in Diets with Different Energy Levels Average Feed Kcal/ Weight Conver. Live Points.sup.2Treatment (lbs) F/G.sup.1 lb. P.sub.W + P.sub.FC______________________________________Chicken Broilers on Diet Bendo-1, 4.975.sup.a3 1.828.sup.a 2,6804-β-D-mannanaseControl 4.870.sup.bc 1.855.sup.b 2,720Improvement 0.087 0.027 -40 4.2Chicken Broilers on Diet Aendo-1, 4.905.sup.ab 1847.sup.ab 2,5884-β-D-mannanaseControl 4.765.sup.d 1.911.sup.d 2,679Improvement 0.140 0.064 -91 8.7Diet A Plus Hemicellulase vs. Diet B without Enzymeendo-1, 4.905.sup.ab 1.847.sup.ab 2,5884-β-D-mannanaseControl 4.870.sup.bc 1.855.sup.b 2,720Improvement 0.035 0.008 -131 1.4______________________________________ .sup.1 The F/G is corrected for mortality by including the weight of dead birds in the total weight. .sup.2 Feeding improvement points as defined in the text above. .sup.3 Numbers within a column that have different letter superscripts ar statistically different (P < 0.05) as determined by ANOV analysis and Least Significant Differences.
The feed enhancement method of this invention is not unique to any one source of endo-1,4-β-D-mannanase. Other mannanases effective in this method can readily be identified after isolation from nature and production through conventional, or recombinant DNA technology well-known in the art. Mannanase coding genes have been isolated from several sources (Luthi, E., N. B. Jasmat, R. A. Grayling, D. R. Love and P. L. Bergquist, Cloning, sequence analysis, and expression in Escherichia coli of a gene coding for a β-mannanase from extremely thermophilic bacterium Caldocellum saccharolyticum, Appl. Environ. Microbiol. 57: 694-700, 1991; Akino, T., C. Kato, and K. Horikoshi, Two Bacillus β-mannanases having different COOH termini are produced in Escherichia coli carrying pMAH5, Appl. Environ. Microbiol. 55: 3178-3183, 1989). Further, enzymes can be improved for use in this method by the techniques collectively known as protein engineering, well known in the art. Changes in protein structure are made through changing the DNA coding sequence through mutation. For example, mannanases can be improved in stability through changing specific residues in the amino acid sequence that yield decreased oxidative susceptibility, proteolytic susceptibility, or alternatively, a more ridged structure at increased temperatures. Such changes can be readily predicted after determination of the protein's three-dimensional crystal structure by x-ray crystallography. Alternatively, improvements can be made by area directed, but random mutagenesis of the gene sequence, followed by screening the resulting mutant enzymes for desired improved properties.
In a preferred mode of the invention, a mannanase is utilized that has increased thermal stability that can withstand the steam heat treatment delivered to feed during pelleting, expansion, or extrusion. In this case, the enzyme is preferably directly incorporated in a dry form with the other feed ingredients before pelleting. Increased thermal stability can be accomplished, for example, by a combination of methods. One is to start with enzyme that has inherent thermal stability such as an enzyme isolated from a thermophilic microorganism. However, the specific activity must be sufficient at 40° C. to deliver about 100 MU/ton as described in this method. A second option is to increase the thermostability of a mesophilic enzyme through protein engineering as mentioned above or random mutation area directed mutagenesis and selection for enzymes with improved properties. Yet a third option is to mix the enzyme with stabilizing chemicals and/or add coatings that prevent steam penetration, but which do not interfere with ready solubilization and activity in the animal gut.
Certain sugars like threalose (Colaco, C., S. Sen, M. Thangavelu, S. Pinder and B. Roser, Extraordinary stability of enzymes dried in threhalose:simplified molecular biology, Bio/Technology 10: 1007-1011, 1992; Roser, B. J. Protection of proteins and the like, U.S. Pat. No. 4,891,319) are known to stabilize proteins. Also, certain chemicals such as cyclic-2,3-diphosphoglycerate (Seely, R. J. and D. E. Fahrney, The cyclic-2,3-diphosphoglycerate from Methanobacterium thermoautotrophicum is the D-enantiomer, Current Microbiol. 10: 85-88, 1984 ; Hensel, R. and H. Koning, Thermoadaptation of methanogenic bacteria by intracellular ion concentration, FEMS Microbiol. Lett. 49: 75-79, 1988) and di-myo-inositol-1,1'-phosphate (Scholz, S., J. Sonnenbichler, W. Schafer, and R. Hensel, Di-myo-inositol-1,1'-phosphate: a new inositol phosphate isolated from Pyrococcus woesei, FEBS 306: 239-242, 1992) as well as high salt concentrations (Breitung, J., R. A. Schmitz, K. O. Stetter and R. K . Thauer, N 5 , N 10 -methylenetetrahydromethanopterin cyclohydrolase from the extreme thermophile Methanopyrus kandleri: increase of catalytic efficiency and thermostability in the presence of salts, Arch. Microbiol. 156: 517-524, 1991) are known to be involved in the stabilization of proteins in some extremely thermophilic microorganisms. Thus, thermophilic enzymes, stabilizing mutations, stabilizing chemicals or a combination of these factors can be used to prepare mannanases that withstand heating during feed pellet formation in one preferred mode of this invention.
Mannanase-producing microorganisms are readily selected from nature by selecting microbes capable of growing on a mannan based gum as the sole carbon source. Any soil rich in organic matter would be expected to be a good possible source of these microbes. For example, many types of tree wood hemicellulose are known to contain significant amounts of mannan (Sjostrom, E., Chapter 3, Wood Polysaccharides, In Wood Chemistry, Fundamentals and Applications, pp49-67, Academic Press, New York, 1981). Thus, sites with decaying wood are likely to be rich sources of mannanases. Certain types of agricultural locations would also be expected to be rich sources of microbes that produce mannanase. For example, sites for the growth and processing of legume seed plants, coffee plants, coconut/copra processing, or the growth and processing of other botanical species that are known to be a rich source of mannan will likely have abundant mannan degrading microbes that produce endo-1,4-β-D-mannanases. Several sources of endo-1,4-β-D-mannanases have already been described (McCleary, B. V., β-D-Mannanase, Methods in Enzymology 160: 596-610, 1988;) including fungi (Johnson, K. G., Exocellular β-mannanases from hemicelluloytic fungi, World J. Microbiol. Biotechnol. 6: 209-217, 1990; Araujo, A. and O. P. Ward, Studies on the galactomannan-degrading enzymes produced by Sporotrichum cellulophilum, J. Industrial Microbiol. 8: 229-236, 1991; Kusakabe, I., G. G. Park, N. Kumita, T. Yasui and K. Murakami, Specificity of β-mannanase from Penicillium purpurogenum for Konjac glucomannan, Agric. Biol. Chem. 52: 519-524, 1988) extreme thermophiles (Luthi et a.l., 1991, supra; Bicho, P. A., T. A. Clark, K. Mackie, H. W. Morgan and R. M. Daniel, The characterization of a thermostable endo-β-1,4-mannanase cloned from Caldocellum saccharolyticum, Appl. Micrbiol. Biotechnol, 36, 337-343, 1991), hyper-thermophiles (Adams, M. W., and R. M. Kelly, Enzymes from Extreme Environments, Chemical & Engineering News, pp 32-42, Dec. 18, 1995), Streptomyces (Kusakabe, I., R. Takahashi, β-mannanase of Streptomyces, Methods in Enzymology 160: 611-614, 1988; Takahashi, R., I. Kusakabe, H. Kobayashi, K. Murakami, A. Maekawa and T. Suzuli, Purification and some properties of mannanase from Streptomyces sp. Agric. Biol. Chem. 48: 2189-2195, 1984), and Bacillus species (Araujo, A., and O. P. Ward, Hemicellulases of Bacillus species: preliminary comparative studies on production and properties of mannanases and galactanases, J. Appl. Bacteriol. 68: 253-261, 1990; Araujo, A. and O. P. Ward, Mannanase components from Bacillus pumilus, Appl. Environ. Microbiol. 56: 1954-1956, 1990; Akino et al., 1989, supra; Akino, T., N. Nakamura and K. Horikoshi, Characterization of three β-mannanases of an alkalophilic Bacillus sp., Agric Biol. Chem. 52: 773-779, 1988; Emi et al., 1972, supra). Also, mannanases from Aspergillus niger are available commercially (two examples are Solvay Enzymes, Hemicellulase and Novo Nordisk, Gamanase™).
Once a microbial population is identified as a potential source of mannanase enzyme based on the ability to grow on mannan as the sole carbon source, individual microbes that secrete mannanase can be readily identified by overlaying cultures grown on Petri dishes with blue dye modified mannan dissolved in molten agarose solutions. After the agarose solidifies, mannanase producing microbes generate apparent clearing zones caused by rapid diffusion of the blue dye labeled mannan fragments. Once identified, standard methods including genetic improvement (Rowlands, R. T., Industrial strain improvement: mutagenesis and random screening procedures, Enzyme Microb. Technol. 6: 3-10, 1984) and fermentation technology both well known in the art are used to produce enough enzyme for testing. Once a useful mannanase is identified, then strain improvements, which could include gene cloning and expression, are used to further improve the enzyme production by fermentation methods. In some cases, it may even be advisable to clone the mannanase gene prior to sub-culturing and purifying individual microbial species that produce the mannanase. DNA can be isolated directly from natural sources, cloned into expression vectors in, for example, E. coli, followed by screening the recombinant clones for production of the desired mannanase (Robertson, D. E., E. J. Mathur, R. V. Swanson, B. L. Marrs, and J. M. Short, The discovery of new biocatalysts from microbial diversity, SIM News, 46:3-8, 1996).
An alternative source of mannanase useful in this application is from a botanical source. Because mannans are frequently used as storage polymers in seeds, certain germinating seeds such as Lucerne (Medicago sativa) or Guar (Cyamopsis tetragonolobus) are good sources of mannanases (McCleary, 1988, supra). Seeds would be germinated, then processed to yield a concentrated source of enzyme. Alternatively, complete germinating seeds could be ground into a meal for direct use in the feed. In this case, the seeds could have two purposes in the feed, first as a source of mannanase enzyme, but secondly as a source of protein and carbohydrate. However, if germinating seeds have some other anti-nutritive property that overpowers the mannanase effect, then that type of seed would not likely be significantly useful in this method. It is also possible to genetically engineer plants to cause a mannanase to be produced in their fruits, seeds, stems or leaves. As one example of numerous examples that could be cited, foreign enzyme has been expressed in Brassica napus (van Rooijen, G. J. H., and M. M. Moloney, Plant seed oil-bodies as carriers for foreign proteins, Bio/Technology 13: 72-77, 1995) a commercial oil seed plant that is grown on a large scale. Plant genetic engineering is yet another possible source of mannanase enzyme well known in the art that can be used for the practice of this invention.
Yet another approach to introduce mannanase in feed in the digestive tract, and a preferred mode of this invention, is to genetically modify the animal (i.e hogs, chickens or turkeys) such that endo-1,4-β-D-mannanase is synthesized in the digestive tract. This is accomplished by introducing a mannanase gene with an altered structure such that it is under the control of regulatory sequences that normally regulate the production and/or cause the secretion of another digestive enzyme such as for a protease into the digestive tract. By using regulatory sequences from genes that code for enzymes that are secreted into different parts of the digestive tract, mannanase secretion can be directed to different locations to optimize its impact. This type of transgenic technology has been used, for example, to cause the production of heterologous proteins into milk in the mammary glands of engineered animals (Campbell, A. M., Transgenic technology, Biopharm 9: 28, 1996; Velander, W. H., J. L. Johnson, R. L. Page, C. G. Russell, A. Subramanian, T. O. Wilkins, F.C. Gwazdauskas, C. Pittius, W. N. Drohan, High-level expression of a heterologous protein in the milk of transgenic swine using the cDNA encoding human protein C, Proc. Natl. Acad. Sci. 89: 12003-12007, 1992; Hansson, L., M. Elund, A. Elund, T. Johansson, S. L. Marklund, S. Fromm, M. Stromqvist, and J. Tornell, Expression and characterization of biologically active human extracellular superoxide dismutase in milk of transgenic mice, J. Biol. Chem. 269: 5358-5363, 1994).
Independent of the method of manufacture or introduction into the digestive tract, the effectiveness of any individual mannanase in this method must be tested in animal feeding trials. Such a test can best be conducted by a protocol similar to that described in detail in Examples 1 and 2. The enzyme amount added into the test should preferably be determined according to the pH and temperatures as used herein, even if these conditions are not optimal for the enzyme to be tested. Then, 100 MU of enzyme is utilized per ton of feed.
For the purposes of this invention, the following definitions are given with respect to certain aspects of the technology used during the development of this invention. Mannan is considered to be any carbohydrate polymer that can be partially or extensively degraded by the enzyme endo-1,4-β-D-mannanase. Thus, the term mannan includes β-1,4-D-mannan based polymers such as galactomannan that has 1,6 linked -galactose branches (or any other branching sugars) on the 1,4-β-D-mannan polymer backbone, or glucomannan that has some 1,4-β-D-glucose residues interspersed in the main polymer chain. Some practical examples of mannans and their sources according to this definition include guar (Cyamopsis tetragonolobus) gum, locust bean gum, tagua palm (ivory nut), copra mannan (palm), salep mannan, coffee mannan, carob (Ceratonia siliqua) mannan (Whistler, R. L. and C. L. Smart, Polysaccharide chemistry, Academic press, (1953)), sunflower meal, alfalfa meal, (Tookey et al., J. Agr. Foods Chem. 10: 131-133, 1962), sunflower meal and palm date meal (Dusterhbft et al., J. Science Food Agr. 59: 151-160, 1992). Galactomannans are very widely spread in nature. For example, galactomannans are present in the endosperm of most, but not all, legume seeds (Whistler and Smart, 1953, supra). Therefore, the beneficial effect of adding an effective mannanase is predicted with any feed containing a significant amount of any legume seed meal that is positive for endosperm mannan.
For the purposes of this invention endo-1,4-β-D-mannanase (E.C. 3.2.1.78) is also described by other names such as mannan endo-1,4-β-D-mannosidase or simply endo-mannanase, mannanase or hemicellulase. An effective mannanase for animal feed applications is defined as an enzyme preparation (purified or crude) with the ability to enzymatically reduce the viscosity of locust bean gum or guar gum solutions, and that is effective in increasing the feed conversion in scientifically controlled feeding trials using diets based on corn/legume seed meal (e.g. soybean meal) diets as first described by Fodge and Anderson (Fodge and Anderson, supra, U.S. Pat. No. 5,429,828). Soybean meal is a current commercial product widely used and available primarily as a source of protein in animal feed diets. Soybean meal is enriched for protein through extraction of the soybean oil and most of the hull and is currently the main source of mannan in highly optimized animal feed diets. Soybean meal is generally available in a form that is 44% crude protein, called SBM 44, or 48% crude protein, called SBM 48 for the purposes of this invention. In developing countries, soybean meals with protein contents lower than 44%, are also available.
The positive interaction of the mannanase effect with low diet ME energy for feeding improvement is predicted with diets that contain other sources of mannan, particularly a source of mannan from other members of the legume family such as peas, beans, lentils, alfalfa and others. The legume plant family for the purposes of this invention is the common name used to signify the Leguminosae or Fabaceae family, also commonly known as the pulse family of plants. Many members of this family, like soybeans, are rich in high quality protein and contain mannan in their endosperm (Whistler and Smart, 1953 supra). Many are desirable as feed components and have improved value through the practice of this invention.
For the purposes of this invention, a unit of endo-1,4-β-D-mannanase is may be obtained by the assay methods described herein. An effective dose of mannanase is equivalent to 100,000,000 units (100 MU) per ton of feed. Hemicell® is the registered trademark of an effective mannanase for the purposes of this invention, but any other effective mannanase could be utilized in this invention.
The metabolizable energy (ME) is the amount of energy (measured in kilocalories/kilogram) in feed that can be digested by an animal. The metabolizable energy for a given feed component varies from species to species of animal consuming it. The approximate ME content of common feed ingredients have been published (Dale, N., Ingredient analysis table:1995 Edition, Feedstuffs 67: 24-39, 1995). This information is used by animal nutritionists when balanced diets are formulated, and reformulated on a least cost basis, as the price and availability of feed components vary. For the purposes of this invention, the metabolizable energy of a feed is defined by the summation of the metabolizable energy (ME) supplied by each component at levels defined in the Feedstuffs Ingredient Analysis Table (Dale, 1995, supra) or updated versions of this reference.
The NRC essential amino acid requirement for the purposes of this invention is as published in the Feedstuffs reference issue for both swine (Easter, R. A., J. Odle, G. R. Hollis and D. H. Baker, Dietary nutrient allowances for swine, Feedstuffs, 67: 40-46, 1995) and poultry (Waldroup, P. W., Dietary nutrient allowances for poultry, Feedstuffs 67: 69-76, 1995). The requirement is defined in this reference in terms of the amount of amino acid required per unit of metabolizable energy content of the diet.
For the purposes of this invention transgenic manipulation is defined as causing the production of a protein in an animal through the application of recombinant DNA. Recombinant DNA is defined as in vitro manipulation of DNA, whether isolated form natural sources or completely chemically synthesized, followed by introduction into a organism for the purpose of subsequent expression. Mutation is defined as changing the DNA sequence of a gene by either area directed, site directed or random mutagenesis for the purposes of this invention.
Endo-1,4-β-D-mannanase is readily measured by any known method; for example, by a reducing sugar assay.
In an exemplary reducing sugar assay, the following materials are used:
3,5-dinitrosalicyclic acid (DNS), Aldrich, >98% pure
Phenol-reagent grade
Rochelle salt (potassium, sodium tartrate),
reagent grade
sodium hydroxide (NaOH)
hydrochloric acid (HCl)
sodium sulfite (anhydrous)
locust bean gum (Sigma Chemical Co., product # G0753)
Trishydroxymethylaminomethane (Tris) Buffer
D(+)-mannose, reagent grade (Sigma, product # M-4625)
tetracycline-HCl
40° C. water bath
boiling water bath
Sorvall table top centrifuge
microcentrifuge (e.g. Eppindorph, 1.5 mL plastic tubes)
vortex mixer
spectrophotometer (for reading at 550 nm)
pH meter
16×100 mm glass tubes
13×100 mm glass tubes
magnetic stir bars and magnetic stirring/heating plate
beakers, volumetric flasks, storage bottles analytical balance
variable pipetting device (1 mL) with disposable tips
250 mL baffled shake flasks (Bellco)
Platform flask shaker (New Brunswick Scientific)
Dinitrosalicylic Acid (DNS) Reagent may be used as a reagent. To make 1 liter of a stable stock solution, the following ingredients are dissolved in water.
______________________________________NaOH 10 g (added first)DNS 10 gphenol 2 gRochelle Salt 200 g______________________________________
The solution is aged 1 day prior to use and stored in the dark. A working solution should be prepared daily by adding 0.5 g/liter anhydrous sodium sulfite to the stock solution.
Locust Bean Gum (LBG) Substrate may be prepared at 5 g/liter by slowly adding LGB into a fast stirring solution of 50 mM Tris Buffer (pH 7.5) at room temperature. After the powder is well dispersed, heat the suspension slowly to boiling and simmer for 1 hour with fast stirring on a heated stir plate to get a very consistent, well hydrated gel. Make sure there are no small clumps of non-hydrated gel in the solution. If there are, start over using slower addition of the LBG to the Tris buffer solution. Cool to room temperature and adjust the solution to the desired final volume to give 5 g/liter LBG. Add tetracycline-HCl (30 mg/mL) to the gum solution as preservative. Store at 4° C when not in use. After storage, mix well prior to use.
Standard Solutions and Standard Curve may be obtained by preparing a series of D-(+)-mannose standard solutions dissolved in water in the concentration range of 0.1 to 0.5 g/liter. Add 0.6 mL of each mannose standard (in duplicate or triplicate) with 1.5 mL of DNS working solution in 13×100 mm glass tubes. Also include a reaction with a 0.6 mL aliquot of water as a reagent blank to zero the spectrophotometer. Heat in a boiling water bath for 5 minutes, cool to ambient temperature and read the absorbance at 550 nm. The expected result is a linear dose response between 0.25 and 1.7 O.D. units. [Note--In enzyme assays (described below), only data generated in the range of 0.25 to 1.2 O.D. is used in calculations because due to substrate limitation, the enzyme reaction is not linear beyond this range]. Calculate the slope of the standard curve (O.D 550/g/liter mannose) from the linear portion of the curve only.
This standard curve will vary with the Lot of DNS reagent obtained. If numerous assays are anticipated, it is advisable to obtain a large lot of DNS when purchased. A typical standard curve is shown in the attached figure. Slope of this curve equals 4.706 O.D/g/liter Mannose.
The samples are prepared by diluting liquid samples to approximately 100,000 U/liter (0.1 MU/liter) in 20 mM Tris-HCl buffer (pH 7.5). For the best accuracy, first determine the density of the enzyme solution, then make use of an analytical balance to very accurately make the dilutions by weight. Solid samples of animal feed are extracted prior to assay. Add 10 grams of solid enzyme carrier to 100 mL of water in a 250 mL non-baffled shake flask and mix at 200 rpm at room temperature for 30 minutes. Transfer some of the extract solution to an Eppindorph centrifuge tube and centrifuge (10,000-12,000 RPM) for 2 minutes. Remove some of the clear liquid supernatant and dilute into 20 mM Tris-HCl buffer (pH 7.5) to about 0.1 MU/liter for assay.
In an enzyme assay, all assays are preferably done in duplicate or triplicate at each dilution level tested. Weigh 4 grams of LBG substrate into 16×100 mm glass tubes and bring to 40° C. in a water bath. [Note--weighing the LGB solution is most accurate because its viscosity makes it difficult to pipette.] Add 0.8 mL of enzyme solution, mix vigorously with a vortex mixer, replace in the 40° C. bath and begin timing. Include a tube with water in place of enzyme as control to zero the spectrophotometer. The enzyme reaction should be mixed about every 5 minutes and immediately before taking samples. At times of 12, 18 and 24 minutes remove a 0.6 mL aliquot of the reaction and add to 1.5 mL DNS working reagent in a 13×100 mm glass tube. Immediately vortex to stop the reaction. Place in a boiling water bath for exactly 5 minutes. Cool to room temperature, centrifuge for 10 minutes at 2,700 RPM in a table top centrifuge and read the supernatant optical density (O.D.) at 550 nm. Using readings that produce numbers in the linear range of the assay (between 0.25 and 1.2 O.D. 550), calculate the enzyme rate as O.D./minute.
A ChemGen unit for Hemicell mannanase has an arbitrary definition that was originally defined from a viscosity method. The size of the unit was chosen based on certain performance characteristics and cannot be directly compared to other assay methods without a conversion factor. When the viscosity method was correlated to the reducing sugar method described here, 1 CG Unit produces 0.574 microgram reducing sugar/minute from LBG. Thus 1 CG MU produces 0.574 gram reducing sugar/minute.
In practical terms, the calculation can be performed in the following way. ##EQU1## For endo-1,4-β-D-mannanase-Liquid MU/Liter (in assay soln.)×diln. factor=MU/Liter (orig. soln)
For endo-1,4-β-D-mannanase-Dry :
MU/Liter (in assay soln.)×diln. factor=MU/Liter (orig. extrt.)
MU/Liter (orig. extrt.)×0.1 Liter/0.01 kg=MU/kg
Endo-1,4-β-D-mannanase may also be obtained by a viscosity assay.
This method is a very sensitive assay for mannanase type activities that hydrolyze the internal manosidic bonds of Locust Bean gum. The corresponding reduction in substrate viscosity is measured with a calibrated viscometer and used to calculate the unit of activity defined by ChemGen (CG Unit). This assay is used where the activity to be measured is low or high accuracy is needed. However, the procedure is time consuming.
The following apparatus and materials are preferably used:
Viscometer. Use a size 100 calibrated Cannon-Fenske type viscometer or its equivalent. A suitable viscometer is supplied as Catalog No. 2885-100 by Scientific Products, 1210 Waukegan Road, McGaw Park, Ill. 60085.
Glass Water Bath. Use a constant temperature glass water bath, maintained at 40° C.±0.1° C. A suitable bath is supplied as Catalog No. W3520-10 by Scientific Products.
Two electronic timers
pH meter
beakers, volumetric flasks (1000 mL, 500 mL)
NaOH, HCl
glycine (reagent grade)
magnetic mixer/hot plate and magnetic stir bars
10 mL pipettes, 2.0 mL pipettes
1.0 mL pipettor with disposable tips (e.g. Pipettman, Rainin Instruments)
0.1 mL pipetor with disposable tips (e.g. Pipetteman, Rainin Instruments)
analytical balance
18×150 mm glass tubes
suction device (designed for use with pipettes)
tube vortex mixer
aluminum foil
The following reagents and solutions are preferably used in the viscosity assay:
A. Locust Bean Gum (LBG). Powdered Locust Bean Gum supplied by Sigma Chemical Company may be used. Locust Bean gums will loose viscosity with time. For accurate results, substrate should be prepared fresh at least once a month. For good substrate, the T S (see below) should be greater than 110 seconds.
LGB is prepared at 2 g/liter (0.2%) by slowly adding LGB into a fast stirring solution of deionized water at room temperature. Add 2 grams of LBG to about 900 mL of deionized water very slowly with rapid mixing on a stir plate. After the powder is well dispersed, heat the suspension slowly to boiling and simmer with continued fast mixing on a heated stir plate for one hour or more to get a very consistent, well hydrated gel. Make sure there are no small clumps of non-hydrated gel in the solution. If there are, start over using slower addition of the LBG to the water solution. Cool to room temperature and adjust the solution to the desired final volume by quantitatively transferring to a 1000 mL volumetric flask, dilute to volume with water, and mix. After storage, mix well prior to use. The pH of the final solution should be close to pH 6.
B. Glycine Buffer, 2 M (pH 9.0). Dissolve 75 grams of glycine in 450 mL deionized water, add 5 N NaOH with continuous mixing until the pH is 9.0±0.05 unit as determined with a pH meter. Quantitatively transfer to a 500 mL volumetric flask and dilute to volume with water. Verify pH 9.0 pH in the final solution.
C. Sample Preparation. Prepare a solution of the sample in deionized water so that 0.5 mL of the final solution will produce a change in relative fluidity (F R ) between 0.035 and 0.045 per minute under the conditions specified in the Procedure below. This corresponds to activity in the range of about 1850 to 2400 CG U/liter in the sample. The linearity of the assay is not guaranteed outside this activity range. For liquid samples make dilutions in water using an analytical balance to measure enzyme and the water added for the best accuracy.
For samples extracted from solids, centrifuge or filter to remove solids that could plug the fine bore of the viscometer.
To perform the procedure and calculation, scrupulously clean the viscometer by drawing a large volume of detergent solution (if necessary to remove adhering residue), followed by water, through the instrument and place the previously calibrated viscometer in the glass water bath at 40° C. in an exactly vertical position. These steps are necessary between each measurement.
Determine T w . Pipette 10 mL of deionized water in the viscometer reservoir and allow a few minutes to equilibrate temperature. Draw the water up into the viscometer past the top mark. Allow the solution to flow back starting a timer when the meniscus falls past the top mark and stopping the timer when the meniscus falls past the second mark. Repeat the measurement several times. The average time is defined as the T w (efflux time for water).
Determine T Ss and Control Rate. Place 10 mL of the LBG substrate in a 18×150 mm glass tube, add 2 mL of 2.0 M glycine buffer (pH 9.0), mix, cap with aluminum foil and place in the 40° C. water for a few minutes to heat. Add 0.5 mL of water, quickly mix with a vortex mixer, and immediately start the first timer. Pipette 10 mL of the solution to the viscometer reservoir, allow a minute to equilibrate, then draw up the solution and determine the efflux time with the second timer, this will be the T S (recorded in seconds). Each time the T S is determined, record the elapsed time (T R , reaction time, recorded in digital minutes) on the first timer when the meniscus falls past the top mark. In the ideal case, the T S will not change indicating no control loss of viscosity. In this case, T S for calculations should be the average of the determinations. In some cases however, there is a background rate. For background rates, the substrate efflux values are treated as T T values for calculation with the corresponding T R values to calculate a background rate as described below. The first efflux time measured after starting is used as T S in this background rate calculation. Some lots of substrate may become contaminated with small amounts mannanase type activity. If more than 500 U/L are measured or the initial T S is less than 110 seconds, it is best to prepare a new substrate solution.
Enzyme Rate. Place 10 mL of the LBG substrate in a 18×150 mm glass tube, add 2 mL of 2.0 M glycine buffer (pH 9.0), mix and place in the 40° C. water for a few minutes to heat. Cap the tube with aluminum foil to prevent water evaporation prior to use. Add 0.5 mL of enzyme dilution, quickly mix with a vortex mixer, and immediately start the first timer to determine T R values. Pipette 10 mL of the solution to the viscometer reservoir, allow a minute to equilibrate, then draw up the solution. When the meniscus passes the top mark, record the T R on the first timer and begin determining the efflux time with the second timer, this will be the T T . Immediately redraw the solution above the top mark to obtain a T T at a second T R . Continue repeating the determinations until a period of about 15 minutes have elapsed after the last T R measurement. At least four time points are recommended.
To perform the required calculation, the data are used to calculate the relative fluidity (F R ) and the normalized reaction time (T N ) which is T R plus half the corresponding efflux time. The calculations are done as follows:
F.sub.R =(T.sub.S -T.sub.W)/(T.sub.R -T.sub.W),
and
T.sub.N =0.5(T.sub.T /60 s/min)+T.sub.R =(T.sub.T /120)+T.sub.R
Plot the relative fluidities (F R ) as the ordinate against four reaction times (T N ) as the abscissa. A straight line should be obtained. The slope of the line corresponds to the relative fluidity change per minute (F R /min.) and is proportional to the enzyme concentration. Using the slope through a series of points is a better criterion of enzyme activity than using a single relative fluidity value. Ideally, the relative fluidity change should be about 0.04/minute. If there is background substrate degradation in the reaction, the plot will not be linear in the initial part of the plot. Use the data after the line becomes linear to determine the slope. We generally use the Lotus spreadsheet program to plot and calculate the best fit of the plot slope and to perform the other calculations necessary obtain units.
The CG Units/liter in the 0.5 mL sample added to the reaction are defined as:
CG U/Liter=9.397×10.sup.4 ×F.sub.R /min.
Thus, the original sample enzyme concentration is calculated as:
CG U/L (orig. sample)=(1 CG U/L--Substrate Control U/L)×dilution factor
Endo1,4-β-D-mannanase may also be assayed using a blue dye assay.
According to this assay an enzyme substrate is prepared preferably using a procedure (Methods in Enzymology 160: 538, 1988) described for the production of RBB(remizol brilliant blue)-xylan that was adapted for attaching the RBB blue dye to locust bean gum. The procedure was modified by adding 0.7% Locust bean gum (LBG) and 0.07% dye into the initial reaction. Also, after the reaction with RBB in sodium acetate and sodium hydroxide, the dyed locust bean gum solution was dialyzed to remove salt prior to ethanol precipitation. This facilitated resuspension of the gum after precipitation. The dye bound gum can be precipitated with one volume of ethanol at room temperature rather than two volumes on ice as used in the xylan procedure.
Dissolve 3.5 g of RBB-LBG in one liter of 50 mM Tris-HCl, pH 7.5 by adding dry powder slowly to a rapidly-stirred buffer. Heat with stirring to boiling, then autoclave for 20 minutes at 121° C. and cool to room temperature. Centrifuge to remove undissolved material. Pour the supernatant into suitable tubes, then autoclave again. The solution is stable for at least six months if no microbial contamination is introduced into the bottles. The reagent blank in the assay (see below) should give an optical density (OD) of less than 0.15 when read against 70% ethanol. If the OD is higher, the RBB-LBG reagent is discarded.
Assay Protocol
A. Make appropriate dilutions of samples and standards in non-chlorinated water. For the standard curve, dilution are made that have about 1.5, 2.0 and 2.5 MU/Liter using an enzyme standard previously determined by the reducing sugar method. The test samples should be diluted so that the activity falls between the 1.5 to 2.5 MU/Liter range. For best results dilutions are made using volumetric flasks and an analytical balance to exactly determine the amount of enzyme solution added.
B. Dispense 0.54 mL of RBB-LBG reagent into 1.5 mL microcetrifuge tubes and place the tubes in a 400 water bath for at least 10 minutes.
C. To start the reaction, add 20 μL of enzyme and mix by vortexing. Incubate each sample for exactly 10 minutes. Samples should be tested in duplicate for best results.
D. Stop the reaction by adding 0.9 mL of absolute ethanol (reagent alcohol) and mixing thoroughly. Allow the tubes to sit at room temperature for at least 10 minutes.
E. Centrifuge the tubes at 8-12,000 RPM in a centrifuge for three minutes.
F. Read the optical density at 590 nm using a reagent blank treated exactly as the test samples above using 20 μL of water instead of enzyme to zero the spectrophotometer.
G. Plot the OD 590 nm observed for the standards against the activity in MU/Liter in the diluted standards and determine the slope.
Calculation
The activity in the samples (MU/Liter)=OD 590 nm×slope×sample dilution factor
The present invention is further described below by reference to the following illustrative examples.
EXAMPLE 1
Chicken Growth Pen Trial Method
Commercial broiler chickens (50/50 male/female Peterson×Arbor Acres) supplied by the ConAgra Hatchery, Hurlock, Md. were grown with 70 birds per pen from day 1 to day 45 and were delivered to the test site on the day of hatching. All chicks were vaccinated and treated as normal at the hatchery. The density was 0.850 ft 2 per bird using pens 5 feet by 12 feet in size. The building was a wood/cinderblock structure heated with forced air heating (plus heat lamps the first week) and incandescent lighting. The temperature was monitored daily and maintained at 92° F. for the first 3 days, then reduced 1° F. per day until 70° F. was reached and maintained until the end of the trial. Air exchange was enhanced by fans on time delay that ran on average between 1-4 minutes every 10 minutes. The test was conducted from Oct. 31, 1995 to Dec. 15, 1996 on the Maryland Eastern shore.
Feeds were prepared using known requirements typical to the poultry industry and commercial specifications. The feed for the entire test was all mixed and pelleted at about 175° F. The feed utilized in the experiment was all prepared at the same time and equaled or exceeded the nutritional requirements set by the National Research Council (Nutrient Requirements of Poultry, 9 th Revised Edition, U.S. National Research Council, 1994). A portion of the control mix was taken for enzyme addition by uniformly spraying it with liquid concentrate. The starter feed for days 0 to 21 was crumbled pellets. Grower and finisher feeds were used as whole pellets.
Twenty five chicks are initially caught and weighed. The mean weight was determined and a range of five grams around the mean was established. Chicks with weights within this range were randomly chosen and divided at 70 per pen. A total of 3,840 female and male chicks (50/50) were used in the experiment. All pens were monitored three times per day during the study. More specifically, the availability of food and water, temperature maintenance, and the general condition of chicks and litter were monitored. For the first seven days of the experiment, chicks that died were replaced with chicks from a pool of birds separately maintained on their respective diets and chosen at random.
The eight pens for each of the different treatments were randomized throughout the building to eliminate any possible bias caused by the physical location of pens in the building. The following data was collected during the trial:
1. Individual body weights on day 21 and day 45. ed efficiency on day 21 and 45.
2. The feeding efficiency was calculated as the feed/gain ratio. The gain was the sum of the live bird weights as well as the weight of any dead birds on the day that they died. The feed weight was determined by adding known amounts of feed to each pen, and subtracting the weight of any uneaten feed left in the pen at the time of weighing the birds.
3. Mortality analysis included the total mortality as well as the day of death.
4. Standard deviations and coefficients of variation were calculated for the individual body weights on day 21 and 45.
5. Other observations of the birds included feathering and physical appearance.
TABLE 6______________________________________Pen Trial Body Weight Data, Day 1-45 AveragePen Body Weight (pounds)Rep T1 T2 T3 T4______________________________________R1 4.819 5.026 4.822 5.080R2 4.850 4.946 4.831 4.936R3 4.974 4.881 4.657 4.819R4 4.885 5.021 4.793 4.841R5 4.892 4.918 4.705 4.809R6 4.946 4.943 4.695 4.849R7 4.782 4.895 4.794 4.955R8 4.812 5.025 4.823 4.950Mean 4.870 4.957 4.765 4.905Stat. bc a d abS.D. 0.063 0.056 0.064 0.087C.V. 1.286 1.127 1.341 1.765______________________________________
There were no significant differences observed between any of the groups with respect to mortality, feathering or physical appearance. The results are summarized in Table 5 above and the details of the diet preparations are shown in Example 2 (Table 8). Details of the data are given in Tables 6 and 7.
TABLE 7______________________________________Pen Trial Feed Conversion Data, Feed/Gain1-45 Days Corrected for MortalityRep T1 T2 T3 T4______________________________________R1 1.872 1.810 1.920 1.850R2 1.851 1.871 1.923 1.871R3 1.866 1.864 1.926 1.892R4 1.877 1.848 1.944 1.879R5 1.852 1.800 1.905 1.820R6 1.822 1.803 1.881 1.842R7 1.818 1.818 1.889 1.807R8 1.883 1.807 1.900 1.815Mean 1.855 1.828 1.911 1.847Stat. b a d abS.D. 0.023 0.027 0.020 0.030C.V. 1.234 1.483 1.030 1.607______________________________________
In Tables 6 and 7, the treatment groups are assigned as follows:
T1=3229 Kcal/Kg, no enzyme
T2=3229 Kcal/Kg, plus enzyme
T3=3085 Kcal/Kg, no enzyme
T4=3085 Kcal/Kg, plus enzyme
EXAMPLE 2
Details of Diets Used in Pen Trials to Assess the Interaction of Diet Energy and Mannanase
Table 8 provides a detailed description of the diets used in the pen trial described in Example 4. The ingredients are well recognized by anyone skilled in the art of animal nutrition. The starter diet was used on days 0-21, the grower diet on days 22-39 and the finisher diet on days 40-45.
TABLE 8__________________________________________________________________________Detailed description of diets used in the Pen Trial to Assess EnergyLevel Effects Weight % - Diet A Weight % - Diet BComponent Starter Grower Finisher Starter Grower Finisher__________________________________________________________________________yellow corn 62.381 68.415 71.406 58.593 64.627 67.618soybean meal 48% 31.077 24.982 21.352 31.726 25.63 22.000Fat 3700 0.731 1.063 1.857 3.858 4.191 4.985Salt (NaCl) 0.307 0.305 0.258 0.307 0.305 0.258limestone 0.537 0.583 0.544 0.527 0.573 0.533DEFPHOS 32-18 1.258 1.095 1.077 1.267 1.104 1.086choline CH-60% 0.073 0.049 0.010 0.081 0.057 0.017meat blend - 58% 3.000 3.000 3.000 3.000 3.000 3.000vitamin premix 0.025 0.025 0.025 0.025 0.025 0.025trace mineral PRX 0.075 0.075 0.075 0.075 0.075 0.075DL-methionine 0.285 0.156 0.145 0.290 0.161 0.151SACOX 0.100 0.100 0.100 0.100 0.100 0.100bacitracin MD 0.042 0.042 0.042 0.042 0.042 0.042cromophyl-Oro 0.110 0.110 0.110 0.110 0.110 0.110Compositionlysine (total) 1.212 1.031 0.922 1.223 1.043 0.934methionine + cysteine 1.020 0.83 0.788 1.020 0.830 0.780crude protein 22% 19.5% 18% 22% 19.5% 18%Kcal/Kg 3008.5 3085.6 3162.7 3151.7 3228.9 3306.0__________________________________________________________________________
EXAMPLE 3
Spraying System for Application of Enzyme to Food Pellets at a Poultry Feed Mill
In many cases it may be preferable to spray enzyme onto preformed feed pellets if extreme temperatures are used during the formation of the pellets. In some locations heating time and temperatures are used during pellet formation that essentially cook the feed and thus denature most enzymes effective in this method.
FIG. 1 shows a flow diagram of a pumping system for coating feed with enzyme. The pump is a two headed diaphragm pump (Duriron #E2-(16)(07)115-68A31) that is used to pump water and endo-1,4 - β-D-mannanase in approximately a 9 to 1 ratio into a common outlet. The mixture flows past a pulse dampener (Blacoh #A301N) and a solenoid valve (Asco #EF8210G87) is used to prevent water flow while the pump is off. A flow meter (King Instruments 7511 series) allows visual inspection of liquid flow rates and the color of the water diluted enzyme solution.
The adjustable pressure switch (Omega #PSW121) is used to detect any line blockages and automatically turns off if the pressure setting is exceeded. The setting used depends on the height of the enzyme outlet relative to the pump and is generally slightly greater than the pressure created by the head height. Valves are provided to allow liquid sampling and priming of the endo-1,4 - β-D-mannanase side of the pump head. House water pressure is reduced to 15 psi before the pump by the water pressure regulator. The endo-1,4 - β-D-mannanase storage tank or drum may be pressurized to 2 psig with the air regulator to prevent loss of pump prime.
The mixture in the storage tank is provided at 1000 MU/liter and 100 MU is applied to each ton of feed. The water flow rate is adjusted to 900 mL per ton of feed using the stroke length adjuster. The endo-1,4 - β-D-mannanase flow rate on the other side of the pump is then independently adjusted to 100 mL/ton. The rate is verified by measuring the rate of enzyme concentrate leaving the storage drum or tank. Thus, after water dilution, about 1 liter of diluted liquid enzyme is applied to each ton of feed adding only about 0.1% moisture. In a preferred mode, enzyme is applied to feed through existing mill fat coating equipment known as a roto-coater manufactured by APEC (Automated Process Equipment Co., Laurel Drive, Lake Odessa, Mich., 48849) Typically, enzyme will be piped to the same location where the fat falls onto a spinning dish that disperses it onto a thin curtain of feed falling around the dish at a uniform rate. The fat coating equipment is often at the top of the mill. The elevation change creates enough pressure in the diluted enzyme containing pipe to properly seat the pump check valves for normal operation.
The signal from the mill's computer is run through the normally closed side of the pressure switch to the motor starter, pilot light and solenoid valve. Therefore, when the mill begins making feed, the pumping system is automatically turned on unless there is an over-pressure situation.
Samples of feed are taken where it is loaded into bins or trucks for enzyme level verification. The assay method used is known in the art as described, supra. Success in application is achieved when the mean enzyme level is 100 MU/ton and the coefficient of variation (CV) is less than 15%. FIG. 2 shows an example of successful enzyme application over a period of several weeks at a feed mill capable of producing up to 50 tons of pelleted feed per hour.
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A method is provided to increase the efficiency with which monogastric animals utilize low caloric content dietary rations. Addition of a hemicellulase enzyme, such as mannanase, to dietary rations that are not supplemented with concentrated fat, or which contain reduced fat content, increases the efficiency with which monogastric animals utilize the rations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to retractable awnings, and more specifically to a mounting system for connecting a retractable awning to a support surface in a manner to prevent leakage of water through the connection.
2. Description of the Prior Art
Retractable awnings have been utilized for many years, particularly as awnings for windows or entry doors of building structures. The awnings are typically rolled out during daylight hours to block undesired sun rays and rolled in at night when the sun has gone down. Such awnings normally include a roll bar which is mounted in a movable manner along an outer edge of an awning so as to roll away from and back to the building as the awning is extended and retracted respectively.
Retractable awnings have more recently been mounted on the sides of mobile homes, recreational vehicles, travel trailers or the like. The additional function of awnings used in this manner is to provide shelter from the weather. Such retractable awnings normally include support posts for supporting the outer edge of the awning either by forming a brace from a side wall of the vehicle or by forming a ground support. While the outer edge of the awning is supported in this manner, the inner edge of the awning is typically supported by a mounting rail operably attached to the sidewall of the vehicle.
Historically, awnings were comprised of an awning sheet with a weatherized fabric material attached to its inner edge. The weatherized fabric material protected the awning sheet from environmental damage when the awning was rolled-up in its retracted position adjacent to the support structure. The inner edge of the weatherized fabric material was operably attached to the support structure by a conventional connection system.
In recent times, the weatherized fabric material has been in some instances replaced by a plurality of elongated slats pivotally connected together along their length in an articulated manner. The inner edge of the awning sheet is attached to the outermost one of the articulated slats, and the innermost slat is connected to the side of the vehicle. The slats protect the awning sheet from environmental degradation by encapsulating the awning sheet when the awning is rolled up in its retracted position.
A concern with all retractable awnings relates to the leakage of water through the line of connection between the awning and the support surface of the vehicle. Leakage can occur while the awning is in either the extended or retracted position. Water, from rain or condensation from roof-top air conditioners, can come into contact with the connector. Where the connector is not water-tight, leakage around the connector can occur. Also, the water that does not leak through the connector can flow out onto the awning, if extended, where it may leak through elsewhere. U.S. Pat. No. 4,909,296 issued to Richard G. Selke and Richard B. Rader, on Mar. 20, 1990, and entitled WATER-TIGHT SEALING SYSTEM FOR ARTICULATED SLATS acknowledges and addresses the problem of water leakage through the slats by establishing tiny rubber sealing strips in the connections between the articulated slats.
Historically, the mounting rail on the support surface to which the awning sheet is connected has been composed of metal. Since the articulated slats currently used to protect the awning sheet from the weather are also metal, the joint is characterized by metal-to-metal contact. The metal-to-metal contact is not inherently water-tight, and accordingly water is able to leak through the connection. The water that does not leak through the awning at the connector flows onto the awning and increases the risk of leakage between the articulated slats.
A recent development adapted to prevent leakage from between the awning and the support surface is described in U.S. Pat. No. 4,634,172 issued to Henry J. Duda on Jan. 6, 1987, and entitled FLEXIBLE HINGE RAIN SEALING MECHANISM. The Duda '172 mechanism prevents leakage between the awning and the support structure by utilizing a connector strap made of flexible material which is seated in opposing C-shaped grooves provided in a mounting rail on the vehicle wall and the innermost articulated slat. The Duda '172 connector forms a water-tight seal between the innermost articulated slat and the support structure when the connector is put under tension. Such a system works to effect a watertight seal between the support structure and the awning, but the flexible connector has a limited life, so the system is not totally satisfactory. Further, the flexible connector does not prohibit water from flowing onto the awning, nor is it of sufficient rigidity to keep the articulated slats from binding up when the awning is being retracted or extended.
It is to overcome the shortcomings in the prior art that the present invention was developed.
SUMMARY OF THE INVENTION
The present invention in general terms concerns a leak-proof connector for connecting an awning to a support surface, and more particularly to the use of such a connector between a support surface and a plurality of articulated slats attached to the inner edge of the awning sheet.
When a retractable awning is in use the outer edge of its awning sheet or canopy is operably supported either by a support arm extending from the support surface, or a ground support. The awning sheet's inner edge is connected to the outermost slat of the plurality of slats, with the innermost slat being operably connected by a connector to the support surface.
The present invention for establishing a water-tight connection between the awning and the support surface utilizes an elongated slat having an inner longitudinal edge, an outer longitudinal edge, and an intermediate trough portion extending downwardly between the inner and outer longitudinal edges. The outer longitudinal edge is operably connected to the innermost slat, while the inner longitudinal edge is operably connected to the support surface.
The elongated slat connector has a trough-like transverse cross-section to catch water that flows onto the awning near the support surface. The water then drains off either end of the elongated slat connector. The lateral drainage of the water diverts the water so that it does not flow across the connector and onto the awning, thus reducing leakage through the articulated slats or elsewhere through the awning.
The elongated slat connector is rigid, helping to prevent the articulated slats from binding up when the awning is being retracted or extended. Additionally the elongated slat connector does not engage the support surface directly at any point when the awning is extended or retracted and rolled up adjacent to the support surface.
Accordingly, it is a primary object of the present invention to provide a connector between an awning sheet and a support structure that prevents water leakage therethrough.
It is another object of the present invention to provide a connector to support a retracted awning adjacent to the support structure in such a way that the rolled up awning does not engage the support structure.
Still another object of the present invention is to provide a connector that is pivotally connected to the awning sheet and the support structure.
Yet another object of the invention is to provide a connector that is sufficiently rigid so that the awning, when being retracted or extended, does not bind.
It is a further object of the invention to provide a connector that has a relatively long life.
Additionally, an object of the invention is to provide a connector that diverts water flow laterally away from the awning.
Other aspects, features and details of the present invention can be more completely understood by reference to the following detailed description of a preferred embodiment, taken in conjunction with the drawings, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary isometric view of a retractable awning, in its extended position, on a camper trailer utilizing the elongated slat connector of the present invention.
FIG. 2 is an enlarged fragmentary isometric view of the retracable awning system including details of the articulated slats, the support surface, the awning sheet, the mounting rail and the elongated slat connector of the present invention.
FIG. 3 is a section taken along line 3--3 of FIG. 2.
FIG. 4 is a vertical section taken through the awning of FIG. 2 in its retracted position adjacent to the support surface.
FIG. 5 is an enlarged fragmentary section taken along 5--5 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a travel trailer 2 having a retractable awning 4 incorporating the mounting or connection system of the present invention is illustrated and includes a pair of support arms 6 (only one shown), a pair of rafter arms 8 (only one shown), a roll bar 10 rotatably mounted on the distal ends of the support arms, an awning sheet 12 connected along an outer edge to the roll bar 10 and having its inner edge 14 operably connected to the side of the support surface 16 through a plurality of articulated slats 18.
The support arms 6 have a lower end pivotally connected to lower support brackets 20 mounted on the support surface 16, while the rafter arms 8 have upper ends pivotally connected to upper support brackets 22 on the support surface. The distal end of each rafter arm is slidably received in an associated support arm for movement along the length thereof. With this arrangement, the awning 4 can be reciprocally moved between the extended position of FIG. 1 and the retracted position of FIG. 4 in a manner described in more detail in U.S. Pat. No. 4,909,296, issued Mar. 20, 1990, which is hereby incorporated by reference.
The awning sheet 12, at its outer edge, is attached to the roll bar 10 in any conventional manner. Referring to FIG. 4., in the disclosed embodiment of the awning 4, the roll bar 10 is of elongated substantially cylindrical configuration having a plurality of grooves 24 of C-shaped cross section formed in the surface thereof. The outer edge 26 of the awning sheet 12 is hemmed to define a sleeve 28 which is inserted into one of the C-shaped grooves in the roll bar and it is retained therein by inserting a rod 30 or other tubular member through the sleeve. The rod has a diameter of sufficient size to be retained in the C-shaped groove. Similarly, a valence 32 might be attached to the roll bar in an identical manner as is illustrated in FIGS. 1 and 4.
The awning sheet 12, at its inner edge 14, is attached to a plurality of horizontally deployed articulated slats 18 in any conventional manner. Referring to FIGS. 3 and 4, in the disclosed embodiment of the awning 4, the outer edge 34 of the outermost one of the plurality of articulated slats is of C-shaped cross section. The inner edge of the awning sheet is hemmed to define a sleeve 36 which is inserted into the C-shaped outer edge 34 of the outermost slat and is retained therein by inserting a rod 38 or other tubular member through the sleeve 36. The rod has a diameter of sufficient size to be retained in the C-shaped groove of the outer edge 34 of the outermost one of the plurality of articulated slats. The awning sheet 12, the roll bar 10, the valence 32, and the plurality of articulated slats 18 make up the awning 4.
The articulated slats 18, which form an extension from the support surface 16 and a means for protecting the awning sheet 12 from environmental damage when rolled up in its retracted position, are best illustrated in FIGS. 2, 3, and 4. Each slat 40 is identical and may be made of a fairly rigid material such as aluminum. The slats 40 are elongated and of a length equal to the width of the awning sheet 12 and are slightly arcuate in transverse cross-section. Each slat has a bead or male connection element 42 along one edge and a mating female connection element 44 along the opposite edge so that the male connection element of one slat can be inserted into the female connection element of an adjacent slat to form an articulated tongue-in-groove type joint between the slats. The male and female connection elements 42,44 are basically C-shaped grooves, where the opening of the groove defining a slot 46 is smaller in dimension than the interior diameter of the groove.
The male element 42 has a larger diameter than the width of the slot 46 in the female element 44 so that the male element can be pivotally received and retained in the groove of the female element of an adjacent slat 40. The male element is slidably inserted into the female element longitudinally for purposes of connecting adjacent slats.
The elongated slat connector 48 of the present invention, which is best illustrated in FIGS. 3, 4, and 5, includes an outer longitudinal edge 50, an inner longitudinal edge 52, and an intermediate trough portion 54 extending downwardly between the longitudinal edges. Each of the longitudinal edges form a connection element allowing the outer longitudinal edge to be secured to the innermost articulated slat 40, and the inner longitudinal edge to be secured to a mounting rail 56 on the support surface 16. The mounting rail is an elongated rigid element that is affixed to the supporting surface in any suitable manner and has a female connection element 58 along its length.
The intermediate trough portion 54 of the elongated slat connector has a basic trough shape, which might be defined as having an outer section 60 and an inner section 62 integrally formed along a hypothetical line of connection, and is best seen in FIG. 5. The outer longitudinal edge 50 is contiguous with the outer edge of the outer section 60, and the inner longitudinal edge 52 is contiguous with the inner edge of the inner section The outer section 60 has an arcuate transverse cross section that is upwardly convex while the inner section 62 has a substantially S-shaped transverse cross-section. The orientation of the inner and outer sections form an acute angle between the two sections as illustrated by the phantom lines A and B in FIG. 5.
The outer longitudinal edge 50 defines a female connection element 64 of C-shaped cross section that pivotally receives a corresponding male connection element 42 along the inner edge of the innermost articulated slat 40. The inner longitudinal edge 52 of the elongated slat connector 48 forms an elongated male connection element 66 of C-shaped cross section that is pivotally received in an elongated corresponding female connection element 58 on the mounting rail. The inner and outer longitudinal edges 52,50 of the elongated slat connector are sealingly connected to the mounting rail 56 and to the awning 4 to prohibit leakage in the most severe operating conditions where the water level rises above the connector elements 64,66. A sealing means such as the type disclosed in the aforementioned U.S. Pat. No. 4,909,296 can be used to sealingly connect the inner and outer longitudinal edges 50,52 of the elongated slat connector 48 to the mounting rail 56 and to the awning 4, respectively. The sealing means disclosed in the '296 patent is a small resilient strip of material 78 bridging the space between the connected male and female connection elements.
The pivotal connections facilitate extension and retraction of the awning 4 as will be appreciated in the description that follows. During retraction, referring to FIG. 4, the awning sheet 12 is rolled up around the roll bar 10 first, then the plurality of articulated slats 18 roll up around the roll bar and awning sheet to envelope them in a protective cover to minimize damage caused by weather or the like. When retracted, the awning sheet and the plurality of articulated slats are adjacent to the support surface 16, supported by both the elongated slat connector 48 attached to the mounting rail 56 and the support arms 6. The joint between the elongated slat connector and the mounting rail is constructed so that the elongated slat connector supports the retracted awning 4 without engaging the support surface 16. It is important to ensure that the elongated slat connector does not engage the support surface so that the support surface is not marked or structurally damaged by contact with the elongated slat connector.
The female connection element 58 on the mounting rail 56 interacts with the male connection element 66 on the elongated slat connector 48 to cause physical interference when the elongated slat connector is pivoted to its extreme downward position. Such interference acts to limit the rotation of the elongated slat connector. The physical interference limiting the downward rotation of the elongated slat connector is the result of the specially extruded shape of the male C-shaped connector 66 on the inner longitudinal edge 52 of the elongated slat connector.
As can be seen in FIG. 5, the C-shaped male connector 66 along the inner edge of the elongated slat connector 48 is integrally formed with a neck portion 68 substantially directly opposite the opening or slot 70 in the male connector 66, thus distinguishing a lower leg 72 from an upper leg 74 in the male connector 66. The lower leg 72 is thicker than the upper leg 74 at the point of connection with the neck portion 68. When pivotally inserted into the female C-shaped connector 58 on the mounting rail 56 and moved downwardly, the elongated slat connector pivots about the joint. As the elongated slat connector pivots downwardly, the lower, thicker leg 72 rests upon one edge of the slot 76 in the female C-shaped connector on the mounting rail and causes the upper leg of the male C-shaped connector 66 to forcibly contact the interior wall of the female C-shaped connector 58. The neck portion 68 then forcibly contacts the edge of the slot 76 in the female C-shaped connector 58 terminating any downward pivotal movement thus keeping the elongated slat connector from engaging the support surface 16. As a result of the physical interference in the joint between the elongated slat connector and the mounting rail, the elongated slat connector is prevented from contacting the support surface in either the extended or retracted position.
The elongated slat connector 48 is fabricated from a rigid, water impervious material, such as aluminum, so that it does not deflect significantly during retraction or extension. Deflection of the elongated slat connector during retraction or extension might cause the articulated slats 18 to become misaligned, inhibiting the free pivotal movement of the articulated slats, thereby interfering with retraction or extension. It should be appreciated that whether the awning is retracted or extended, the present invention prevents water from passing through the joint between the innermost articulated slat 40 and the support surface 16.
The linear distance between the inner longitudinal edge 52 and the outer longitudinal edge 50 of the elongated slat connector 48 is preferably in the range of one inch to four inches. The depth of the trough portion 54 as measured along line C of FIG. 5 is preferably in the range of one-eighth inch to about one inch. The maximum width of the trough portion 54 as measured along line D of FIG. 5 is preferably in the range of one-quarter inch to one inch. It that the trough extends up to an inch below an imaginary line interconnecting the inner and outer edges of the connector.
In operation of the awning, it will be appreciated that in the extended position illustrated in FIGS. 1, 2, and 3, the articulated slats 18 form an extension from the support surface 16 which is substantially co-planar with the awning sheet 12 itself. As appreciated from the foregoing, the plurality of articulated slats are operably connected to the support surface 16 by the elongated slat connector 48 so that water deposited in the elongated slat connector will not flow out across the articulated slats where leakage may occur. As water contacts the support surface or the elongated slat connector itself, it flows into the trough 54 of the elongated slat connector and then drains laterally to either end of the elongated slat connector and onto the ground. If the elongated slat connector is slanted along its length, the drainage is facilitated by gravity. If the elongated slat connector is not slanted to one end or the other, the drainage occurs anyway as the trough portion 54 has enough volume to allow some accumulation in the trough portion before it drains laterally by necessity.
Under all but the most severe conditions, the water level in the trough portion 54 does not rise to or above the connection elements 64,66 on either of the longitudinal edges 50,52 of the elongated slat connector 48. The water is maintained at this level because it continuously drains off the ends of the elongated slat connector. Because the water does not pool in the elongated slat connector and thereby stand at a level above the longitudinal edges 50,52, the elongated slat connector prevents water leakage.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example, and changes in detail or structure may be made without departing from the spirit of the invention, as defined in the appended claims.
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A system establishing a leak resistant connection between a retractable awning and a support surface includes an elongated slat with male and female connection elements along opposite longitudinal edges, and an intermediate downwardly extending trough portion between the longitudinal edges to catch and drain water laterally away from the retractable awning.
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BACKGROUND
[0001] The present invention relates to surveillance systems, and particularly to multi-camera closed circuit video systems.
[0002] Modern property surveillance systems, especially for commercial or institutional sites, typically have multiple TV or video cameras distributed throughout the site to monitor activity inside and/or outside buildings on the site. All the cameras at a given site deliver image signals to a head unit on the site. Commercial grade surveillance/security CCTV systems allow a user to view one or all of the cameras on the system simultaneously via imbedded local and remote view software in the head unit at the head end of the system. The head unit can be implemented by DVR, DVMR, or NVR devices, in digital or analog, form.
[0003] In a relatively simple system, the head unit or other processor is connected to a display panel on or offsite, where a security officer can observe the field of view of each camera and take appropriate action in the event of an unusual occurrence.
[0004] In a more comprehensive system, a surveillance agency at a central location receives inputs from the head units of multiple sites, and displays images on one or more panels, where an agent can observe suspicious activity or deviations derived from intermediate intelligence processing. Upon observing a predetermined level of deviation from “normal” conditions in the field of view of a particular camera at a particular site, the agent can call the security officer for the site, or initiate a general site alarm or an alarm associated with a particular camera.
[0005] Systems of the type described above are available in a DVR platform from PELCO (DX8100), American Dynamics (Intellex DVMS), Dedicated Micros (Digital Esprite), or GANZ (Triplex). In these systems, the security officer or agent can send a control signal to the head unit by which a particular camera can be panned or angulated, and/or an alarm activated.
SUMMARY
[0006] The systems described above do not permit the security officer on site or the agent in the central station, to speak to a potential intruder observed in the field of view of a particular camera.
[0007] It is an object of the present invention, to enable a security officer on site or an agent in a central station, to speak to, and optionally receive speech from, a potential intruder observed or otherwise detected in the field of view of a particular camera.
[0008] This object is achieved by locating speakers and optionally microphones at each camera, and locating an audio unit at the head unit in communication with the speakers, by which the security officer or central station agent can select and speak through a particular speaker, thereby warding off an intruder who is near the particular camera. If the speech communication is two-way, the officer or agent can interrogate the potential intruder to determine if access to the site is authorized.
[0009] The audio unit is configured for particularly advantageous use in routing an audio signal originating at a remote central station agent to a speaker associated with a particular camera.
[0010] By adding the audio unit to existing systems, the user of any major manufacturer's intelligent video systems has the ability to speak and/or listen from any or all camera locations within the particular facility represented on a panel display such that the user can easily choose the location at which to speak and/or listen while either on site or from any remote monitoring location.
[0011] The audio unit is multiplatform because it integrates with intelligent video systems of all major manufacturers, and the size of the system is not a limitation because multiple audio units can be used in tandem to provide unlimited audio channels. A standard audio unit of the type disclosed herein preferably has 16 channels of bi-directional audio (most major manufacturers of intelligent video have standardized their units with 16 channels of video) but can be built with an unlimited number of channels.
[0012] In the most useful embodiment, the central station agent activates an alarm out signal from the head unit using the pre-existing software and graphic user interface (GUI) in one of several major manufacturers' CCTV systems. This signal is transferred over a hard wired connection to corresponding relay inputs on the audio unit. The inputs to the audio unit manipulate the state of a relay bank to direct the audio received via a separate analog or digital input to a pre-determined channel, which has a corresponding audio device (e.g. loudspeaker) in the field.
[0013] The audio unit preferably has a multichannel input corresponding to the number of cameras that deliver signals to the head unit, and a multichannel output corresponding to the number of speakers (which in general has a one-to one correspondence with the cameras). The problem to be overcome, is that the officer or agent will send a speech (audio) signal through one line originating at the panel, but that speech signal must be routed through the audio unit to the desired camera/speaker. This is preferably accomplished by a logic circuit that receives a channel-dependent signal from the head unit, and enables a signal path to the corresponding channel for the selected speaker. The logic in the audio unit preferably has a relay input for each camera connected to the head unit and an audio output to each speaker associated with a camera. The audio signal from the panel enters the audio unit where the logic circuit directs the audio signal to the particular/selected speaker.
[0014] Preferably, a bi-directional communications processor receives the speech signal from the officer or agent, directs it to the enabled speaker, receives the speech signal from a microphone associated with that speaker, and directs it back to the officer or agent. The officer or agent operates on any convenient from of voice communication, either digital or analog, such as telephone or Internet. Digital signals would require digital to analog conversion to the speaker and analog to digital conversion from the microphone in a bi-directional system. This is accomplished using well-known techniques.
[0015] Before installation on site, an audio unit of this kind comprises a multi-channel array of hardwired input signal terminals, a multi-channel array of hardwired voice output terminals corresponding respectively to the array of input terminals, and a voice communications circuit operatively connected to relays between the input terminals and the output terminals. A bank of relays is respectively connected to the array of input terminals and output terminals such that an input signal on a given input terminal activates one relay that electrically connects the communications circuit to one of the audio output terminals. A voice input terminal is provided for the voice communications circuit, whereby a user who initiates an input signal on a given input signal terminal enables a voice communications path from the voice input terminal to the unique voice output terminal.
[0016] On site, a conductor is extended from each output terminal to a respective remote speaker, and a voice communications device such as a telephone line is connected to the voice communications circuit. The audio unit is connected to the head unit whereby the officer or agent can initiate a signal through the head unit for selectively delivering an input signal to only one of the input signal terminals on the audio unit, enabling him or her to speak at the location of a particular camera.
[0017] In the comprehensive system embodiment, one agent at the central station can observe one or more panels, with each panel displaying an image of the field of view of all cameras at a particular site. When a deviation is observed at one camera, the agent can send an alarm signal along the same communications path that carries the individual camera control signal to the head unit. However, in the head unit this alarm signal is directed via a different channel dependent output port of the head unit, to the audio unit.
BRIEF DESCRIPTION OF THE DRAWING
[0018] Exemplary embodiments are described below with reference to the accompanying drawing, in which:
[0019] FIG. 1 is a block diagram of a comprehensive surveillance system incorporating an embodiment of the invention;
[0020] FIG. 2 is a schematic of the external connections for an audio unit having 16 channels;
[0021] FIG. 3 is a circuit diagram of the audio unit of FIG. 2 ; and
[0022] FIG. 4 is a schematic of another system implementation.
DETAILED DESCRIPTION
[0023] FIG. 1 shows a comprehensive surveillance system 10 comprising a multiplicity (but showing only four) site monitoring systems 12 a , 12 b , 12 c , 12 d located at a respective plurality of sites that are remote from each other. Each site monitoring system has a plurality (but showing only four) video cameras 14 a , 14 b , 14 c , 14 d distributed throughout the site and a head unit such as 16 a , 16 b , 16 c , 16 d to which each camera delivers a video signal carrying an image of the field of view of the camera.
[0024] A central station 18 is located remotely from but in communication with the head units at all the sites. A computer or similar digital processing system C receives signals via lines 22 a , 22 b , 22 c , 22 d from the head units 16 and presents associated information on a plurality (but only showing two) display panels 20 a,b , 20 c,d . A display panel for a given head unit 16 a displays an image 24 a , 24 b , 24 c , 24 d of the field of view of each camera 14 a , 14 b , 14 c , 14 d associated with the given head unit 16 a , whereby an agent 26 at the panel can observe the field of view of each camera at a particular site. One agent may observe more than one panel; a given panel may display images from more than one site; and one or more additional agents 26 ′ may be in the central station.
[0025] A signal path 28 a (others not shown) is established from the central station to each head unit, such as 16 a . This signal path provides for the agent to select any one camera, such as 14 a , from among the plurality of cameras associated with the given head unit, for controlling zoom, pan, or the like. Signal paths 22 and 28 can be distinct, or common, with bidirectional bandwidth. The paths need not be visible, in that a universal communications network (Internet) or proprietary intranet can be employed for this purpose. The head unit 16 at each site has an input option for receiving alarm selection signals generated from the central station, and corresponding alarm output terminals for outputting respective alarm signals.
[0026] As shown in FIGS. 2 and 3 , the present disclosure is directed to an audio unit such as 30 a , by which the agent or other user has the ability to speak and/or listen via speakers and/or microphones from any or all camera locations within the particular facility represented on the panel display such that the user can easily choose the site/location to speak and or listen while either on site or at any remote monitoring location. In FIG. 1 , only four of the cameras 14 a - 14 d and associated speakers 34 a - 34 d are shown, whereas FIG. 2 shows the full, preferred implementation of a 16 channel audio unit with 16 associated cameras ( 14 a - p ) and speakers ( 34 a - p ).
[0027] Each audio unit such as 30 a at site 12 a is in communication with the respective head unit such as 16 a at that site, for receiving a signal 32 a - p from the head unit, commensurate with the agent's selection of a particular camera 14 a-p at the particular site. In this context, “commensurate” means related physically, logically or by intention. An audio speaker 34 a - p is mounted in proximity to each camera 14 a - p at each site. An audio communication path 36 a - p is present from the audio unit to each respective speaker.
[0028] A logic circuit 38 in the audio unit is responsive to the particular one of the alarm/control signals 32 a - p commensurate with the agent's selection of a particular camera for enabling an audio communications path to a speaker such as 34 a in proximity to the selected camera such as 14 a . A voice communications circuit 40 in the audio unit, receives speech on line 42 from the agent and delivers this speech through the enabled communications path such as 36 a to the speaker 34 a in proximity to the selected camera 14 a . A conductor 36 a - p is attached to each output terminal 46 a - p and to a respective remote speaker 34 a - p . Microphones can be electrically connected respectively to the conductors 36 a - p that are attached to each output terminal 46 a - p and to a respective remote speaker 34 a - p . Alternatively, speakers that also serve as microphones can be employed.
[0029] The audio unit 30 a at each site has input terminals 44 a - p hardwired to the alarm output terminals of the respective head unit 16 a , for receiving an alarm signal 32 a - p from the head unit commensurate with the agent's selection of a particular camera at a particular site and delivering the alarm signal as an input to the logic circuit 38 . The logic circuit is preferably a bank of 16 relays. In this manner, the generation of a particular alarm selection signal at the central station is transmitted through the head unit to the audio unit, enabling delivery of the agent's speech through the enabled communications path 36 a to the speaker 34 a in proximity to the selected camera 14 a.
[0030] Preferably, the audio unit 30 comprises a multi-channel array of hardwired input signal terminals 44 a - p , and a multi-channel array of hardwired audio output terminals 46 a - p corresponding respectively to the array of input terminals. The bank of relays 38 a - p are respectively connected to the array of input terminals 44 a - p and output terminals 46 a - p such that an input signal 32 a on a given input terminal 44 a activates one relay 38 a that electrically connects the communications circuit 40 to a unique one of the voice output terminals 46 a.
[0031] A audio input terminal 50 , such as a telephone jack, provides the input path to the voice communications circuit. The voice communications circuit is any conventional, bi-directional circuit board. A user who initiates an input signal 32 a on a given input signal terminal 44 a enables a voice communications path from the voice input terminal to a unique voice output terminal 46 a.
[0032] The communications circuit 40 is connected to one leg of the output side of each relay 38 a - p , and the other output leg of each relay is connected to one of the output terminals 46 a - p . The input side of each relay is connected to one of the alarm signal input terminals 44 a - p . In this manner when a particular relay such as 38 a is closed as a result of receiving a signal 32 a through terminal 44 a , the communications board 40 is electrically connected only to the output terminal 46 a for voice communication over conductor 36 a with speaker 34 a The audio unit 30 requires a source of electrical power for the relays and communications circuit. The power source can be a conventional power supply 48 in the audio unit and power cord for plugging into a 120V AC socket. Alternatively, the head unit has a power supply and the power supply of the audio unit is connected to the power supply of the head unit.
[0033] As previously mentioned, the conventional head unit at each site typically has an input option for receiving alarm selection signals generated from the central station, and corresponding alarm output terminals for outputting respective alarm signals. If the head unit has only one set of alarm out terminals, these can be used for the audio feature as a replacement for, e.g., a flashing alarm feature. The alarm signal may be used to trip more than one relay, e.g., alarm and the logic relay in audio unit. The audio unit delivers the alarm signal as an input to the logic circuit, enabling the delivery of the agent's speech through the enabled communications path 36 a to the speaker 34 a in proximity to the selected camera 14 a.
[0034] Although the foregoing description is illustrative of the agent selecting one speaker 34 a associated with one camera 14 a for speaking to a potential intruder, one of ordinary skill in electromechanical devices can adapt the audio unit to enable a plurality of communications paths 32 a,b ; 36 a,b ; 38 a,b ; for the bidirectional functionality of the communications circuit 40 with a corresponding plurality of speakers 34 a,b.
[0035] FIG. 3 shows a detailed circuit diagram of one implementation of the audio unit. The relays in the middle are activated when selecting an output relay from the graphic user interface of the IVRD. The output relay # 1 from the IVRD is hardwired to DVR trips in on the audio unit. The DVR trips screw terminal in is an extension of the circuitry internal to the audio unit and it is terminated on the corresponding relay internally. Once the signal is sent from the IVRD to the DVR trips in terminals and received by the internal relay, the coil on the relay is activated causing a closure on the output side of the chosen relay and thus allows audio to be passed out to the speaker. The sole function of the bi-directional communications circuit is to provide inbound audio (telephone connection) to the audio unit. The selection of an audio channel is through the relay logic and the graphic user interface of the existing CCTV platform.
[0036] FIG. 4 shows a surveillance system implementation 50 that is dedicated to a single site. The head unit 52 is in communication with the on-site panel 54 . The security officer observes the fields of view of the cameras 56 a - c (only three shown) and can control camera movements, from the panel 54 through communications line 58 to the head unit 52 and associated camera connections 60 a - c . As in the system shown in FIGS. 2 and 3 , an audio unit 62 receives a camera specific alarm out signal on one of the lines 64 a - c from the panel 54 via the head unit 52 . The audio unit logic enables delivery of a voice signal to a particular speaker such as 66 a associated with a particular camera 56 a , via line 68 a . The voice can be directed to any of the other speakers 66 b,c via respective lines 68 b,c . The voice originates on (for example phone) line 70 from the panel 54 or from a remote viewing station 72 in communication with the panel and is not channeled before delivery to the audio unit.
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A system and device that enables a security officer on site or an agent in a remote central station, to speak to, and optionally receive speech from, a potential intruder observed or otherwise detected in the field of view of a particular one of a multiplicity of surveillance cameras at the site. This is achieved by locating speakers and optionally microphones at each camera, and locating an audio unit at the camera head unit in communication with the speakers, by which the security officer or central station agent can select and speak through a particular speaker, thereby warding off an intruder who is near the particular camera. If the speech communication is two-way, the officer or agent can interrogate the potential intruder to determine if access to the site is authorized. The audio unit is configured for integration with many types of surveillance systems, and is particularly advantageous for routing an audio signal originating at a remote central station agent to a speaker associated with a particular camera.
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FIELD OF THE INVENTION
The present invention relates generally to improvements in automated voice response systems. More particularly, the invention relates to advantageous systems and techniques for providing menus and other assistance to a user of a voice response system.
BACKGROUND OF THE INVENTION
Automated voice response systems, particularly systems employing speech recognition, must frequently provide guidance to a user so that the user may properly format his or her inputs and repeat inputs that were not properly recognized by the system. In order to achieve user satisfaction, voice response systems must provide prompts to users that indicate the format and content of the inputs needed from a user, so that the user's inputs can be interpreted accurately. In addition, presentation of prompts by the systems must not be too time consuming for a user. The nature of voice response systems makes them particularly prone to consume too much of a user's time because much of the information presented by a system, particularly menu information, is presented in sequence. The information a user needs to hear may be preceded by other information of no interest to the user.
One approach to providing user menus that are not excessively burdensome is the use of contextual menus. Contextual prompting provides prompts that are based on the user's position in the application. For example, if a user is listening to voicemail, one set of prompts is provided. If a user is searching a directory in order to place a call, another set of prompts is provided. Such directed selection of prompts helps reduce the number of choices presented to the user, but typical present day systems do not sufficiently advantageously distinguish between users. For example, expert users may know all the different inputs that are required for each stage of an application, other users may be very experienced with some portions of the application but not with other portions, and relatively inexperienced users are likely to be unfamiliar with the inputs required for a system and need fairly extensive information, such as a relatively complete list of available input choices.
In typical prior art systems, however, little or no distinction is made between such users. Instead, because of the necessity that all users be provided with enough information to enable them to provide a correctly formatted input that will achieve the result they desire, all users are typically treated in the same manner. More experienced users, therefore, are forced to listen to much more extensive prompts than they need. Systems that provide extensive prompts to all users waste time and cause significant dissatisfaction among users that do not require elaborate prompts. Conversely, if a system employs shorter prompts, it may run the risk that the prompts will be insufficiently detailed for less expert users.
There exists, therefore, a need for automated voice response systems that are capable of determining the experience level of a user for various stages of an application and for providing prompts that take into account the particular user's level of experience or ability to successfully work with the stage of the application being used.
SUMMARY OF THE INVENTION
A system according to one aspect of the invention includes a central server hosting various modules providing services to users. The modules may suitably employ voice recognition in order to interpret user inputs. When a module needs an input from a user, it selects an appropriate prompt for presentation to the user. The module has access to user information that includes information indicating the user's experience with each function of each module. The module examines the user information to determine the user's experience with the module and function. Suitably, the module categorizes a user as belonging to an experience category, such as novice, intermediate or expert based on the user's level of experience with the function. The module selects a prompt associated with the user's level of experience with the function and presents it to the user. The use of context and experience information in selection of prompts is also discussed in “Methods and Apparatus for Context and Experience Sensitive Help in Voice Applications,” U.S. Pat. Ser. No. 10/772,483, assigned to a common assignee with the present invention and filed on even date herewith, and incorporated herein by reference in its entirety.
A more complete understanding of the present invention, as well as further features and advantages of the invention, will be apparent from the following Detailed Description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a system employing user and context sensitive prompting according to an aspect of the present invention; and
FIG. 2 illustrates a process of voice response employing user and context sensitive prompting according to an aspect of the present invention.
DETAILED DESCRIPTION
FIG. 1 illustrates a system 100 employing user and context sensitive prompting according to an aspect of the present invention. For purposes of illustration, the system 100 is a central telephone system providing telephone services and related services, such as directory lookup, voice dialing and voice mail to users. It will be recognized, however, that a system such as the system 100 may suitably be implemented so as to provide any of a number of services. For example, a system may provide bank account information to customers or potential customers or may be used in a customer service center, allowing selection of prerecorded information for some problems and referring a customer to an appropriate agent for other problems.
The system 100 may suitably comprise a central server 102 , including a processor 104 , memory 106 and long term storage 108 . The server 102 hosts or has access to information and data storage facilities of interest to users, for example, directory information and voice mail storage. The directory information may suitably be stored in a directory information database 110 , hosted as a file on the long term storage 108 , and the voice mail storage may be allocated to storage space 112 on the long term storage 108 . It will be recognized that storage facilities such as the directory 110 and the storage space 112 , and data such as the data stored therein, need not be hosted on the server 102 , but may be hosted in any desired location or component.
The system 100 may suitably host a voice response application 114 , suitably implemented as software residing on the long term storage 108 and executed under the control of the processor 104 . The voice response application 114 includes a user interface module 118 A and a plurality of additional modules. As illustrated here, the additional modules are a directory module 118 B, a voice dial module 118 C and a voicemail access module 118 D. The modules 118 B, 118 C and 118 D are invoked by the user interface module 118 A as required, in response to a user's inputs.
Each user communicates with the server 102 by means of a telephone set such as the internal telephone sets 123 A . . . 123 N. Such telephone sets may be part of an internal office phone system or may be external sets that connect to the server 102 by dialing a central exchange 124 communicating with the server 102 . When a user makes an initial contact with the server 102 , for example, by placing a call to the central exchange 124 or by picking up a handset of an internal telephone, the user interface module 118 A provides an initial prompt to the user and receives user inputs. Depending on the user's response, the user interface module 118 A invokes the module 118 B, 118 C or 118 D, as appropriate. The module that has been invoked then issues prompts, receives user inputs and takes actions, such as placing a call or retrieving voice mail, in order to perform the service desired by the user.
The modules 118 A, 118 B, 118 C and 118 D include prompt selection modules 125 A, 125 B, 125 C and 125 D, in order to provide for selection of prompts appropriate for the operation being performed and for the experience level of the user.
The prompt selection modules 124 A, 124 B, 124 C and 124 D maintain awareness of the particular function for which prompting is required. During operation of each of the modules 118 A, 118 B, 118 C and 118 D, each module passes information to its prompt selection module indicating the active function. Each of the prompt selection modules 124 A, 124 B, 124 C and 124 D receives information indicating the active function, that is, the function with which the user is currently engaged. In addition, each of the prompt selection modules 124 A, 124 B, 124 C and 124 D is operative to receive proficiency information for the user, indicating the user's facility with the function being executed and with the use of the system 100 as a whole. The proficiency information may suitably be taken from a user information database 130 . Each of the prompt selection modules 124 A, 124 B, 124 C and 124 D uses the proficiency information to select or create an appropriate prompt to be provided to the user. Prompts may suitably be selected from a prompt repository 132 , according to a set of rules implemented by the currently operating one of the modules 124 A, 124 B, 124 C and 124 D. The prompts may suitably be stored in a prompt database 134 stored in the repository 132 .
Alternatively, the currently operating prompt selection module may create a prompt based on information stored in the database 134 , taking into consideration the module and function being employed, as well as proficiency information taken from the database 130 .
Suitably, the prompt delivered to the user is based on the user's proficiency, as indicated in a user record stored in the database 130 . Each user record may suitably include a function usage tally for each function, indicating the number of times the user has successfully performed the function. Prompts are suitably oriented toward novice, intermediate or expert users. Parameters or settings of the prompt selection modules 125 A, 125 B, 125 C and 125 D may suitably include criteria for distinguishing between novice, intermediate and expert users and may adapt prompts to the appropriate level of user based on the user's proficiency information. Alternatively, the prompts stored in the prompt repository 132 may suitably be organized according to module, function and function usage tally. When a prompt is to be selected, the currently operating prompt selection module receives or looks up module, function and function usage tally information, and the currently operating prompt selection module may use this information as an index for searching the database 134 .
For example, the database 134 may include a comprehensive explanatory prompt to be presented by the user interface module 118 A to a user with no experience using the system 100 . The prompt might be a comprehensive recitation of all the functions that were available, and might be associated with a function usage tally of 0 for all functions. The prompt selection module 125 A would simply search the database 134 for the prompt associated with the user interface module 118 A and also associated with a function usage tally of 0.
Each of the modules 118 A, 118 B, 118 C and 118 D has access to the user information database 130 . The user information database 130 includes a usage history for each user. In the embodiment discussed here, the usage history for a user includes a tally for each function, indicating the number of times the user has successfully employed the function. It will be recognized, however, that alternative techniques for describing a user's usage history are possible. For example, a proficiency score may be maintained, with the score taking into account information including the number of times the user has successfully employed the function as well as the number of errors made when using the function and the number of repetitions and prompts that have been required.
The usage history for a user is suitably organized by module. That is, the user's usage history for the functions carried out by the module 118 A are grouped together, the user's usage history for the functions carried out by the module 118 B are grouped together, and so on. This organization provides a simple and convenient way for a module to retrieve information relating to a user's likely needs for prompting for a particular function. For example, when the voicemail module 118 D is to issue a prompt relating to a function, the prompt selection module 125 D searches the user information database 130 to find a user entry for the user. The voicemail module 118 D searches the user entry for the function for which the prompt is to be issued. The prompt selection module 125 D obtains the user's usage tally for the function. The prompt selection module 125 D uses the usage tally as an index to search the prompts related to the function for which the prompt is to be issued, and to select the prompt associated with the user's usage tally value for the function. The prompt is then passed to the user interface module 118 A, which presents the prompt for the user, suitably by playing the prompt using a sound recorder or a voice synthesizer.
The prompts stored in the database 134 may suitably be organized by module, by functional area and by experience category. The database 134 includes a collection of prompts for each of the modules 118 A- 118 D. For example, the voice mail access module 118 D may include the functions “play messages,” “next message,” “delete message,” “repeat message” and “save message.” Depending on a user's facility with each function, different messages may be needed to assist the user in providing a correct voice input for a particular function. Thus, for example, the database 134 may include three prompts for each of the functions performed by the module 118 D. The prompts for each function may include a prompt directed to novice users, a prompt directed to intermediate users and a prompt directed to expert users. It will be recognized that while three experience categories are described, additional experience categories may be employed as desired.
One example of a prompt might be one directed toward an expert user of the “play messages” function of the “voicemail access” module. An expert user might need only a simple and short prompt, such as an indication of the function being employed. A suitable prompt for such circumstances might be “messages” and might be characterized and indexed as “voicemail access, play messages, expert user,” or by a suitable symbolic or numerical representation of such indexing.
An exemplary technique of organizing and indexing prompts, that may suitably be employed in constructing and searching the database 134 , is as follows. The prompts are grouped in the database 134 according to the module with which they are associated, and the search for a particular prompt is performed in the prompts associated with the module being used. Each module performs a number of different functions, and a number of experience levels may be associated with each function. For one embodiment, the prompts for each module are organized in the form of an array P(X, g(F x )), where
P is the prompt to be played, X indicates the function being performed, and g(F x ) indicates the experience category associated with the prompt P, where F x is the user's usage tally for the function X. The value of F x is the number of times a user has successfully used the function X. For example, if the function under consideration is the function “repeat messages,” the value of F x would be the number of times a user had successfully used that function.
The value of g(F x ) may suitably be an integer and may be assigned a value depending on the value of F x . If a user may have one of m different experience levels for the function X, the value of g(F x ) may suitably be defined as follows:
g ( F x )=1 if 0 ≦F x <C 1
g ( F x )=2 if C 1 ≦F x <C 2
g ( F x )=3 if C 2 ≦F x <C 3
g ( F x )= m if F x >C m−1 .
The values of C 1 , C 2 , C 3 , and so on, are chosen based on an estimate of how many successful uses of a function puts a user into a particular experience category. For example, if a novice user is considered to be a user who has successfully used a function four times or less, the value of C 1 for that function may be set to 5. An intermediate user may be one who has used the function 5 to 24 times, in which case the value of C 2 is set to 25, and an advanced user may be one who has used the function 25 times or more. In this example, there would be only three categories, that is, novice, intermediate and expert, and values would be assigned only to C 1 and C 2 .
To take an example, suppose that a user, Mary, is using the system 100 . The user information database 130 includes a user entry for Mary. The entry includes function tallies for each function, with the function usage tally indicating the number of times the user has successfully used the function. The function tallies provide evidence that can be interpreted to indicate the user's proficiency for each of the functions performed by the voice dial module 118 C and the voicemail module 118 D, as well as with the overall system 100 , and is organized as follows:
Module
Function
Function usage tally
Overall system
Main menu accesses
188
Overall system
Main menu commands
202
Voice dialing module
Call menu accesses
197
Voice dialing module
Call by contact
98
Voice dialing module
Call by directory
52
Voice dialing module
Call by number
47
Voicemail module
Message menu accesses
5
Voicemail module
Play message
0
Voicemail module
Delete message
0
The tally for main menu accesses indicates the number of times Mary has employed the system 100 . Mary's user entry indicates a large number of successful uses of each function of the voice dial module 118 C, suggesting that she is an expert user of the voice dial module 118 C. Mary's user entry indicates only a few menu accesses of the voicemail module 118 D and no successful uses of the other functions of that module, suggesting that Mary is a novice user of the voicemail module 118 D. Therefore, the voice dial module 118 C will provide relatively brief prompts, and the voicemail module 118 D will provide more detailed prompts.
Suppose that Mary accesses the system 100 in order to place a call. Based on her expertise with the voice dialing module 118 C, the dialog between Mary and the system might proceed as follows:
System—“Call control menu.”
Mary—“Dial by directory.”
System—“Directory.”
Mary—“Derek Sanders.”
The prompts are relatively short, and have the advantage of consuming little time. Because Mary is an expert user, the prompts are sufficient to allow her the guidance she needs. If Mary were a less expert user, the following interaction might take place:
System—“Call control menu. What would you like to do?”
Mary—“Dial by directory.”
System—“Directory. Whom would you like to call?”
Mary—“Derek Sanders.”
Once Mary has finished the interaction, her user tallies for Main menu accesses, main menu commands and dial by directory are incremented in order to reflect her additional experience.
As noted above, Mary's function usage tally suggests that she is less expert with the voice mail module 118 D than with the voice dial module 118 C. Thus, a dialog with the voice dial module 118 D might proceed as follows:
System—“Main menu.”
Mary—“Go to messages.”
System—“Message menu. Here you can say “read my messages” or “help” for more options.”
Mary—“Read my messages.”
System—“<Plays first message>. Now you can say, “save message,” “delete message,” or “play next message.” At any time during a message, you can say “skip message” in order to go to the next message.”
In this case, the initial prompt is brief because Mary is an expert user with respect to the initial interaction, that is, with the user interface module 118 A. The prompts relating to the voicemail module 118 D are more detailed, because Mary is a novice user with respect to the voicemail module 118 D.
FIG. 2 illustrates the steps of a process 200 for voice response including user and context sensitive prompting according to an aspect of the present invention. At step 202 , in response to user commands and data inputs, navigation through various modules and functions is performed. At step 204 , when a prompt is to be presented to a user, function and user data is examined in order to provide information required to select an appropriate prompt for the user. The function and user data indicates the function for which prompting is required, and the user data indicates the user's level of experience with the function and with the voice response system as a whole. At step 206 , the user data is evaluated and the user is categorized by experience level, for example, novice, intermediate, or expert. At step 208 , a prompt matching the function and the user's experience category is retrieved from a previously assembled collection of prompts indexed by module, function and experience category. At step 210 , the prompt is presented to the user. At step 212 , upon receiving a user input, services are performed and data is entered in response to the input. The process then returns to step 202 .
While the present invention is disclosed in the context of a presently preferred embodiment, it will be recognized that a wide variety of implementations may be employed by persons of ordinary skill in the art consistent with the above discussion and the claims which follow below.
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Systems and techniques for improved user prompting. A system according to one aspect of the invention includes a central server hosting various modules providing services to users. The modules suitably employ voice recognition in order to interpret user inputs. Each module has access to user information that includes information indicating the user's experience with each function of each module. When a module needs to issue a prompt to the user, it retrieves and examines the user information to determine the user's experience with the module and function. Suitably, each module is operative to categorize a user as belonging to an experience category, such as novice, intermediate and expert based on the user's level of experience with the function. The module selects a prompt associated with the user's level of experience with the function and presents it to the user.
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This is a continuation of U.S. patent application Ser. No. 07/960,596, filed Oct. 13, 1992, now U.S. Pat. No. 5,219,617 which is a continuation of Ser. No. 07/584,771, filed Sep. 19, 1990, now abandoned, which is a continuation-in-part of Ser. No. 07/409,364, filed Sep. 19, 1989, now abandoned all having the same title "CORROSION RESISTANT COATED ARTICLES AND PROCESS FOR MAKING SAME."
BACKGROUND OF THE INVENTION
This invention relates to articles having integral chemically-formed surface coatings that provide an improved combination of adherence and corrosion resistant properties to such products and to a process for making same. More particularly, the articles of this invention have on their surfaces an integral, chemically-formed coating that is strongly adherent and resistant to chipping or flaking at elevated temperatures and provides to the product a unique combination of corrosion properties including commercially satisfactory resistance to oxidation during use in gases at elevated temperatures such as encountered in the engine compartments of vehicle engines, resistance to corrosion from humidity, from organic solvents such as ethylene glycol, oils and gasoline, from acidic or alkaline solutions such as salt spray to the extent that is required of a base for paint or other protective organic or water-based protective coating on parts used within the engine compartments of vehicles.
Chemical coatings on aluminum for various purposes including oxides, chromate-phosphates, chromates, and phosphates have long been known and have been commercially employed since the 1930's when the original Bauer-Vogel process of German patent 423,758 for chemically forming oxide coatings on aluminum was improved in 1937 by reducing the time required from hours to minutes but still produced only gray coatings at near boiling temperatures, see Aluminum, 1937, 19, 608-11 (hereby expressly incorporated by reference). Colorless oxide coatings suitable for a wider range of aluminum alloys were later developed but were less desirable as a base for paint than the Bauer-Vogel products and could not be successfully dyed, see Aluminum, 1938, 20, 536-8 (hereby expressly incorporated by reference). Chromate-phosphates were developed in the 1940's as paint base coatings and disclosed in U.S. Pat. No. 2,438,877 (all of which are hereby expressly incorporated by reference herein) and later modified as disclosed in British Patent 1,114,645 and French Patent 1,477,179. Chromate processes developed during the 1960's and 1970's have been asserted to provide improved paint bases relative to the chromate-phosphate coatings and are disclosed in a number of United States patents, including U.S. Pat. Nos. 3,009,482, 3,391,031, 3,404,043, 3,410,707, 3,447,972, 3,446,717, 3,982,951, 4,036,667, and 4,146,410, all of which are hereby expressly incorporated by reference and in British Patent 1,409,413. A number of additional patents discuss various types of chemical coatings, protective layers or processes, and include U.S. Pat. Nos. 28,015, 29,827, 1,811,298, 1,840,562, 1,946,151, 1,995,225, 2,035,380, 2,059,801, 2,060,192, 2,106,227, 2,106,904, 2,134,830, 2,440,969, 2,680,081, 2,694,020, 2,825,697, 3,175,931, 3,214,287, 3,400,021, 3,950,575, 3,967,984, 3,982,951, 4,070,193, 4,141,758, 4,200,475, 4,341,878, 4,569,699, and 4,657,599, all of which are hereby expressly incorporated by reference.
Even though extensive development of chemical coatings for aluminum and its alloys has resulted from worldwide research efforts each heretofore known process and product present some problem or lack a particular set of properties needed for use in specific applications. Thus, there is a continuing need for other efficient, low cost processes for providing corrosion resistant coatings on aluminum and its alloys to satisfy specific commercial needs. For example, there are needs for uses other than bases for paints or other organic finishes, other needs for coating aluminum alloy substrates which contain alloy constituents known to hinder coating formation on alloys such as magnesium, silicon, copper, chromium and manganese. There remains a need for coating aluminum alloy sand castings which contain silicon, copper and magnesium and may contain other heavy metals such as nickel, chromium, titanium or silver to provide coatings that resist thermal and gaseous engine fume degradation and development of localized white corrosion products during long periods of use such as in commercial truck and automobile engine compartments. There also remains a need for improved coatings for zinc-based, cadmium-based, and magnesium-based materials.
The present invention provides articles that are coated with a new integral coating that results in good corrosion resistance and resistance to dislodgment during use in environments, such as vehicle environments. This invention also provides an economic, continuous process for producing the new coated articles of this invention, as will be described hereinafter.
SUMMARY OF THE INVENTION
In accordance with the present invention, articles are coated with a new, thin colorless coating, which preserves the appearance of the uncoated articles. In a first preferred embodiment, the coating contains as its essential component a chemical complex of alkali metal-chromium-silicates as defined in the claims. In an alternative second preferred embodiment, the coating contains as its essential components a "water glass" complex of alkali metal-silicates and water; a metallic oxide; and a lithium-containing compound. The amount of the essential components in the coating in each preferred embodiment is that which is sufficient to provide the coated articles with an unexpectedly unique combination of properties of appearance, adherence, resistance to chipping and flaking, corrosion resistance to acidic and alkaline gases and aqueous solutions and oils, solvents and fuels, and is sufficient to make it suitable as a surface treatment, such as a base for paint and the equivalent of paint on parts within the engine compartment of vehicles. The preferred coatings are colorless and so thin as to be virtually invisible to the naked eye. The coating thickness varies from about 50 angstroms, or 0.0005 micron, to about 2 microns.
This invention also provides a process for the continuous, efficient production of the improved coated articles of this invention. The continuous process makes use of known production line dip or spray apparatus in which the articles or parts to be coated are mounted on racks or in rotating barrels supported on conveyor means capable of sequentially contacting the articles with aqueous solutions positioned in a plurality of in-line tanks, each tank containing an aqueous solution of selected coating-producing ingredients with intervening rinse solution-containing tanks, the in-line apparatus terminating in conventional means for drying the coated parts. The process of this invention has the advantages of using dilute aqueous solutions of inexpensive, commercially available chemicals that are maintained at low treatment bath temperatures ranging from ambient room temperatures up to about 160° F., or 71° C., and for short times of contact of the solution with the article being coated, for example, by immersion contact in the range of about 20-180 seconds, preferably about 30 seconds, or spray contact for about 10 to 60 seconds and preferably 5-20 seconds. Longer contact times are also possible. The end result is that the continuous production process provides a resultant product that is less expensive than most heretofore available corrosion resistant products.
The process of this invention is useful to form coatings on non-ferrous metals such as aluminum, zinc, cadmium, magnesium and many of their alloys that are commercially available as sand castings, plate, sheet, forgings or extrusions. Particularly good results have been obtained by using the process for coating vehicle engine manifolds made from sand cast aluminum alloys as described in Example I. Also, good results are obtained using the process for coating zinc plated steels such as described in Example V.
DETAILED DESCRIPTION OF THE INVENTION
In a first embodiment the new articles of this invention include articles fabricated from aluminum or an aluminum alloy which have on their surfaces a thin, adherent coating having a thickness up to about 2 microns comprising as its essential component a chemical complex of an alkali metal-chromium-silicate having proportions of each in the range, expressed as oxides in weight percent of:
Na.sub.2 O--9.9%--12.1%;
Cr.sub.2 O.sub.3 --4.1%--4.3%; and
SiO.sub.2 --76.8%--91.2%.
In an alternative second preferred embodiment, the new articles of this invention include articles fabricated from aluminum, zinc, cadmium, magnesium or their alloys which have on their surfaces a thin adherent coating having a thickness up to about 2 microns, and comprising as its essential components a water glass complex, a metallic oxide, and a lithium-containing compound. Water glass complexes are known in the art and typically include an alkali metal-silicate (such as including Na 2 O and SiO 2 ) and water. Preferably the constituents of the water glass (e.g. H 2 O, Na 2 O and SiO 2 ) are present at or near their art-disclosed levels, and more preferably are present such that the proportions of each, expressed in percent, by weight of the final bath composition (wherein "the final bath composition" refers to an aqueous solution in which the coating has been dissolved or dispersed) are:
Na 2 O in an amount of about 0.44 to about 0.82%, and more preferably about 0.63%;
SiO 2 in an amount of about 1.27 to about 2.37%, and more preferably about 1.82%; and
H 2 O in an amount of about 2.29 to about 4.25%, and more preferably about 3.27%.
Accordingly, preferably the water glass complex is present in the coating composition in an amount of about 4 to about 7.44 percent, by weight of the final bath composition, and more preferably is present in an amount of about 5.72 percent by weight of the final bath composition.
The coating of the alternative second preferred embodiment further comprises a metallic oxide-containing compound, and preferably a molybdenum oxide compound such as that having the chemical formula MoO 3 . In a highly preferred embodiment, the metallic oxide-containing compound, preferably MoO 3 , is present in an amount of about 0.1 to about 1.0%, more preferably from about 0.5 to about 1.0% and still more preferably at about 0.50%, by weight of the final bath composition.
Preferably the coating of the present alternative second preferred embodiment further comprises a lithium-containing compound, and more preferably a lithium hydroxide monohydrate (LiOH·H 2 O) compound. The lithium-containing compound, preferably LiOH·H 2 O, is present in an amount of about 0.1 to about 1.0 percent, by weight of the final bath composition, more preferably about 0.5 to about 1.0 percent, by weight of the final bath composition, and still more preferably about 0.50 percent by weight of the final bath composition.
Of course, the skilled artisan will appreciate that different concentrations than those set forth above are possible, particularly where concentrates containing the coating are involved.
The coating of the present alternative second embodiment, as well as the first embodiment described herein, is useful for coating articles made from aluminum or its alloys. The coating of the present alternative second embodiment also unexpectedly improves corrosion resistance of articles made from non-ferrous materials such as zinc, cadmium, magnesium and their respective alloys. The coating is especially useful as applied over steel articles plated (using conventional techniques) with zinc, cadmium or their respective alloys.
The process for making the coated new articles of this invention using the composition of the first preferred embodiment comprises the following sequential steps, omitting intervening water rinsing steps:
1) cleaning with an acidic cleaner to remove foreign matter, oils, greases or surface remnants from the forming of the article;
2) contacting the cleaned article from step 1 with an aqueous, strongly acidic solution capable of removing surface aluminum oxides;
3) contacting the clean, rinsed, substantially oxide-free article of step 2 with an aqueous acidic solution for forming a chromium-silicate-containing adherent surface coating;
4) elevated temperature water rinsing of the step 3 coated article;
5) contacting the rinsed coated article of step 4 with an aqueous, strongly alkaline solution capable of forming an alkali metal-chromium silicate coating containing a chemical complex having the composition, expressed as oxides in percent by weight of:
Na.sub.2 O--9.9%--12.1%;
Cr.sub.2 O.sub.3 --4.1%--4.3%; and
SiO.sub.2 --76.8%--91.2%.
A preferred method for coating articles using the composition of the alternative second preferred embodiment comprises the steps of:
1) cleaning with an acidic cleaner to remove foreign matter, oils, greases or surface remnants from the forming of the article;
2) contacting the cleaned article from step 1 with an aqueous, strongly acidic solution capable of removing surface metallic oxides from the surface of the cleaned article;
3) contacting the clean, rinsed, substantially oxide-free article of step 2 with an aqueous acidic solution for forming an adherent surface coating;
4) elevated temperature water rinsing of the step 3 coated article;
5) contacting the rinsed coated article of step 4 with a solution (i.e. bath) capable of forming a coating, wherein the coating is made by adding to water an admixture containing the following composition, expressed in percent, by weight of the final bath composition:
Na 2 O in an amount of about 0.44% to about 0.82%, and more preferably about 0.63%;
SiO 2 in an amount of about 1.27% to about 2.37%, and more preferably about 1.82%;
H 2 O in an amount of about 2.29% to about 4.25%, and more preferably about 3.27%;
MoO 3 in an amount of about 0.1% to about 1.0%, more preferably about 0.5% to about 1.0%, and still more preferably about 0.5%; and
LiOH·H 2 O in an amount of about 0.1% to about 1.0%, more preferably about 0.5% to about 1.0%, and still more preferably about 0.5%.
The following provides specific preferred details concerning the above methods of coating with the compositions of the first preferred embodiment and the alternative second preferred embodiment. The description that follows is of a process which is particularly preferred for use to coat articles of aluminum or aluminum alloy. Nonetheless, the skilled artisan will appreciate that the methods are also useful for coating articles made from many other nonferrous materials such as zinc, cadmium, magnesium or their alloys. In this regard, steps ordinarily taken to treat aluminum or aluminum alloys may be deleted or substituted with like steps known in the art for treating zinc, cadmium, magnesium or their alloys. Further, the skilled artisan will appreciate that techniques such as rinsing, oxide removal techniques and techniques for forming an adherent surface coating (e.g. chromating) are generally known in the art, and even though the following discussion constitutes a description of preferred techniques, such techniques can be substituted with any suitable known techniques, or the sequence of steps may be modified, for achieving the purpose stated.
Cleaning solutions suitable for use in the first step of the process include a wide variety of commercially available inhibited acidic cleaners. Good results are obtained by using an aqueous phosphoric acid solution containing phosphoric acid in an amount sufficient to give a pH in the range of about 5 to 6, and which may contain organic solvents such as tri- or diethylene glycol monobutyl ether in an amount of about 2% to 10% and may also contain any of a number of commercially available organic surfactants, for example, about 2% to 10% of a fluorocarbon surfactant such as PC 95 available under the tradename Fluorad from Minnesota Mining & Manufacturing Co. The parts to be cleaned are immersed in such a cleaning solution at a temperature of about 130° to 180° F. for 2 to 5 minutes, preferably about 3 minutes, followed by rinsing in water at a temperature of about 120° to 140° F., preferably about 130° F., for 30 to 90 seconds.
The cleaned articles from step 1 are then contacted with a stronger aqueous acidic solution capable of removing oxides from the surfaces of the article. Good results are obtained by using a chromic acid-based solution containing 70% to 80% chromic acid, 20% to 30% potassium dichromate and 2% to 4% ammonium silicofluoride in a concentration of 3 to 6 oz./gal., preferably about 4 oz./gal. to form a solution having a pH in the range of about 0.5 to 1 and contacting the article with such solution for a time period in the range of about 1/2 to about 3 minutes. The oxide free cleaned articles are then water rinsed in one to three water tanks at ambient temperatures, for about 30 seconds in each rinse solution.
The deoxidized, rinsed article is then subjected in step 3 to a coating forming step by contacting the article by dip or spray with a suitable aqueous solution to form a chromate coating, and preferably a silicon-chromate coating on the surface. Good results are obtained in forming such coatings by using an aqueous solution made up by adding to water, preferably deionized water, about 0.5-2.0 oz./gallon of a composition containing in weight percent about 50% to 60% chromic acid, about 20% to 30% barium nitrate and about 15-20% sodium silicofluoride and preferably containing a catalyst in an amount of up to about 5% such as an alkali metal ferricyanide, i.e., potassium or sodium ferricyanide to form a solution having a pH in the range of about 1.2-1.9 and preferably about 1.5. Other formulations which are also satisfactory for use may omit the barium nitrate component, and may include additional coating catalysts of the molybdic acid type in the event color is desired, such as the formulations disclosed in U.S. Pat. No. 3,009,842 (hereby incorporated by reference) and in the other patents identified therein. Other useful, but less desirable compositions that are suitable for coated articles having less stringent requirements for salt spray resistance include those set forth in U.S. Pat. Nos. 3,410,707 and 3,404,043, which are hereby incorporated by reference. Compositions that are satisfactory are commercially available from a wide variety of suppliers in the United States and especially good results are obtained by using the material commercially designated Iridit 14-2 which is available from Witco Chemical Company.
It is to be further understood that the proportions of the components in the preferred composition described above are not critical to the formation of the base coating that is formed directly on the oxide free surface of the metallic article being coated in accordance with this invention. Useful coated articles are formed when the formulation given above is varied to employ proportions within the ranges set forth in U.S. Pat. No. 3,982,951 (hereby incorporated by reference). When the article is dipped, an immersion time of about 30 seconds is adequate when the temperature is maintained at less than 120° F., or 49° C. When the article is sprayed at a similar temperature, about 5 to 20 seconds is adequate.
It is important to insure a thorough water rinsing of the coating formed in step number three. This is best done using deionized water at ambient temperature, i.e., about 60° F.-90° F. in 1 to 3 immersions, preferably three, for about 30 seconds each, or a single power spray for about 30 seconds. Following the thorough ambient temperature rinsing of the coated article from step 3, the fourth step is a final water rinse at a temperature that is higher than the ambient temperature employed in step 3. This higher temperature rinse serves to remove unwanted chromate colors, if present, and also to prepare the coating from step three to enhance its reactivity with the components in the strong alkaline solution to be next applied to form the coating of this invention. Preferred conditions for step 4 include using deionized water at a temperature in the range of about ambient to about 160°, and more preferably about 110° F. to 160° F., or about 43° C. to 71° C., and preferably about 130° F. or 54°-55° C. The coated article from step 3 should be rinsed at the selected temperature for a time sufficient to raise the temperature of the article to about the elevated temperature of the rinse solution. Thus, the optimum time required varies for specific articles depending on the selected composition used in step 3 and also depends on the size or bulk of the article. The optimum time may be affected by the particular alloy composition of the article being coated. For example, the time required may vary from about 30 seconds up to about 5 minutes, and the needed, or optimum, time is easily determinable by a few trials. Where the article is formed by sand casting a metallic material, the article may include pits or surface imperfections. When such imperfections are present it has been found that potential, undesirable white corrosion products may develop in such pit or imperfection areas during salt spray testing or use and this undesirable corrosion can be avoided by exercising care in selecting a sufficiently high temperature toward the 160° F. limit and a sufficiently long time for the selected elevated temperature rinse step.
The elevated temperature rinsed coated article from step 4 is then subjected in step 5 to a second coating step by contacting the coated article with the coating composition of the first preferred embodiment, the coating composition of the alternative second preferred embodiment, or mixtures thereof.
When coated with the coating composition of the first preferred embodiment the coated article from step 4 is contacted with a highly alkaline aqueous solution having a pH in the range of about 10 to about 12, and more preferably about 11 to 12, and containing disodium oxide and silicon dioxide components having a weight ratio of SiO 2 /Na 2 O in the range of about 2.4 to 3.25 and a range of densities between about 40 and 52 degrees Baume' at 20° C. Otherwise expressed the silicate solutions may contain in weight percent, about 26.5% to about 33.2% SiO 2 and about 8.6% to about 13.9% Na 2 O, at a similar range of densities. Preferred solutions are those which contain disodium oxide and silicon dioxide in a weight ratio of SiO 2 /Na 2 O of about 2.5 to 2.9 and a density in the range of about 42 to about 47 degrees Baume' at 20° C. The best results have been obtained from a solution formulated by adding to water an amount of about 2% to 6% by volume, and more preferably about 4.5%, of a sticky, heavy silicate having a weight ratio of SiO 2 /Na 2 O of 2.9 and a density of 47° F. Baume' at 20° C. to thereby produce a coating solution having a pH of about 11.5.
When coated with a highly preferred coating composition of the alternative second preferred embodiment the coated article from step 4 is contacted with an aqueous solution or bath having a pH in the range of about 10.5 to about 12 being prepared from a water glass complex including disodium oxide, silicon dioxide, and water, having a weight ratio of SiO 2 /Na 2 O/H 2 O in the range of about 0.44 to 0.82 parts Na 2 O: about 1.27 to about 2.37 parts SiO 2 : about 2.29 to about 4.25 parts H 2 O and still more preferably about 0.63 parts Na 2 O to about 1.82 parts SiO 2 to about 3.27 parts H 2 O, and a range of densities between about 40 and about 52 degrees Baume' at 20° C. The solution further comprises MoO 3 and LiOH·H 2 O present such that the weight ratio of MoO 3 to LiOH·H 2 O is about 1:1, and further wherein each of MoO 3 and LiOH·H 2 O are present in an amount of about 0.5 parts by weight to about 1.82 parts SiO 2 , about 0.63 parts Na 2 O, and about 3.27 parts H 2 O.
Otherwise expressed (as percent, by weight of the final bath composition), a highly preferred final bath composition preferably includes the water glass complex having constituents present in an amount of about 0.63 percent Na 2 O, about 1.82 percent SiO 2 , and about 3.27 percent H 2 O. The final bath composition further includes MoO 3 in an amount of about 0.5 percent, and LiOH·H 2 O in an amount of about 0.5 percent.
In a highly preferred embodiment the coated article from step 4 is contacted with an aqueous solution formed by adding to water an amount of about 2 to about 6 percent by volume of the final bath composition of a compound containing about 5.72 parts by weight water glass (i.e., about 0.63 parts by weight Na 2 O; about 1.82 parts by weight SiO 2 ; and about 3.27 parts by weight water); about 0.5 parts by weight MoO 3 ; and about 0.5 parts by weight LiOH·H 2 O.
The articles from step 4 are immersed for about 30 seconds to 2 minutes in the solution of step 5 at a temperature of ambient to about 130° F., with the solution having a preferred pH between about 11.2 and 11.5 when using the composition of the first embodiment, and a pH between about 10.5 and 12, when using the composition of the alternative second preferred embodiment. The thus coated articles are finally dried either in ambient air, by using clean forced air, or by placing them in a low temperature furnace at 150° to 200° F. for 1 to 2 minutes.
The dried, coated articles are the new articles of this invention. In their preferred form, the articles have a thin, adherent coating that is substantially invisible to the naked eye but has a thickness in the range of about 50 angstroms to about 20,000 angstroms, or about 0.0005 micron to about 2 microns. The coated article has the same overall appearance as the uncoated article unless a tint is intentionally produced by varying the composition of step 3 or the temperature of step 4 as will be readily apparent to those skilled in the art of forming chromate coatings.
Tests conducted on the articles coated with the composition of the first preferred embodiment have established that the coating is sufficiently adherent and hard to resist chipping or flaking when used at elevated temperatures up to about 400° F. such as may be attained in the engine compartments of automobiles and trucks, and even as high as about 1200° F. When the articles from step 5 using the composition of the first preferred embodiment were vehicle intake manifolds and were tested for salt spray resistance under the conditions of ASTM B117 test method no corrosion products were visible for 250 hours.
Articles coated with the composition of the alternative second preferred composition exhibit no visible corrosion products for at least about 250 hours. For some applications (such as applied to panels of forged aluminum alloy 1100 treated with trivalent chromate) no corrosion products are visible for about 720 hours.
EXAMPLE I
Automobile intake manifolds were sand cast from a Ford Motor material designated 319 Aluminum having a specification of 5.5-6.5 Si, 0.4-0.6 Mn., 3.0-4.0 Cu, 0.1-0.6 Mg., 0.7-1.0 Zn and 1.0 Max Fe. The articles were mounted on racks carried by a dip-type conveyor adapted to dip the racks into tanks to form coated manifold articles of this invention in the following sequence of steps:
1) A tank of aqueous acidic cleaning solution was prepared to contain, in percent by weight, 5% of the commercial product Niklad Alprep 230 a . The intake manifolds were dipped in the solution having a pH of 5-6 at approximately 130° F., for about 2 minutes;
2) water rinse at 130° F.±5° F., for about 30 seconds;
3) repeat step 2;
4) A tank of aqueous acidic coating solution was prepared by mixing about 1 oz. per gallon of Iridit 14-2 b with water to form a solution having a pH of 1.4-1.5. The rinsed manifolds from step 3 were immersed in the solution for 30 seconds;
5) Water rinse at ambient room temperature of about 60° F.-90° F. for 30 seconds;
6) repeat step 5;
7) A tank of deoxidizing strongly acidic cleaner was prepared by mixing 4 oz./gallon of Deoxidizer No. 2 c with water to form a solution having a pH of 0.5-1.0. The rinsed manifolds of step 6 were immersed in the solution for 90 seconds;
8) water rinse at ambient temperature;
9) repeat step 8;
10) repeat step 8;
11) repeat immersion for 3 minutes in the same solution as in step 4;
12) water rinse at ambient temperature;
13) repeat step 12;
14) repeat step 12;
15) water rinse, deionized water, at approximately 140° F.-150° F. for about 30-50 seconds.
16) A tank of strongly alkaline coating solution was prepared by mixing 4% by volume of Ultraseal d to form a solution having a pH of about 11.5. The manifolds from step 15 were immersed at a temperature of about 130° F. for about 30 seconds.
17) The coated manifolds from step 16 were drained and dried at ambient temperature.
Coated articles from step 17 were analyzed using Electron Spectroscopy for Chemical Analysis (ESCA) to establish coating thickness and the elemental composition of the surface coating. The coating thickness of the dried articles from step 17 was greater than 50 angstroms and less than 2 microns.
An ARL SEMQ electron microprobe analysis using 10 KeV accelerating voltage and wave length dispersive spectrometry (WDX) established that the elemental surface coating on the rinsed article from step 6 contained 4.2% silicon, 0.6% chromium and 2.0% oxygen, and it was concluded to be majorly a siliconchromate coating. The rinsed coating from step 14, which resulted from the second application of the same solution which produced the article from step 6, included increased quantities of silicon and chromium in the coating to 7.4% silicon, 1.1% chromium and 2.0% oxygen. After the rinsed and elevated temperature silicon-chromate coating of step 15 was contacted with the strongly alkaline solution in step 16 the final, dried coating was analyzed. The above identified electron microprobe and accelerating voltage was used. The coating composition, in weight percent, expressed as oxides of the detected elements and taking into account the applicable accuracy level of the use conditions of the analyzing equipment, contained:
9.9-12.1% Na.sub.2 O;
4.1-4.3% Cr.sub.2 O.sub.3 ; and
76.8-91.2% SiO.sub.2.
Articles were tested for salt spray resistance using ASTM B-117 test conditions (the concentration of salt in solution is 5% by weight, the pH is about 6.5 to about 7.2, the specific gravity is about 1.026 to about 1.040, the condensation rate is about 1 to about 2 ml/hr and the temperature is about 92° to about 97° F. and no corrosion products were visible after 250 hours. Other articles were tested under Engineering material Specification Number ESE-M2P128-A of Ford Motor Co. which is the specification of a superior quality of paint required on the engine, engine accessories and/or parts within the engine compartments of automobiles and trucks. Coated articles from step 17 of the above described process qualified as passing all of the requirements of a superior quality paint including adhesion, hardness, water resistance, gasoline resistance, hot oil resistance, glycol resistance, heat resistance and 96 hours salt spray resistance using the conditions of ASTM B-117.
The process was also used to coat other manifolds sand cast from the materials designated alloy 355.0-T6, UNS Number A03550, comprising about 5.0% silica, about 1.2% copper and about 0.5% magnesium, by weight, and a die cast aluminum alloy designated BS 1490-LM20 having a specification of 13.0 Si, 1.0 Iron, 0.5 Mn, 0.4 Cu, 0.2 Mg, 0.2 Zn, 0.1 Ti, 0.1 Ni, 0.1 Pb and 0.1 Sn.
Substantially similar results are obtained when the above process is used to coat articles made from zinc, cadmium, magnesium or their alloys.
While not intending to be bound by theory, it is believed that the steps above are unique in opening the "pores" on the surface of the metal, allowing the beneficial coating to impregnate these pores for more efficacious treatment and sealing of the metallic surface.
EXAMPLE II
Diode plates for automobile alternators that were stamped into the desired configuration using extruded aluminum alloy 6061-T6, AMS 4150G comprising about 1.0% magnesium, about 0.6% silica, about 0.28% copper and about 0.20% copper, by weight, were coated using the process of this invention. The diode plates were approximately 5" long, 5/8" wide and 1/8" thick and in the shape of an arcuate segment of a circle having a radius of about 5 inches, and provided with a plurality of openings for receiving and supporting diodes.
A quantity of the stamped diode plates were positioned in rotatable barrels, as opposed to the racks described in Example I, and the barrels were sequentially processed through the same coating solutions used in Example I except that steps 4-6 were omitted and certain of the times of immersion in some of the other solutions were changed. In step 1 the immersion was for 3 minutes. In step 7, the immersion was for 2-3 minutes. In step 11, the silicon-chromate coating forming tank, the immersion time was 12 minutes and immersion time in the rinses in steps 12-15 was for a total of 5 minutes.
The coated diode plates retained the aluminum appearance of the stamped parts and were coated with an adherent, scratch and chip resistance coating having a thickness of approximately 2 microns.
The coated diode plates from step 17 were tested for their ability to continue to pass current when assembled into an automobile alternator that was positioned in a salt spray cabinet using the salt spray test conditions of ASTM B-117. The diode plates were found to resist salt spray corrosion and to continue to pass the test current without failure for 1000 hours.
EXAMPLE Ill
Manifolds of aluminum alloy SAE-331 (AA333)-F Temper are cast, coated with hexavalent chromate (bleached to colorless). The manifolds are then coated to a thickness of about 1-2 microns, by contacting the manifolds with an aqueous bath having therein a coating composition set forth in Table I (expressed as parts by weight of the final bath composition).
TABLE I______________________________________Component Parts by Weight______________________________________Water glass: 5.72Na.sub.2 O (0.63 parts by weight)SiO.sub.2 (1.82 parts by weight)H.sub.2 O (3.27 parts by weight))MoO.sub.3 0.50LiOH.H.sub.2 O 0.50______________________________________
Using salt spray test conditions of ASTM B117, 264 hours pass before the first sign of corrosion.
EXAMPLE IV
Forged panels of aluminum alloy 1100 having a composition of about 99.0%, by weight, aluminum are coated with trivalent chromate, and are coated to a thickness of about 1-2 microns with the composition of Table I in Example III. Using salt spray test conditions of ASTM B117, 720 hours pass before the first sign of corrosion. Substantially similar results are obtained with a hexavalent chromate coating.
EXAMPLE V
Three specimens (A,B,C) of a low carbon (e.g. AISI types 1018-1020 steel) steel are plated with zinc to a thickness of about 0.0003" to about 0.0005". Specimen A is yellow chromate coated. Specimen B is black chromate coated. Specimen C is clear chromate coated.
Specimens A, B and C are each coated to a thickness of about 1-2 microns with the composition of Table I in Example III. Using salt spray test conditions of ASTM B117, 384 hours pass before the first sign of corrosion in specimens A and B; and 336 hours pass before the first sign of corrosion in specimen C.
Substantially similar results are obtained with cadmium plated materials. While the above description constitutes the preferred embodiments of the present invention, it will be appreciated that the invention is susceptible of modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.
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Metallic articles, and method for making same, having a thin, adherent, chemically formed coating on their surface which preserves the uncoated article appearance and provides a unique combination of functional properties including resistance to chipping and flaking during elevated temperature use, resistance to corrosion from chemicals in the form of gases or aqueous acidic or alkaline solutions including salt spray, organic solvents, oils and vehicle fuels and suitability as a base for paint for parts within the engine compartment of vehicles.
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BACKGROUND OF THE INVENTION
1. Field of the Invention The present invention relates to a damping circuit for at least two Series-connected turn-off valves according to the preamble of Patent claim 1.
2. Discussion of Background
A known damping circuit is disclosed in the French journal "Electronique de puissance" ("Power electronics"), 11 Sept. 1985, pages 12 and 13. In the circuit represented there in FIG. 3, two GTO thyristors are connected in series via a choke with mid-point tapping. Connected in parallel to each GTO thyristor with antiparallel free-wheeling diode is a series circuit of a turn-off load-shedding capacitor with a turn-off load-shedding diode. The common junction points of the turn-off load-shedding capacitor and turnoff load-shedding diode of the two series circuits are interconnected, on the one hand, via a primary winding of a transformer, the secondary winding of the transformer being connected to the supply direct voltage via a diode, and, on the other hand, via a further series circuit of three diodes and an ohmic resistance. The capacitor ring-around energy can be recovered with this damping circuit. However, the damping circuit is relatively expensive in view of a number of its components. Electric losses occur both in the ohmic resistance, and also in the choke with midpoint tapping.
Concerning the prior art, reference is made in addition to EP-B1-0,134,508. In the circuit represented there in FIG. 4, two GTO thyristors are directly connected in series in each case to a choke with mid-point tapping, there being no interconnection. Parallel to each GTO thyristor, a turn-off load-shedding diode is connected in series to a turn-off load-shedding capacitor. When each GTO thyristor is switched in, the turn-off load-shedding capacitor is discharged via an auxiliary thyristor, especially a breakover voltage thyristor and two diodes, an energy storage choke and the GTO thyristor. Thereafter, a free-wheeling current flows through the energy storage choke, the GTO thyristor and a free-wheeling diode. When the load thyristor is switched out, a portion of the energy temporarily stored in the energy storage choke is used to recharge the turn-off load-shedding capacitor, and a portion is fed back into a direct-voltage source. In this way, an inductive load can be controlled inexpensively via clearly defined switching times. The energy storage choke has an inductance which is approximately 10 4 times as large as the inductance of the circuit composed of GTO thyristor and the series connection, parallel thereto, of turn-off load-shedding capacitor and turn-off load-shedding diode.
Additionally, reference is made to DE-B2-2,641,183. In the low-loss damping circuit given there of two electrical or electronic one-way switches connected in series e.g. two npn transistors, there is provided parallel to each one-way switch, in accordance with a variant, a series circuit of a load-shedding capacitor and a load-shedding diode, the load-shedding diode being of the same polarity as the one-way switch. Parallel to each load-shedding diode, a discharge coil is connected in series to a discharge diode, which has the opposite polarity to that of the load-shedding diode. This damping circuit does not enable recovery of the ring-around energy; it requires 2 discharge diodes and 2 discharge coils. When a one-way switch is turned off, only the respective associated load-shedding capacitor operates.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to achieve the object by providing a novel damping circuit or at least two series-connected turn-off valves, which manages with fewer components and exhibits fewer electrical losses.
An advantage of the invention consists in that no choke has to be provided in series with the turn-off valves. This reduces the electrical losses. Moreover, the turn-off load-shedding capacitors can be dimensioned approximately 25% times smaller, than otherwise necessary according to the data from the manufacturers of the GTO thyristors. The turn-off load-shedding capacitor of the second turn-off valve of two turn-off valves connected in series contributes approximately 50% to the turn-off load-shedding of the first turn-off valve, and the turn-off load-shedding capacitor of the first turn-off valve contributes approximately 50% to the turn-off load-shedding of the second turn-off valve. In this way, it is achieved that readiness for turning off exists immediately after the firing of a turn-off valve. In practice, the earliest instant of the turn-off pulse is not determined by the damping circuit. The damping circuit operates independently of the circuit state of the turn-off valves; it can also be used with zero-point circuits. No transformer with diode is required in the circuit of the secondary winding in order to recover energy.
According to an advantageous embodiment of the invention, correct dimensioning of an inductive reactance in series with a turn-off load-shedding diode between the turn-off load-shedding capacitors of two turn-off valves makes it possible to reduce a ring-back upon the discharge of these turn-off load-shedding capacitors via the particular turn-off valve, so that these valves are subjected to a lower load.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 shows a three-phase inverter for supplying an alternating-current machine, having turn-off valves in the bridge arms and a low-loss damping circuit per phase of the inverter;
FIG. 2 shows a circuit according to FIG. 1 having two turn-off valves connected in series for an inverter phase, with detailed damping circuit;
FIG. 3 shows a circuit having four turn-off valves connected in series for an inverter phase, with detailed damping circuit; and
FIG. 4 shows a circuit, having six turn-off valves connected in series for an inverter phase, with detailed damping circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, in FIG. 1, 1 designates a positive terminal and 2 the negative terminal of a three-phase inverter 3 having alternating voltage phases R, S, T, which are connected to an alternating-current machine or three-phase machine 5. The inverter 3 is a part of a converter (not represented) having a direct voltage link, to which a direct voltage U d is applied between the terminals 1 and 2 from a rectifier of the converter. A link capacitor C01 is connected between the terminals 1 and 2.
Turn-off valves with antiparallel diodes or reverse-conducting GTO thyristors V1, V2, or V3, V4 or V5 or V6 form three pairs of valve arms of the inverter 3, corresponding to the alternating voltage phases R, S, T, which are connected, in each case, to a damping circuit 4.
FIG. 2 shows the circuit of a low-loss damping circuit 4 in conjunction with two series-connected reverse-conducting first and second GTO thyristors V1 and V2 according to FIG. 1. Parallel to each reverse-conducting GTO thyristor V1 or V2, there is connected a series circuit of a first or second turn-off load-shedding capacitor C1 or C2 and a first or second turn-off load-shedding diode D1 or D2, the particular turn-off load-shedding diode D1 or D2 being poled in the same direction as the associated reverse-conducting GTO thyristor V1 or V2. A common junction point 6 of the first turn-off load-shedding capacitor and the first turn-off load-shedding diode D1 is connected electrically to a common junction point 7 of the second turn-off load-shedding capacitor C2 and the second turn-off load-shedding diode D2 via a series circuit composed of a capacitor load-shedding D2 and an inductive reactance or a choke L3. The inductance of the inductive reactance L3 is 1.5 to 5 times, preferably 2 to 3 times, as large as the inductance of the inductive reactance of the circuit V1, C1, D1 or V2, C2, D2. Instead of a special choke L3, the same inductance can be provided as a conductor loop in the shape of several 10 cm cables in series with the capacitor load-shedding diode D3, as indicated in FIG. 2 by dots and dashes. Typical values for the turn-off load-shedding capacitor C1 and C2 are 2.8 μF and 2500 V.
FIG. 3 shows a circuit suitable for very high direct voltages having four series-connected, reverse-conducting GTO thyristors V11-V14 for an inverter phase R. Connected in parallel to each of the reverse-conducting GTO thyristors V11-V14 is a series circuit composed of a turn-off load-shedding capacitor C11 and a turn-off load-shedding diode D11 or C12, D12 or C13, D13 or C14, D14. Common junction points of turn-off load-shedding capacitor and turn-off load-shedding diode of respectively two adjacent series-connected, reverse-conducting GTO thyristors are conductively connected in a unidirectional fashion via a series circuit composed of a capacitor load-shedding diode D3 and a choke L3.
Two link capacitors C01 and C02 are connected in series between terminals 1 and 2. The common junction point of the link capacitors C01 and C02 is connected, on the one hand, via a first diode D01 to the cathode of the reverse-conducting GTO thyristor V11 and, on the other hand via a second diode D02 to the anode of the reverse-conducting GTO thyristor V14, these diodes being of the same polarity as the GTO thyristors mentioned. In this connection, the direct voltage U d /2 occurs at each GTO thyristor.
FIG. 4 shows a circuit corresponding to FIG. 3, but having six series-connected, reverse-conducting GTO thyristors V11-V16. Here, three link capacitors C01-C03 are connected in series between the direct voltage terminals 1 and 2, i.e. half as many as GTO thyristors. The common junction point of the first and second link capacitor C01 or C02 is connected to the common junction point of the first and second reverse-conducting GTO thyristor V11 or V12 via a first diode D01, and to the common junction point of the fourth and fifth reverse-conducting GTO thyristor V14 or V15 via a second diode D02. The common junction point of the second and third link capacitor C02 and C03 is connected to the common junction point of the second and third reverse-conducting GTO thyristor V12 or V13 via a first diode D03, and to the common junction point of the fifth and sixth reverse-conducting GTO thyristor V15 or V16 via a second diode D04. In this connection, the direct voltage U d /3 occurs at each GTO thyristor.
It stands to reason that this series connection principle can be extended to n series-connected valves, n being an even number ≧4. In this case, n/2 link capacitors are connected in series parallel to the n valves, so that the direct voltage 2×U d /n occurs at each valve. The common junction point of the mth and (m+1) th link capacitor is connected to the common junction point of the mth and the (m+1) th turn-off valve via a first diode, and to the common junction point of the (n/2+m) th and (n/2+m+1) th turn-off valve via a second diode, m=1 . . . (n/2-1).
The operation of the damping circuit according to the invention is now to be explained with reference to the circuits of FIGS. 1 and 2.
State 1: In the stationary state, a constant current flows from the positive terminal 1 to the inductive reactance via the switched-in valve V1, i.e. into the alternating-current machine 5 via the alternating voltage phase.
State 2: After the valve V1 has been turned off, the turn-off load-shedding capacitor C1 is recharged with a charging current from the positive terminal 1 via C1, D1 and the inductive reactance 5, while the turn-off load-shedding capacitor C2 is discharged via L3, D3, D1 and the inductive reactance 5. In this process, the sum of the recharging and the discharging current through the inductive reactance 5 remains constant.
State 3: A constant load current forced by the inductance of the load 5 flows back through the antiparallel diode of the valve V2 via the load 5.
State 4: When the valve V1 is switched in, the turn-off load-shedding capacitor C2 is recharged by the positive terminal 1 via V1, D2 and the negative terminal 2. At the same time, the turn-off load-shedding capacitor C1 is discharged via V1, D2, L3, D3. At the same time, a constant current flows into the load 5 from the positive terminal 1 via V1, corresponding to the state 1.
It is important that the capacitor load-shedding diode D3 is used to discharge the turn-off load-shedding capacitors C1 and C2. This diode is rendered "slow" via a somewhat larger inductance L3, in contrast to the two other circuits C1, V1, D1 and C2, V2, D2, which are to be constructed with as low an inductance as possible. Since the two turn-off load-shedding capacitors C1 and C2 are parallel when the valves are turned off, the damping circuit becomes small with regard to the capacity of the turn-off load-shedding capacitors C1 and C2. Each turnoff load-shedding capacitor functions fully for the associated GTO thyristor, and not entirely fully for the second GTO thyristor, because L3 is connected in series to D3.
Depending on the operating state, (GTO thyristor conducting or not), more or less ring-around energy is fed back into the direct voltage source.
In principle, the choke L3 could, instead of being connected in series to the capacitor load-shedding diode D3, also be connected between the valves V1 and V2, it being necessary to connect the turn-off load-shedding diodes D1 and D2 to a mid-point tapping. However, this would have the disadvantage that because of the relatively high load current the electrical losses would amount to approximately 10 3 times by comparison with those for the given circuit. With the object of the present invention, there is no need for chokes in series with the turn-off valves.
For the purpose of vibration damping, it would also be possible to provide, instead of, or additionally in series with, the choke L3 an ohmic resistance, the resistance of which preferably has the value C denoting the capacity of a turn-off load-shedding capacitor C1 or C2, and L the inductance of a capacitor load-shedding circuit C2, L3, D3, D1, V1 or C1, V1, D2, L3, D3.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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Converter inverters, such as are used in the operation of alternating current machines, have turn-off reverse-conducting GTO thyristors in the bridge arms. Parallel to each GTO thyristor there is provided a series circuit composed of a turn-off load-shedding capacitor with a turn-off load-shedding diode. The common junction points of the respective turn-off load-shedding capacitors and diodes are connected in series to a choke via at least one capacitor load-shedding diode. The inductance of the choke is 2 to 3 times as large as the inductance of the circuit. The reverse-conducting GTO thyristors are directly connected in series, without the series connection of a choke. There thus arises a damping circuit of the GTO thyristor, which is very simple and, at the same time, feed back ring-around energy.
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RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/866,976, filed Jun. 14, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to photomasks used in photolithography processes, such as semiconductor wafer fabrication processes. In particular, the present invention relates to photomasks with multiple versions of the same mask pattern having different biases to compensate for process errors that occur during exposure in a photolithography process.
BACKGROUND OF THE INVENTION
[0003] There are a wide variety of photomasks known in the art, as well as diverse uses to which they can put, as described in, e.g., U.S. Pat. Nos. 6,472,107 and 6,567,588. Among the many types of photomasks used in the semiconductor industry, binary and phaseshift photomasks are quite common. A typical binary photomask is comprised of a substantially transparent substrate 2 and opaque layer 4 , in which a pattern is formed, as shown in a cross sectional illustration of an unprocessed binary photomask in FIG. 1A . Further, the opaque layer 4 may also have an anti reflective (“AR”) coating 6 . The pattern of the opaque material in the opaque layer 4 and AR material in the AR coating 6 on the substantially transparent substrate 2 may be a scaled negative of the image desired to be formed on the semiconductor wafer. For a typical chrome on glass (“CoG”) or binary photomask, the substantially transparent substrate 2 is comprised of quartz. The opaque material 4 is comprised of chromium (“Cr”) and the AR material is comprised of chromium oxide (“CrO”).
[0004] A binary photomask used in the production of semiconductor devices is formed from a “blank” photomask. As shown in FIG. 1A , a prior art blank photomask 1 is commonly comprised of at least four layers. The first layer 2 is a substantially transparent substrate, such as quartz, commonly referred to as the substrate. The next layer above the substantially transparent layer 2 is an opaque layer 4 , which is comprised of Cr in the case of a typical CoG photomasks. Thereafter, although not always necessary, there may be an AR layer 6 integral to the opaque layer, which in the case of CoG photomasks is comprised of CrO. A layer of photosensitive resist material 8 resides as the top layer. In the case of CoG photomasks, the photosensitive resist material 8 is typically a hydrocarbon polymer, the various compositions and thicknesses of which are well known in the art. Other layers may also be present for alternative reasons, as is described, for example, in U.S. Pat. No. 6,472,107. Similarly, other materials may be used as is well known in the art.
[0005] The desired pattern of opaque material to be created on the photomask may be defined by an electronic data file loaded into an exposure system which typically scans an electron beam (E beam) or laser beam in a raster fashion across the blank photomask. One such example of a raster scan exposure system is described in U.S. Pat. No. 3,900,737. Other imaging systems can be used that do not use raster scanning, such as shaped vector tools. As the E beam or laser beam is scanned across the blank photomask, the exposure system directs the E beam or laser beam at addressable locations on the photomask as defined by the electronic data file. In the case of a positive photoresist, the areas that are exposed to the E beam or laser beam become soluble, while the unexposed portions remain insoluble. In the case of a negative photoresist, the unexposed areas become soluble, while the exposed portions remain insoluble. As shown in FIG. 1B , after the exposure system has scanned the desired image onto the photosensitive resist material, the soluble photosensitive resist is removed by means well known in the art, and the insoluble photosensitive resist material 8 a remains adhered to the next layer (e.g., the AR layer 6 ).
[0006] After undergoing the foregoing photolithographic process, as illustrated in FIG. 1C , the exposed layer of AR material 6 and the underlying layer of opaque material 4 are no longer covered by the photosensitive resist material 8 a and are removed by a well known etch process. Only the portions of the layer of AR material 6 a and the layer of opaque material 4 a residing beneath the remaining photosensitive resist material 8 a remain affixed to the substantially transparent substrate 2 . This initial or base etching may be accomplished by either a wet etching or dry etch process, both of which are well known in the art.
[0007] Another type of photomask used for transferring images to a semiconductor wafer is commonly referred to as a phaseshift photomask. Phaseshift photomasks are generally preferred over binary photomasks when the design to be transferred to the semiconductor wafer includes smaller, tightly packed feature sizes which are below the resolution capabilities of optical equipment being used. Phaseshift photomasks are engineered to be 180 degrees out of phase with light transmitted through etched areas on the photomask so that the light transmitted through the openings in the photomask is equal in amplitude.
[0008] One type of phaseshift photomask is commonly referred to as an embedded attenuated phaseshift mask (EAPSM). Other types of phaseshift masks are also known, and the teachings of the present invention may be equally applied thereto. As shown in FIG. 2A , a typical blank EAPSM 31 may be comprised of four layers. The first layer is a typically a substantially transparent material 33 (such as quartz, for example) and is commonly referred to as a substrate. The next layer is typically an embedded phaseshifting material (“PSM layer”) 35 , such as molybdenum silicide (MoSi), tantalum silicon nitride (TaSiN), titanium silicon nitride (TiSiN), zirconium silicon oxide (ZrSiO), or other known phase materials. The next layer is typically an opaque material 37 , such as chromium, which may optionally include an anti reflective coating such as chromium oxynitride (CrON). The top layer is a photosensitive resist material 39 , as is well known in the art.
[0009] The method for processing a conventional EAPSM is now described. As with binary photomasks, the desired pattern of the opaque material to be created on the EAPSM is typically scanned by an electron beam (E beam) or laser beam in a raster or vector fashion across a blank EAPSM 31 . As the E beam or laser beam is scanned across the blank EAPSM 31 , the exposure system directs the E beam or laser beam at addressable locations on the EAPSM. In the case of a positive photoresist material, the areas that are exposed to the E beam or laser beam become soluble, while the unexposed portions remain insoluble. In the case of a negative photoresist, the unexposed areas become soluble, while the exposed portions remain insoluble.
[0010] As is done with binary photomasks and as shown in FIG. 2B , after the exposure system has scanned the desired image onto the photosensitive resist material 39 , the soluble photosensitive resist material is removed by means well known in the art, and the insoluble photosensitive resist material 39 a remains adhered to the opaque material 37 . Thus, the pattern to be formed on the EAPSM is formed by the remaining photosensitive resist material 39 a.
[0011] The pattern is then transferred from the remaining photosensitive resist material 39 a to the opaque layer 37 and PSM layer 35 via well known etching techniques, such as plasma assisted etch described above, by etching away the portions of the opaque layer and PSM layer not covered by the remaining photoresist. After etching is completed, the remaining photoresist material is stripped or removed as shown in FIG. 2C . Other processing steps, such as partial or complete etching of the opaque layer 37 a , may be further performed to complete the fabrication of the phaseshift photomask.
[0012] Photomasks are used in the semiconductor industry to transfer micro scale images defining a semiconductor circuit onto a silicon or gallium arsenide substrate or wafer and the like. To create an image on a semiconductor wafer, the photomask is interposed between the semiconductor wafer, which includes a layer of photosensitive material, and a stepper, which houses an energy source, such as a lamp or a laser. The energy generated by the stepper passes through the transparent portions of the substantially transparent substrate not covered by the opaque material (and, if utilized, the anti reflective and/or phaseshift material) and causes a reaction in the photosensitive material on the semiconductor wafer. Energy from the stepper is prevented from passing through the opaque portions of the photomask. As with the manufacture of photomasks, when the photosensitive material is exposed to light it will react. Thereafter, the soluble photosensitive material is removed using processes well known in the prior art. The semiconductor wafer is then etched in a manner similar to that described above. After further processing, a semiconductor product is formed.
[0013] As semiconductor chip features become exponentially smaller and the number of transistors per device become exponentially larger, large burdens have been placed on lithography processes. Resolution of anything smaller than a wavelength of exposure radiation is generally quite difficult, and pattern fidelity can deteriorate dramatically in sub-wavelength lithography. The resulting semiconductor features may deviate significantly in size and shape from the ideal pattern drawn from the circuit designer. This will decrease process yield and increase cost of the overall photomask manufacturing process.
[0014] The semiconductor industry is driven by a desire to lessen processing time and increasing process yield while maintaining or even reducing current costs. In particular, regarding lithograpy techniques using photomasks, the semiconductor industry has attempted to reduce process errors to increase yield by compensating for these process errors in the photomasks themselves. For example, when an image is transferred to a wafer by a 4× stepper tool using a photomask with a critical dimension (CD) of 100 nm, the resulting device layer on the wafer may have a line width of 28 nm. Accordingly, the semiconductor manufacturer will often request that the CD of the photomask be adjusted (or “biased”) so that, when the photomask pattern is developed on the semiconductor wafer, the resulting product will have the desired line width of 25 nm instead of 28 nm.
[0015] As a further example, U.S. Patent Application Publication No. 2003/0134205 (“the '205 application”) discloses a process for manufacturing a photomask in which, for each pitch within a semiconductor design, a bias needed at the pitch that maximizes a common process window for all the pitches is calculated based on the given critical dimension (CD) of the mask design. The '205 application combines this biasing with optical proximity correction to appropriately modify the original layout of the photomask. However, techniques such as that disclosed in the '205 application are costly and increase turn-around time due to the required inspection steps and correction analysis.
[0016] Other techniques have been adopted to decrease cost of the photomask manufacturing process, which do not relate directly to reducing process errors or increasing yield. Such techniques often involve using multiple mask patterns on a common reticle or plate. For example, U.S. Pat. No. 6,421,111 discloses a multiple image reticle including a two dimensional array of spaced images, which obviates the need for rotation of the reticle to expose various levels of circuitry on a semiconductor wafer.
[0017] Similarly, U.S. Patent Application Publication No. 2004/0072083 discloses a photomask including a plurality of mask patterns, each used in an associated photolithography step and corresponding to an associated semiconductor layer, where the mask patterns are arranged so that the photomask is always used oriented in substantially the same direction.
[0018] Finally, U.S. Pat. No. 5,604,059 discloses a mask structure including a plurality of duplicating first device patterns and a plurality of duplicating second device patterns. The first device patterns are used to expose a first part of a semiconductor pattern and the second device patterns are used to expose a second part of the semiconductor pattern over the exposed first part.
[0019] In none of the prior art references is there disclosed the use of single photomask reticle having multiple versions of the same mask pattern, where different biasing is used.
[0020] It is an object of the present invention to provide a reticle that increases process yield and decreases turn-around time by compensating for process errors.
[0021] It is a further object of the present invention to provide an improved reticle which has multiple versions of the same mask pattern with different biasing.
[0022] Other objects and advantages of the present invention will become apparent from the following description.
SUMMARY OF THE INVENTION
[0023] It has now been found that the above and related objects of the present invention are obtained in the form of several related aspects, including providing a single reticle having multiple versions of the same mask pattern with different biasing.
[0024] A method of forming a semiconductor layer of a semiconductor device according to an exemplary embodiment of the invention includes interposing a reticle between an energy source and a semiconductor wafer, the reticle including at least two duplicate mask patterns each having a different bias, and passing energy through an opening in a shutter and through one of the at least two duplicate mask patterns using the energy source to form an image on the semiconductor wafer. The one of the at least two duplicate mask patterns is chosen based on a required bias. The at least two duplicate mask patterns are disposed in a side by side relationship to one another and extend parallel to the shutter opening.
[0025] A method of forming a semiconductor layer of a semiconductor device according to another exemplary embodiment of the invention includes interposing a reticle between an energy source and a semiconductor wafer, the reticle including at least two duplicate mask patterns each having a different bias, and passing energy through an opening in a shutter and through one of the at least two duplicate mask patterns using the energy source to form an image on the semiconductor wafer. The one of the at least two duplicate mask patterns is chosen based on a required bias. The at least two duplicate mask patterns are disposed in a side by side relationship to one another and extend transverse to the shutter opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The above and related objects, features and advantages of the present invention will be more fully understood by reference to the following, detailed description of the preferred, albeit illustrative, embodiment of the present invention when taken in conjunction with the accompanying figures, wherein:
[0027] FIGS. 1A-1C are vertical sectional views showing various steps of a method of forming a conventional photomask;
[0028] FIGS. 2A-2C are vertical sectional views showing various steps of a method of forming another conventional photomask;
[0029] FIG. 3 is a plan view of a conventional mask pattern formed on a reticle plate;
[0030] FIG. 4 is a plan view of multiple duplicate mask patterns having different biases formed on a reticle according to an exemplary embodiment of the present invention;
[0031] FIG. 5 is a plan view of multiple duplicate mask patterns having different biases formed on a reticle according to another exemplary embodiment of the present invention;
[0032] FIGS. 6A-6D are vertical sectional views showing various steps of a method of manufacturing a reticle having multiple duplicate mask patterns with different biases according to an exemplary embodiment of the invention;
[0033] FIG. 7A is a plan view of a shuttle plane over a reticle having multiple duplicate mask patterns with different biases according to an exemplary embodiment of the invention; and
[0034] FIG. 7B is a plan view of a shuttle plane over a reticle having multiple duplicate mask patterns with different biases where the reticle is rotated 90° with respect to the shuttle plane according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The present invention generally relates to the use of multiple copies of the same mask pattern on a reticle using different biases, e.g., +5 nm, 0 nm, and −5 nm. The invention is equally applicable to different ranges and number of copies, as long as two or more copies have different biases on the same photomask. This example would allow a photomask customer/semiconductor manufacturer to choose three (or more) alternative masks patterns depending on the biasing that is appropriate for the particular stepper equipment for which the reticle is to be used. In essence, multiple field biases offer the end user a measure of “tuning” for their imaging systems.
[0036] In various exemplary embodiments of the invention, multiple mask patterns are formed on a reticle plate. Each mask pattern is duplicated any number of times on the plate, with each duplicate mask pattern having a different bias. For example, a first mask pattern on the plate can have a bias of 0 nm, a duplicate second mask pattern can be formed along side the first mask pattern with a bias of +5 nm, and a duplicate third mask pattern can be formed along side the first mask pattern with a bias of −5 nm. The number and location of the various patterns relative to each other and the relative biases are provided merely as an illustrative example and are not intended to limit the scope of the present invention. Thus, each mask pattern can have any suitable bias that satisfies process parameters required by the customer. By way of illustration, suitable biases may be (−10 nm, 0 nm, +10 nm), (−15 nm, 0 nm, +15 nm) and (−20 nm, 0 nm, +20 nm). The various exemplary embodiments of the invention are not restricted to 2-3 duplicates of a single pattern, and any number of duplicate patterns having different biases that can fit on a single reticle can be implemented. Further, the bias does not have to be restricted to a plus bias and a negative bias disposed around a central zero bias, but can be one sided (e.g., 0 nm, +5 nm, +10 nm), or asymmetric (e.g., −5 nm, 0 nm, +5 nm, +10 nm) and can be any incremental value (e.g., +1 nm, +2 nm or −7.5 nm, +2.5 nm, +12.5 nm).
[0037] Further, in various exemplary embodiments, the duplicate reticle mask patterns can be laid out on the reticle plate in any suitable manner. For example, a first group of duplicate mask patterns can be formed on the plate along with a second group of duplicate mask patterns, so that each layer of the semiconductor device associated with a duplicate mask pattern can be formed using multiple biases. Further, the duplicate mask patterns having the different biases can be formed on the same reticle with mask patterns that are not formed in duplicate. In this case, preferably only important and time sensitive masks would be formed multiple times with different biases, and other masks that are not as crucial would not be formed in duplicate. Of course, the application of the present invention is not intended to be limited to only important and time sensitive masks. Further, a first group of duplicate mask patterns can be formed on the plate along with a second group of duplicate mask patterns, with the first group being oriented in a first direction and the second group being oriented in a second direction. Similarly, any number of groups of one or more mask patterns that can fit on the reticle can be used, with any appropriate combination or orientation as long as at least one group has at least two members with different biases.
[0038] FIGS. 3 and 4 are provided to explain the general concept of various exemplary embodiments of the present invention. FIG. 3 illustrates a conventional mask pattern 110 formed on a reticle 100 . The mask pattern 110 is biased 0 nm, i.e., not biased, so that the exposure process to form a semiconductor layer using the reticle 1 is susceptible to process errors. For example, the mean to nominal specification of the semiconductor layer formed using the reticle 100 may be +10 nm due to process errors. Any “non-repairable” defect in the writing area of the reticle will result in a repeat of the value-added steps of the reticle manufacturing process, making them non-valued added cost adders.
[0039] FIG. 4 illustrates an example of multiple mask patterns 210 , 220 and 230 formed on a reticle 200 according to an exemplary embodiment of the present invention. In the present embodiment, the reticle 200 includes three duplicate mask patterns having different biases. However, any number of duplicate mask patterns can be formed depending on the overall area of the reticle and the capabilities of the stepper used to expose the semiconductor device layers. The multiple mask patterns include a first mask pattern 210 , a second mask pattern 220 and a third mask pattern 230 . The first mask pattern 210 is formed in the middle region of the reticle 200 , the second mask pattern 220 is formed adjacent to the first mask pattern 210 at one side region of the reticle 200 , and the third mask pattern 230 is formed adjacent to the first mask pattern 210 at another side region of the reticle 200 . The first, second and third mask patterns 210 , 220 and 230 are duplicate mask patterns that can be used to form the same semiconductor layer, each having a different bias. The appropriate biasing of each duplicate mask pattern 210 , 220 and 230 is based on customer latitude. For example, if the mean to nominal specification is +10 nm, the appropriate biasing may be 0 nm for the first photomask pattern 210 , +10 nm for the second photomask pattern 220 and −10 nm for the third photomask pattern 230 . Thus, the customer can choose from the three mask patterns 210 , 220 and 230 the appropriately biased mask pattern that compensates for the process errors that occur during the semiconductor device fabrication steps. The choice of which photomask pattern has which bias is not a critical aspect of the present invention, such that any suitable order may be chosen. Other amounts of biasing may also be selected within the scope of the present invention.
[0040] The reticle 200 illustrated in FIG. 4 affords the customer greater flexibility regarding optimization of the photolithography process results. As an example, the customer may choose one of the mask patterns that compensates for manufacturing tendencies, but for some reason results in a single defect killer. The customer then has two other mask patterns to choose from that avoids the killer defect, and which at the same time provides appropriate biasing within manufacturing tolerances. The mask pattern that avoids killer defects can be used in conjunction with appropriate biasing of the stepper equipment to optimize the photolithography process.
[0041] FIG. 5 illustrates multiple mask patterns formed on a reticle according to another exemplary embodiment of the present invention. In the present embodiment, the reticle 300 includes two sets of three duplicate mask patterns, each duplicate pattern in each set having a different bias. As shown in FIG. 5 , the reticle 300 includes a first set 310 of mask patterns and a second set 320 of mask patterns. The first set 310 of mask patterns includes a first mask pattern 330 , a second mask pattern 340 and a third mask pattern 350 . The second set 320 of mask patterns includes a fourth mask pattern 360 , a fifth mask pattern 370 and a sixth mask pattern 380 . The first mask pattern 330 is formed in the middle region of the reticle 300 , the second mask pattern 340 is formed adjacent to the first mask pattern 330 at one side region of the reticle 300 , and the third mask pattern 350 is formed adjacent to the first mask pattern 330 at another side region of the reticle 300 . Similarly, the fourth mask pattern 370 is formed in the middle region of the reticle 300 , the fifth mask pattern 380 is formed adjacent to the fourth mask pattern 370 at one side region of the reticle 300 , and the sixth mask pattern 380 is formed adjacent to the fourth mask pattern 360 at another side region of the reticle 300 . The first, second and third mask patterns 330 , 340 and 350 in the first set 310 of mask patterns are duplicate mask patterns that can be used to form the same semiconductor layer, where each of the first, second and third mask patterns 330 , 340 and 350 has a different bias. Similarly, the fourth, fifth and sixth mask patterns 360 , 370 and 380 in the second set 320 of mask patterns are duplicate mask patterns that can be used to form another semiconductor layer, where each of the fourth, fifth and sixth mask patterns 360 , 370 and 380 has a different bias. Of course, the present invention is not limited to two sets of duplicate mask patterns having different biases. Any number of sets can be disposed on the reticle as long as each set contains at least two duplicate mask patterns having different biases. Preferably, each set would contain at least three duplicate mask patterns, where one pattern has no bias, one pattern has negative bias (e.g., −5 nm, −10 nm, −15 nm, −20 nm, etc.) and one pattern has positive bias (e.g., +5 nm, +10 nm, +15 nm, +20 nm, etc.).
[0042] FIGS. 6A-6D show various steps of a method of manufacturing a reticle having multiple duplicate mask patterns with different biases according to an exemplary embodiment of the invention. As shown in FIG. 6A , blank reticle 400 is comprised of a transparent material layer 410 , an opaque layer 420 and a photosensitive resist material layer 430 . The transparent material layer 410 is preferably made of quartz. The opaque layer 420 is formed on the transparent material layer 410 and is formed of a layer of Cr opaque material 422 and an integral layer of CrO AR material 424 formed on top of the layer of Cr opaque material 422 . The layer of photosensitive resist material 430 resides on top of the opaque material layer 420 . The photosensitive resist material 430 is typically a hydrocarbon polymer, the various compositions and thicknesses of which are well known in the art. The desired pattern of opaque material 420 to be created on the reticle 400 may be defined by an electronic data file loaded into an exposure system which typically scans an electron beam (E-beam) or laser beam in a raster fashion across the blank reticle. In exemplary embodiments of the invention, the data for each of the layers or mask patterns on the reticle can be duplicated and biased to produce multiple duplicate mask patterns having different biases in the final reticle 400 . As the E-beam or laser beam is scanned across the blank reticle, the exposure system directs the E-beam or laser beam at addressable locations on the reticle as defined by the electronic data file. The areas of the photosensitive resist material that are exposed to the E-beam or laser beam become soluble while the unexposed portions remain insoluble. As shown in FIG. 6B , after the exposure system has scanned the desired image onto the photosensitive resist material, the soluble photosensitive resist is removed by means well known in the art, and the unexposed, insoluble photosensitive resist material 430 remains adhered to the CrO AR material 424 . Accordingly, the remaining photosensitive resist material 430 forms patterns including patterns 432 that duplicate with different biasing.
[0043] As illustrated in FIG. 6C , the exposed opaque material layer 420 no longer covered by the photosensitive resist material 430 in the reticle 400 is removed by a well known etching process, and only the portions of the opaque material layer 420 residing beneath the remaining photosensitive resist material 430 remain affixed to quartz substrate 410 . Accordingly, the duplicating multiple patterns 432 with different biases in the photosensitive resist material 430 are transferred to the opaque material layer 420 to form corresponding multiple duplicating mask patterns 422 in the opaque material layer 420 . This initial or base etching may be accomplished by either a wet-etching or dry-etching process both of which are well known in the art.
[0044] As shown in FIG. 6D , after the etching process is completed the photosensitive resist material 430 in the reticle 400 is stripped away by a process well known in the art.
[0045] In the various exemplary embodiments of the present invention in which a reticle having multiple duplicate masks with different biases is used to process a semiconductor layer, various issues may need to be addressed depending on the particular stepper being used to expose the semiconductor layer through the reticle. For example, one issue is that radial error may dominate uniformity/registration gains related to reduced field size. Another issue is that spherical aberration of the scanner lens may be too large when overlaying smaller fields to larger fields. Still another issue is that the scanner shuttle plane may be too small to adequately cover all the multiple duplicate mask patterns. This issue is illustrated in FIGS. 7A and 7B . FIG. 7A shows a shutter 500 of a scanner concentric to the center line of the reticle plane CL of a reticle 600 having three duplicate mask patterns with different bias. Due to the shutter limitations, the image fields may need to be rotated 90° as shown in FIG. 7B , which would allow for use of any one of the three fields of the reticle 600 .
[0046] Now that the preferred embodiments of the present invention have been shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. For example, the present invention is not limited to CoG photomasks, but also may be applied to other types of binary photomasks. Similarly, the present invention is not limited to EAPSM, but may also apply to other types of phaseshift photomasks, including by way of example, but not limited to, AAPSM (alternating aperture phase shift mask). Furthermore, application of the present invention is not limited to reticles having multiple versions of only one mask pattern with different biases. It could also apply to reticles having multiple versions of multiple mask patterns where each version of these mask patterns have different biases. Further, the inventive concept of multiple duplicate mask patterns having different biases to improve yield is not solely applicable to scanner technology. The concept is applicable to almost any microlithography approach.
[0047] The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A method of forming a semiconductor layer of a semiconductor device including interposing a reticle between an energy source and a semiconductor wafer, the reticle including at least two duplicate mask patterns each having a different bias, and passing energy through an opening in a shutter and through one of the at least two duplicate mask patterns using the energy source to form an image on the semiconductor wafer. The one of the at least two duplicate mask patterns is chosen based on a required bias. The at least two duplicate mask patterns are disposed in a side by side relationship to one another and extend parallel or transverse to the shutter opening.
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CROSS REFERENCE AND RELATED APPLICATION
This application is a continuation-in-part of Ser. No. 08/706,988 now U.S. Pat. No. 5,761,071 filed Jul. 27, 1996, and entitled "Browser Kiosk System", still pending.
FIELD OF THE INVENTION
The invention relates to self service browser and more specifically, to a device permitting users to access and display documents and electronic information in a user-friendly, tamper-resistant kiosk environment.
BACKGROUND OF THE INVENTION
A kiosk is essentially a self-service system, i.e., a computer system placed inside a box as illustrated in FIG. 1 or a desktop computer system for use in providing information and/or performing transactions (e.g., dispensing money as done by automated teller machines). A kiosk often employs a touch screen as the input device since touch screens are easy to use and immediately intuitive for almost all users; however, other types of pointing devices such as a mouse may also be used. With the advancements achieved by technology in recent years, the use of kiosks has become an economical and efficient alternative to the traditional form of providing interactive information and performing transactions; i.e., human-to-human interaction. Furthermore, kiosks are very effective in marketing and selling services and products since they may be programmed to provide information utilizing all of the resources available on multimedia; e.g., still graphics, sound, animations and full-motion video. This is why more and more government agencies and private business concerns are installing kiosks to better run and better market themselves. It has been estimated that by 1998, the number of kiosks installed in the United States will reach approximately 500,000 units.
Application programs exist which access and display many different types of electronic information, such as a text file, a graphics file, a sound file, a video file and a database item, to name a few. Accessing a file or a document using such software can be as simple as clicking a hyperlink (e.g., a highlighted word showing on a computer monitor screen) using a button on a mouse. A hyperlink, or simply link, is a way to "jump" from one document to another to which the link is connected.
For a kiosk system which is utilized by numerous users, providing access to the world wide web (the web) and/or any other location having browser-displayable documents via the existing graphical user interfaces (GUIs) of the various browsers is not desirable for the following reasons. First, the menu bar, the document title area, etc. not only detract from the appearance of the GUI, but the number of menu choices provided by existing browsers is unwieldy and unnecessary in a kiosk environment where a user is primarily interested in quickly obtaining pertinent information (as an example, Netscape Navigator 2.01 offers 66 menu choices). This is especially the case since many kiosks provide information via touch screens, where a simplified user-friendly interface with a select number of essential buttons is desired.
Second, the menu bar has menu choices which permit a user to alter the settings of the browser. In a kiosk system where uniformity and predictability of use is essential to achieving self-service, having menu choices which permit modification of the desired settings pose significant problems.
Third, a user can access and display any document accessible to the graphical browser, including documents which do not further the goal of the government agency or the business which has established the kiosk to provide interactive information pertaining to the government agency or the business.
And fourth, a user may perform a system function which is not desired by the kiosk provider. For example, a user of the browser running on Microsoft Windows platform may press Ctrl-Alt-Del keys to restart or crash the system. Unless prevented, the system may cease to function as a self-service kiosk device.
It would, therefore, be desirable to provide tamper-resistant, browser software which provides a visually pleasing, user-friendly, user interface suitable for use in a self-service kiosk.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a self-service computer having a monitor which can access and display documents using browser software, and including software for providing at least one image which includes controls for the browser software.
Another object of the invention is to provide the self-service computer where the browser software is either an Active X control or Netscape source-code.
A further object of the invention is to provide the self-service computer where the browser software has access to the world wide web.
Yet another object of the invention is to provide a self-service computer of the above character which includes a microphone.
Yet a further object of the invention is to provide a self-service computer of the above character which includes a serial input device.
These and other objects are achieved by a self-service computer which includes a monitor, a microprocessor electrically coupled to the monitor for controlling what is displayed on the screen, browser software executable on the microprocessor for accessing and displaying documents on the monitor in response to user input, and at least one image positioned for display on the screen and permitting control of but resisting tampering with the browser software.
A microphone, speaker, camera and serial input device can be added to the kiosk to extend its functionality. The serial input device can be provided as a card swipe reader, a bar code reader, a smart card reader, a personal identification verifier and combinations of these. Examples of personal identification verifiers include palm print readers, retina scanners, voice analyzers, finger print scanners, DNA testers, and the like.
The self-service computer can also include a security control software which is programmed to disable operating system functions available to the user of the self-service computer to resist tampering with operation of the self-service computer.
The browser software, the image and the security control software can be remotely updated in a network setting.
The invention and its particular features and advantages will become more apparent from the following detailed description considered with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a kiosk system of the present invention;
FIG. 2 shows the monitor of the kiosk of FIG. 1 having a first window for displaying accessed documents and an image including browser controls;
FIG. 3 is a flowchart showing the operation of a GUI control software in the kiosk of FIG. 1; and
FIG. 4 is a flowchart showing the operation of a security control software in the kiosk of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows one example of a kiosk system 20 of the present invention comprising a casing 21 with a storage compartment 23 which is normally inaccessible to users of the kiosk system 20 by means of a padlock or some other locking device (not shown). It is understood that a kiosk in accordance with the invention could also be provided as a desktop computer or some other self-service system. The storage compartment 23 stores a keyboard 22 and a mouse 24 which are used by the kiosk system 20 provider/operator to set the system settings.
The kiosk system 20 further comprises a monitor 25 having a display screen 27, a microprocessor 30 electrically coupled to the monitor 25 and memory 32. Memory 32, which may include RAM, ROM, fixed disk and/or other types of data storage, stores various programs for execution by the microprocessor 30, including browser software and an operating system. Note that the microprocessor 30 includes a telecommunication link and associated hardware, such as a modem, router or a network adapter 31. Telecommunication link may also be provided in a wireless manner; e.g., using an antenna and a cellular phone. Other hardware components of the kiosk system 20 include a microphone 19, a speaker 21, a camera 23 and a serial input device 29.
As shown in FIG. 1, the display screen 27 of the kiosk system 20 of the present invention is illustrated as a touch screen; however, it is understood that any user input or pointing device (e.g. mouse) will suffice, especially where kiosk 20 is a desktop computer not mounted within casing 21. After the keyboard 22 and the mouse 24 have been used by the kiosk system 20 provider/operator to set the system settings, they are locked in the storage compartment 23 so that users of the kiosk system 20 cannot use the keyboard 22 and the mouse 24 to tamper with the system settings. In desktop computer kiosk systems where the keyboard 22 and the mouse 24 are accessible to users, security control software discussed below is utilized to render the browser software tamper-resistant for reliable self-service. Even without the keyboard 22 and the mouse 24, users can interact with the kiosk system 20 by touching appropriate selections showing on the touch screen. Furthermore, it is also possible to provide the keyboard 22 and/or the mouse 24 along with the touch screen. These different possibilities will be described in more detail hereinbelow.
In FIG. 2, a screen display from monitor 25 is shown. A document viewing window 14 is generated by the browser software for display of accessed software. At least a first image 40 shown as a separate window includes controls for operating the browser software. It is understood that image 40 may overlap some or none of document viewing window 14.
By "browser software" is meant any program for accessing and displaying documents or files. Browser software may include, but is not limited to Netscape source code and Active X controls.
Image 40 has a Go Back button image 46, a Print button image 47, a Main Menu button image 48, a Scroll Up button image 49, a Scroll Down button image 50, a Scroll Left button image 52 and a Scroll Right button image 54. As will be described hereinbelow, the selection of these button images, along with the size and placement (on the touch screen 27), are specified by the provider/operator of the kiosk system 20. Furthermore, other than the Main Menu function (which simply returns the system 20 to the main menu page), the function corresponding to each button image is that which can be recognized and performed by the browser software. In terms of the operation of these button images on the touch screen 27, there is employed an enhanced mouse driver which permits the microprocessor 30 in conjunction with the touch screen 27 to detect whether the user of the kiosk system 20 has touched one of the button images 46, 47, 48, 49, 50, 52 or 54. Depending upon the button image touched (other than Main Menu 48), the browser is instructed by the GUI control software to perform the corresponding function. Since the operation of the enhanced mouse driver for a touch screen is known in the art, no further description about this will be undertaken herein. The operation of the GUI control software is illustrated in the flowchart of FIG. 3.
In block 100, a test is conducted to see if the correct password has been entered for accessing the GUI control software. This test is conducted by an appropriate daemon, which as known, is a background process which spends most of the time "sleeping" until there is a triggering action that requires the daemon to carry out a specific task. If the correct password has been entered, the kiosk system 20 provider/operator is permitted to select the windows and bitmap image 40 to be displayed on the touch screen 27 in block 104. The provider/operator of the kiosk system 20 is further permitted in block 106 to select functions to be performed by the browser. The functions available for selection are each stored in memory 32 as part of a predetermined set of functions capable of being recognized and performed by the browser (can therefore include all the menu choices available from the menu bar 2). For example, for Netscape Navigator, the kiosk system provider/operator may select the Bookmarks function in block 106. Each function selected in block 106 is represented on the touch screen 27 as a button image.
The placement and size of each button on the GUI is left to the kiosk system provider/operator in block 108, the placement and size being specified either by providing bitmap coordinates or by window resizing and dragging techniques familiar to Macintosh and Windows users. Finally, in block 110, the window and bitmap images selected to be displayed in block 104, as well as the buttons from block 108, are positioned and displayed on the touch screen 27.
The GUI control software is stored in memory 32. A security control software module may be an enhancement to or a separate program from the GUI control software. The security control software, which is also stored in memory 32, permits the kiosk system 20 provider/operator to limit access of the browser to uniform resource locators (URLs) specified by the provider. Furthermore, in another embodiment of the kiosk system where the keyboard 22 and/or the mouse 24 are provided for use by the kiosk user, the security control software also permits the kiosk system provider/operator to limit the system functions available to the user. The complete operation of the security control software is illustrated in the flowchart of FIG. 4.
In block 120, a test is conducted to see if the correct password has been entered for accessing the security control software. This test is similar to the test conducted by the appropriate daemon in block 100. In fact, if the security control software is part of the GUI control software, then the same password may access both software modules. If the correct password has been entered, the security control software is then accessed and in block 122, the kiosk system 20 provider/operator is given the option of restricting the browser's access to URL or URLs specified by the provider/operator. If the provider/operator of the kiosk system 20 has specified the URLs accessible to the browser, these URLs are stored in memory 32. The browser may be limited to these specified URLs by, for example, listing the URLs under a button for Bookmarks/Favorites in currently available commercial browsers.
In block 124, the provider of the kiosk system is given the option of limiting the operating system functions (e.g., Window resizing) available to the user of the kiosk system. This is done by providing a predetermined set of operating system functions from which the kiosk system provider can select those system functions to be disabled. Finally, in block 126, the kiosk system provider is given the option of counting the occurrence of certain preselected events, such as starting the browser, printing a document, accessing a particular URL, etc. Logging this data may be desired for marketing reasons, gauging the effectiveness of the interactive information provided by the kiosk system 20, or some other reason. The collected data is stored in memory 32.
Once the settings for the browser kiosk system software, an example of which was developed by the inventors and is currently available commercially as NetKey™ have been set, then the kiosk system 20 of the present invention is ready for use by the public. The GUI control software settings, the security control software settings and the browser settings of the kiosk system 20 may be remotely modified. For example, if the kiosk system 20 is connected to a transmission control protocol/internet protocol (TCP/IP) network, remote modification can be performed using file transfer protocol (FTP). FTP server software executing on the microprocessor 30, which may be an additional module of the NetKey™ software, and FTP client software running on a remote computer can be used to transfer files from the remote host over a network to the kiosk system 20. As another example, if kiosk 20 is connected to the Microsoft network, the kiosk hard drive may be shared with an administrator enabling remote updates. In either case, the update is made by closing the executable and replacing it with a new version having different settings and/or by replacing an .ini file or the like associated with the executable to be modified.
A suspend daemon, which may be provided as an enhancement to NetKey™, running in the background shuts down the GUI control software and/or the security control software and/or the browser software when a SUSPEND file is copied to a specified directory on the kiosk system 20. After settings for the GUI control software and/or the security control software and/or the browser software have been modified by copying over the executable with new settings, a restart daemon running in the background starts the modified software when a RESTART file is copied to a specified directory on the kiosk system 20.
Note that an attract loop stored in memory 32 and executable by the NetKey™ software may be provided to enhance the features of the kiosk system 20. An attract loop is simply a graphic or video which is utilized to draw people to the kiosk system 20 or to keep a user of a kiosk "attracted" to the screen. The appearance of the attract loop on the display screen 27 is preferably controlled by the time-out function, such that when there is no user input for a specified period of time, the attract loop appears on the screen 27.
Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art.
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The invention provides a self-service computer having a monitor which can access and display documents using browser software, and including software for providing at least one image which includes controls for the browser software. A microphone, speaker, camera and serial input device can be added to the kiosk to extend its functionality. The serial input device can be provided as a card swipe reader, a bar code reader, a smart card reader, a personal identification verifier and combinations of these. Examples of personal identification verifiers include palm print readers, retina scanners, voice analyzers, finger print scanners, DNA testers, and the like.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/527,213, filed Jun. 19, 2012, which is a continuation of U.S. application Ser. No. 11/634,343, filed Dec. 5, 2006, now U.S. Pat. No. 8,226,975, which claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 60/748,468, filed Dec. 8, 2005, each of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] According to the World Health Organization, respiratory diseases are the number one cause of world-wide mortality, with at least 20% of the world's population afflicted. Over 25 million Americans have chronic lung disease, making it the number one disabler of American workers (>$50B/yr), and the number three cause of mortality.
[0003] Currently, most infections are treated with oral or injectable antiinfectives, even when the pathogen enters through the respiratory tract. Often the antiinfective has poor penetration into the lung, and may be dose-limited due to systemic side-effects. Many of these issues can be overcome by local delivery of the antiinfective to the lungs of patients via inhalation. For example, inhaled tobramycin (TOBI®, Chiron Corp, Emeryville, Calif.), is a nebulized form of tobramycin, that has been shown to have improved efficacy and reduced nephro- and oto-toxicity relative to injectable aminoglycosides. Unfortunately, rapid absorption of the drug necessitates that the drug product be administered twice daily over a period of ca., 20 min per administration. For pediatrics and young adults with cystic fibrosis this treatment regimen can be taxing, especially when one takes into account the fact that these patients are on multiple time-consuming therapies. Any savings in terms of treatment times would be welcomed, and would likely lead to improvements in patient compliance. Achieving improved compliance with other patient populations (e.g., chronic obstructive pulmonary disease (COPD), acute bronchial exacerbations of chronic bronchitis) will be critically dependent on the convenience and efficacy of the treatment. Hence, it is an object of the present invention to improve patient compliance by providing formulations with sustained activity in the lungs. Sustained release formulations of antiinfectives are achieved by encapsulating the antiinfective in a liposome. Improving pulmonary targeting with sustained release formulations would further improve the therapeutic index by increasing local concentrations of drug and reducing systemic exposure. Improvements in targeting are also expected to reduce dose requirements.
[0004] Achieving sustained release of drugs in the lung is a difficult task, given the multiple clearance mechanisms that act in concert to rapidly remove inhaled drugs from the lung. These clearance methods include: (a) rapid clearance from the conducting airways over a period of hours by the mucociliary escalator; (b) clearance of particulates from the deep lung by alveolar macrophages; (c) degradation of the therapeutic by pulmonary enzymes, and; (d) rapid absorption of small molecule drugs into the systemic circulation. Absorption of small molecule drugs has been shown to be nearly quantitative, with an absorption time for hydrophilic small molecules of about 1 hr, and an absorption time for lipophilic drugs of about 1 min.
[0005] For TOBI® the absorption half-life from the lung is on the order of 1.5 hr. High initial peak concentrations of drug can lead to adaptive resistance, while a substantial time with levels below or near the effective minimum inhibitory concentration (MIC), may lead to selection of resistant phenotypes. It is hypothesized that keeping the level of antiinfective above the MIC for an extended period of time (i.e., eliminating sub-therapeutic trough levels) with a pulmonary sustained release formulation may reduce the potential for development of resistant phenotypes. Hence, it is a further object of the present invention to maintain the ratio of the area under the lung concentration/time curve to the MIC at 24 hr (i.e., the AUIC), not only at an adequate sustained therapeutic level, but above a critical level, so as to reduce the potential for selection of resistant strains.
[0006] It is assumed that only the “free” (un-encapsulated) drug has bactericidal activity. One potential disadvantage of liposomal sustained release formulations is that the encapsulation of drug in the liposomal formulation decreases the concentration of free drug reaching the lung pathogens, drug which is needed to achieve efficient killing of bacteria immediately following administration. Hence, it is further an object of the present invention to provide a formulation that contains sufficient free drug, to be bactericidal immediately following administration.
[0007] The disclosures of the foregoing are incorporated herein by reference in their entirety.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to use lipid-based composition encapsulation to improve the therapeutic effects of antiinfectives administered to an individual via the pulmonary route.
[0009] The subject invention results from the realization that administering a pharmaceutical composition comprising both free and liposome encapsulated antiinfective results in improved treatment of pulmonary infections.
[0010] In one aspect, the present invention relates to a system for treating or providing prophylaxis against a pulmonary infection, wherein the system comprises a pharmaceutical formulation comprising mixtures of free and lipid-based composition encapsulated antiinfective, wherein the amount of free antiinfective is sufficient to provide for immediate bactericidal activity, and the amount of encapsulated antiinfective is sufficient to provide sustained bactericidal activity, and reduce the development of resistant strains of the infectious agent, and an inhalation delivery device.
[0011] The free form of the antiinfective is available to provide a bolus of immediate antimicrobial activity. The slow release of antiinfective from the lipid-based composition following pulmonary administration is analogous to continuous administration of the antiinfective, thereby providing for sustained levels of antiinfective in the lungs. The sustained AUC levels provides prolonged bactericidal activity between administrations. Further, the sustained levels provided by the release of antiinfective from the lipid-based composition is expected to provide improved protection against the development of resistant microbial strains.
[0012] Combinations of free and encapsulated drug can be achieved by: (a) formulation of mixtures of free and encapsulated drug that are stable to the nebulization; (b) formulation of encapsulated drug which leads to burst on nebulization.
[0013] The ratio of free to encapsulated drug is contemplated to be between about 1:100 w:w and about 100:1 w:w, and may be determined by the minimum inhibitory concentration of the infectious agent and the sustained release properties of the formulation. The ratio of free to encapsulated drug can be optimized for a given infectious agent and drug formulation based on known pharmacodynamic targets for bacterial killing and prevention of resistance. Schentag, J. J. J. Chemother. 1999, 11, 426-439.
[0014] In a further embodiment, the present invention relates to the aforementioned system wherein the antiinfective is selected from the group consisting of antibiotic agents, antiviral agents, and antifungal agents. In a further embodiment, the antiinfective is an antibiotic selected from the group consisting of cephalosporins, quinolones, fluoroquinolones, penicillins, beta lactamase inhibitors, carbepenems, monobactams, macrolides, lincosamines, glycopeptides, rifampin, oxazolidonones, tetracyclines, aminoglycosides, streptogramins, and sulfonamides. In a further embodiment, the antiinfective is an aminoglycoside. In a further embodiment the antiinfective is amikacin, gentamicin, or tobramycin.
[0015] In a further embodiment, the lipid-based composition is a liposome. In a further embodiment, the liposome comprises a mixture of unilamellar vesicles and multilamellar vesicles. In a further embodiment, the liposome comprises a phospholipid and a sterol. In a further embodiment, the liposome comprises a phosphatidylcholine and a sterol. In a further embodiment, the liposome comprises dipalmitoylphosphatidylcholine (DPPC) and a sterol. In a further embodiment, the liposome comprises dipalmitoylphosphatidylcholine (DPPC) and cholesterol.
[0016] In a further embodiment, the present invention relates to the aforementioned system wherein the antiinfective is an aminogylcoside and the liposome comprises DPPC and cholesterol. In a further embodiment, the antiinfective is amikacin, the liposome comprises DPPC and cholesterol, and the liposome comprises a mixture of unilamellar vesicles and multilamellar vesicles.
[0017] In a further embodiment, the present invention relates to the aforementioned system, wherein the ratio by weight of free antiiinfective to antiinfective encapsulated in a lipid-based composition is between about 1:100 and about 100:1. In a further embodiment, the ratio by weight is between about 1:10 and about 10:1. In a further embodiment, the ratio by weight is between about 1:2 and about 2:1.
[0018] In another embodiment, the present invention relates to a method for treating or providing prophylaxis against a pulmonary infection in a patient, the method comprising: administering an aerosolized pharmaceutical formulation comprising the antiinfective to the lungs of the patient, wherein the pharmaceutical formulation comprises mixtures of free and lipid-based composition encapsulated antiinfectives, and the amount of free antiinfective is sufficient to provide for bactericidal activity, and the amount of encapsulated antiinfective is sufficient to reduce the development of resistant strains of the infectious agent.
[0019] In a further embodiment, the aforementioned method comprises first determining the minimum inhibitory concentration (MIC) of an antiinfective for inhibiting pulmonary infections, and wherein the amount of free antiinfective is at least 2 times the MIC, preferably greater than 4 times the MIC, and preferably greater than 10 times the MIC of the antiinfective agent, where the MIC is defined as either the minimum inhibitory concentration in the epithelial lining of the lung, or alternatively the minimum inhibitory concentration in the solid tissue of the lung (depending on the nature of the infection).
[0020] In a further embodiment, the present invention relates to the aforementioned method, wherein the aerosolized pharmaceutical formulation is administered at least once per week.
[0000] In a further embodiment, the present invention relates to the aforementioned method, wherein the antiinfective is selected from the group consisting of antibiotic agents, antiviral agents, and antifungal agents. In a further embodiment, the antiinfective is an antibiotic selected from the group consisting of cephalosporins, quinolones, fluoroquinolones, penicillins, beta lactamase inhibitors, carbepenems, monobactams, macrolides, lincosamines, glycopeptides, rifampin, oxazolidonones, tetracyclines, aminoglycosides, streptogramins, and sulfonamides. In a further embodiment, the antiinfective is an aminoglycoside. In a further embodiment, the antiinfective is amikacin, gentamicin, or tobramycin.
[0021] In a further embodiment, the lipid-based composition is a liposome. In a further embodiment, the liposome encapsulated antiinfective comprises a phosphatidylcholine in admixture with a sterol. In a further aspect, the sterol is cholesterol. In a further aspect, the liposome encapsulated antiinfective comprises a mixture of unilamellar vesicles and multilamellar vesicles. In a further aspect, the liposome encapsulated antiinfective comprises a phosphatidylcholine in admixture with cholesterol, and wherein the liposome encapsulated antiinfective comprises a mixture of unilamellar vesicles and multilamellar vesicles.
[0022] The ratio of the area under the lung concentration/time curve to the MIC at 24 hr (i.e., the AUIC) is greater than 25, preferably greater than 100, and preferably greater than 250.
[0023] The therapeutic ratio of free/encapsulated drug and the required nominal dose can be determined with standard pharmacokinetic models, once the efficiency of pulmonary delivery and clearance of the drug product are established with the aerosol delivery device of choice.
[0024] In one aspect, the present invention relates to a method of treating a patient for a pulmonary infection comprising a cycle of treatment with lipid-based composition encapsulated antiinfective to enhance bacterial killing and reduce development of phenotypic resistance, followed by a cycle of no treatment to reduce the development of adaptive resistance. The treatment regimen may be determined by clinical research. In one embodiment, the treatment regime may be an on-cycle treatment for about 7, 14, 21, or 30 days, followed by an off-cycle absence of treatment for about 7, 14, 21, or 30 days.
[0025] In another aspect, the present invention relates to a method for reducing the loss of antiinfective encapsulated in lipid-based compositions upon nebulization comprising administering the antiinfective encapsulated in lipid-based compositions with free antiinfective.
[0026] The systems and methods of the present invention are useful for treating, for example, lung infections in cystic fibrosis patients, chronic obstructive pulmonary disease (COPD), bronchiectasis, acterial pneumonia, and in acute bronchial exacerbations of chronic bronchitis (ABECB). In addition, the technology is useful in the treatment of intracellular infections including Mycobacterium tuberculosis, and inhaled agents of bioterror (e.g., anthrax and tularemia). The technology may also be used as a phophylactic agent to treat opportunistic fungal infections (e.g., aspergillosis) in immunocompromised patients (e.g., organ transplant or AIDS patients).
[0027] With bacteria and other infective agents becoming increasingly resistant to traditional treatments, new and more effective treatments for infective agent related illnesses are needed. The present invention addresses these issues by providing a system comprising a pharmaceutical composition comprising both free and lipid-based composition encapsulated antiinfective and an inhalation device. Formulating the antiinfective as a mixture of free and lipid-based composition encapsulated antiinfective provides several advantages, some of which include: (a) provides for a bolus of free antiinfective for immediate bactericidal activity and a sustained level of antiinfective for prevention of resistance; (b) simplifies the manufacturing process, as less free antiinfective need be removed via diafiltration; and (c) allows for greater antiinfective contents to be achieved in the drug product.
[0028] These embodiments of the present invention, other embodiments, and their features and characteristics, will be apparent from the description, drawings and claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 depicts the plot of lung concentration (μg/ml) as a function of time following nebulization of unencapsulated tobramycin at a nominal dose of 300 mg (TOBI®, Chiron Corp., Emeryville, Calif.), and liposomal amikacin at a nominal dose of 100 mg. Lung concentrations for both drug products are calculated assuming a volume of distribution for aminoglycosides in the lung of 200 ml. The tobramycin curve was determined by pharmacokinetic modeling of the temporal tobramycin plasma concentration curve (Le Brun thesis, 2001).
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0030] For convenience, before further description of the present invention, certain terms employed in the specification, examples and appended claims are collected here. These definitions should be read in light of the remainder of the disclosure and understood as by a person of skill in the art. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by a person of ordinary skill in the art.
[0031] The articles “a” and “an” are used herein to refer to one or to more than one (i.e. to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element.
[0032] The term “antibacterial” is art-recognized and refers to the ability of the compounds of the present invention to prevent, inhibit or destroy the growth of microbes of bacteria.
[0033] The terms “antiinfective” and “antiinfective agent” are used interchangeably throughout the specification to describe a biologically active agent which can kill or inhibit the growth of certain other harmful pathogenic organisms, including but not limited to bacteria, yeasts and fungi, viruses, protozoa or parasites, and which can be administered to living organisms, especially animals such as mammals, particularly humans.
[0034] The term “antimicrobial” is art-recognized and refers to the ability of the compounds of the present invention to prevent, inhibit or destroy the growth of microbes such as bacteria, fungi, protozoa and viruses.
[0035] The term “bioavailable” is art-recognized and refers to a form of the subject invention that allows for it, or a portion of the amount administered, to be absorbed by, incorporated to, or otherwise physiologically available to a subject or patient to whom it is administered.
[0036] The terms “comprise” and “comprising” are used in the inclusive, open sense, meaning that additional elements may be included.
[0037] The term “illness” as used herein refers to any illness caused by or related to infection by an organism.
[0038] The term “including” is used herein to mean “including but not limited to”. “Including” and “including but not limited to” are used interchangeably.
[0039] The term “lipid-based composition” as used herein refers to compositions that primarily comprise lipids. Non-limiting examples of lipid-based compositions may take the form of coated lipid particles, liposomes, emulsions, micelles, and the like.
[0040] The term “mammal” is known in the art, and exemplary mammals include humans, primates, bovines, porcines, canines, felines, and rodents (e.g., mice and rats).
[0041] The term “microbe” is art-recognized and refers to a microscopic organism. In certain embodiments the term microbe is applied to bacteria. In other embodiments the term refers to pathogenic forms of a microscopic organism.
[0042] A “patient,” “subject” or “host” to be treated by the subject method may mean either a human or non-human animal.
[0043] The term “pharmaceutically-acceptable salts” is art-recognized and refers to the relatively non-toxic, inorganic and organic acid addition salts of compounds, including, for example, those contained in compositions of the present invention.
[0044] The term “prodrug” is art-recognized and is intended to encompass compounds which, under physiological conditions, are converted into the antibacterial agents of the present invention. A common method for making a prodrug is to select moieties which are hydrolyzed under physiological conditions to provide the desired compound. In other embodiments, the prodrug is converted by an enzymatic activity of the host animal or the target bacteria.
[0045] The term “treating” is art-recognized and refers to curing as well as ameliorating at least one symptom of any condition or disease.
Lipids
[0046] The lipids used in the pharmaceutical formulations of the present invention can be synthetic, semi-synthetic or naturally-occurring lipids, including phospholipids, tocopherols, sterols, fatty acids, glycoproteins such as albumin, negatively-charged lipids and cationic lipids. In terms of phosholipids, they could include such lipids as egg phosphatidylcholine (EPC), egg phosphatidylglycerol (EPG), egg phosphatidylinositol (EPI), egg phosphatidylserine (EPS), phosphatidylethanolamine (EPE), and phosphatidic acid (EPA); the soya counterparts, soy phosphatidylcholine (SPC); SPG, SPS, SPI, SPE, and SPA; the hydrogenated egg and soya counterparts (e.g., HEPC, HSPC), other phospholipids made up of ester linkages of fatty acids in the 2 and 3 of glycerol positions containing chains of 12 to 26 carbon atoms and different head groups in the I position of glycerol that include choline, glycerol, inositol, serine, ethanolamine, as well as the corresponding phosphatidic acids. The chains on these fatty acids can be saturated or unsaturated, and the phospholipid may be made up of fatty acids of different chain lengths and different degrees of unsaturation. In particular, the compositions of the formulations can include dipalmitoylphosphatidylcholine (DPPC), a major constituent of naturally-occurring lung surfactant. Other examples include dimyristoylphosphatidycholine (DMPC) and dimyristoylphosphatidylglycerol (DMPG) dipalmitoylphosphatidcholine (DPPQ and dipalmitoylphosphatidylglycerol (DPPG) distearoylphosphatidylcholine (DSPQ and distearoylphosphatidylglycerol (DSPG), dioleylphosphatidyl-ethanolarnine (DOPE) and mixed phospholipids like palmitoylstearoylphosphatidyl-choline (PSPC) and palmitoylstearolphosphatidylglycerol (PSPG), and single acylated phospholipids like mono-oleoyl-phosphatidylethanolarnine (MOPE).
[0047] The sterols can include, cholesterol, esters of cholesterol including cholesterol hemi-succinate, salts of cholesterol including cholesterol hydrogen sulfate and cholesterol sulfate, ergosterol, esters of ergosterol including ergosterol hemi-succinate, salts of ergosterol including ergosterol hydrogen sulfate and ergosterol sulfate, lanosterol, esters of lanosterol including lanosterol hemi-succinate, salts of lanosterol including lanosterol hydrogen sulfate and lanosterol sulfate. The tocopherols can include tocopherols, esters of tocopherols including tocopherol hemi-succinates, salts of tocopherols including tocopherol hydrogen sulfates and tocopherol sulfates. The term “sterol compound” includes sterols, tocopherols and the like.
[0048] The cationic lipids used can include ammonium salts of fatty acids, phospholids and glycerides. The fatty acids include fatty acids of carbon chain lengths of 12 to 26 carbon atoms that are either saturated or unsaturated. Some specific examples include: myristylamine, palmitylamine, laurylamine and stearylamine, dilauroyl ethylphosphocholine (DLEP), dimyristoyl ethylphosphocholine (DMEP), dipalmitoyl ethylphosphocholine (DPEP) and distearoyl ethylphosphocholine (DSEP), N-(2,3-di-(9-(Z)-octadecenyloxy)-prop-1-yl-N,N,N-trimethylammonium chloride (DOTMA) and 1,2-bis(oleoyloxy)-3-(trimethylammonio)propane (DOTAP).
[0049] The negatively-charged lipids which can be used include phosphatidyl-glycerols (PGs), phosphatidic acids (PAs), phosphatidylinositols (Pls) and the phosphatidyl serines (PSs). Examples include DMPG, DPPG, DSPG, DMPA, DPPA, DSPA, DMPI, DPPI, DSPI, DMPS, DPPS and DSPS.
[0050] Phosphatidylcholines, such as DPPC, aid in the uptake by the cells in the lung (e.g., the alveolar macrophages) and helps to sustain release of the bioactive agent in the lung. The negatively charged lipids such as the PGs, PAs, PSs and PIs, in addition to reducing particle aggregation, are believed to play a role in the sustained release characteristics of the inhalation formulation as well as in the transport of the formulation across the lung (transcytosis) for systemic uptake. The sterol compounds are believed to affect the release characteristics of the formulation.
Liposomes
[0051] Liposomes are completely closed lipid bilayer membranes containing an entrapped aqueous volume. Liposomes may be unilamellar vesicles (possessing a single membrane bilayer) or multilamellar vesicles (onion-like structures characterized by multiple membrane bilayers, each separated from the next by an aqueous layer). The bilayer is composed of two lipid monolayers having a hydrophobic “tail” region and a hydrophilic “head” region. The structure of the membrane bilayer is such that the hydrophobic (nonpolar) “tails” of the lipid monolayers orient toward the center of the bilayer while the hydrophilic “heads” orient towards the aqueous phase.
[0052] Liposomes can be produced by a variety of methods (for a review, see, e.g., Cullis et al. (1987)). Bangham's procedure (J. Mol. Biol. (1965)) produces ordinary multilamellar vesicles (MLVs). Lenk et al. (U.S. Pat. Nos. 4,522,803, 5,030,453 and 5,169,637), Fountain et al. (U.S. Pat. No. 4,588,578) and Cullis et al. (U.S. Pat. No. 4,975,282) disclose methods for producing multilamellar liposomes having substantially equal interlamellar solute distribution in each of their aqueous compartments. Paphadjopoulos et al., U.S. Pat. No. 4,235,871, discloses preparation of oligolamellar liposomes by reverse phase evaporation.
[0053] Unilamellar vesicles can be produced from MLVs by a number of techniques, for example, the extrusion of Cullis et al. (U.S. Pat. No. 5,008,050) and Loughrey et al. (U.S. Pat. No. 5,059,421)). Sonication and homogenization cab be so used to produce smaller unilamellar liposomes from larger liposomes (see, for example, Paphadjopoulos et al. (1968); Deamer and Uster (1983); and Chapman et al. (1968)).
[0054] The original liposome preparation of Bangham et al. (J. Mol. Biol., 1965, 13:238-252) involves suspending phospholipids in an organic solvent which is then evaporated to dryness leaving a phospholipid film on the reaction vessel. Next, an appropriate amount of aqueous phase is added, the 60 mixture is allowed to “swell”, and the resulting liposomes which consist of multilamellar vesicles (MLVs) are dispersed by mechanical means. This preparation provides the basis for the development of the small sonicated unilamellar vesicles described by Papahadjopoulos et al. (Biochim. Biophys, Acta., 1967, 135:624-638), and large unilamellar vesicles.
[0055] Techniques for producing large unilamellar vesicles (LUVs), such as, reverse phase evaporation, infusion procedures, and detergent dilution, can be used to produce liposomes. A review of these and other methods for producing liposomes may be found in the text Liposomes, Marc Ostro, ed., Marcel Dekker, Inc., New York, 1983, Chapter 1, the pertinent portions of which are incorporated herein by reference. See also Szoka, Jr. et al., (1980, Ann. Rev. Biophys. Bioeng., 9:467), the pertinent portions of which are also incorporated herein by reference.
[0056] Other techniques that are used to prepare vesicles include those that form reverse-phase evaporation vesicles (REV), Papahadjopoulos et al., U.S. Pat. No. 4,235,871. Another class of liposomes that may be used are those characterized as having substantially equal lamellar solute distribution. This class of liposomes is denominated as stable plurilamellar vesicles (SPLV) as defined in U.S. Pat. No. 4,522,803 to Lenk, et al. and includes monophasic vesicles as described in U.S. Pat. No. 4,588,578 to Fountain, et al. and frozen and thawed multilamellar vesicles (FATMLV) as described above.
[0057] A variety of sterols and their water soluble derivatives such as cholesterol hemisuccinate have been used to form liposomes; see specifically Janoff et al., U.S. Pat. No. 4,721,612, issued Jan. 26, 1988, entitled “Steroidal Liposomes.” Mayhew et al., PCT Publication No. WO 85/00968, published Mar. 14, 1985, described a method for reducing the toxicity of drugs by encapsulating them in liposomes comprising alpha-tocopherol and certain derivatives thereof. Also, a variety of tocopherols and their water soluble derivatives have been used to form liposomes, see Janoff et al., PCT Publication No. 87/02219, published Apr. 23, 1987, entitled “Alpha Tocopherol-Based Vesicles”.
[0058] The liposomes are comprised of particles with a mean diameter of approximately 0.01 microns to approximately 3.0 microns, preferably in the range about 0.2 to 1.0 microns. The sustained release property of the liposomal product can be regulated by the nature of the lipid membrane and by inclusion of other excipients (e.g., sterols) in the composition.
Infective Agent
[0059] The infective agent included in the scope of the present invention may be a bacteria. The bacteria can be selected from: Pseudomonas aeruginosa., Bacillus anthracis, Listeria monocytogenes, Staphylococcus aureus, Salmenellosis, Yersina pestis, Mycobacterium leprae, M. africanum, M. asiaticum, M. avium - intracellulaire, M. chelonei abscess us, M. fallax, M. fortuitum, M. kansasii, M. leprae, M. malmoense, M. shimoidei, M. simiae, M. szulgai, M. xenopi, M. tuberculosis, Brucella melitensis, Brucella suis, Brucella abortus, Brucella canis, Legionella pneumonophilia, Francisella tularensis, Pneumocystis carinii, mycoplasma, and Burkholderia cepacia.
[0060] The infective agent included in the scope of the present invention can be a virus. The virus can be selected from: hantavirus, respiratory syncytial virus, influenza, and viral pneumonia.
[0061] The infective agent included in the scope of the present invention can be a fungus. Fungal diseases of note include: aspergillosis, disseminated candidiasis, blastomycosis, coccidioidomycosis, cryptococcosis, histoplasmosis, mucormycosis, and sporotrichosis.
Antiinfectives
[0062] The term antiinfective agent is used throughout the specification to describe a biologically active agent which can kill or inhibit the growth of certain other harmful pathogenic organisms, including but not limited to bacteria, yeasts and fungi, viruses, protozoa or parasites, and which can be administered to living organisms, especially animals such as mammals, particularly humans.
[0063] Non-limiting examples of antibiotic agents that may be used in the antiinfective compositions of the present invention include cephalosporins, quinolones and fluoroquinolones, penicillins, and beta lactamase inhibitors, carbepenems, monobactams, macrolides and lincosamines, glycopeptides, rifampin, oxazolidonones, tetracyclines, aminoglycosides, streptogramins, sulfonamides, and others. Each family comprises many members.
Cephalosporins
[0064] Cephalosporins are further categorized by generation. Non-limiting examples of cephalosporins by generation include the following. Examples of cephalosporins I generation include Cefadroxil, Cefazolin, Cephalexin, Cephalothin, Cephapirin, and Cephradine. Examples of cephalosporins II generation include Cefaclor, Cefamandol, Cefonicid, Cefotetan, Cefoxitin, Cefprozil, Ceftmetazole, Cefuroxime, Cefuroxime axetil, and Loracarbef. Examples of cephalosporins III generation include Cefdinir, Ceftibuten, Cefditoren, Cefetamet, Cefpodoxime, Cefprozil, Cefuroxime (axetil), Cefuroxime (sodium), Cefoperazone, Cefixime, Cefotaxime, Cefpodoxime proxetil, Ceftazidime, Ceftizoxime, and Ceftriaxone. Examples of cephalosporins IV generation include Cefepime.
Quinolones and Fluoroquinolones
[0065] Non-limiting examples of quinolones and fluoroquinolones include Cinoxacin, Ciprofloxacin, Enoxacin, Gatifloxacin, Grepafloxacin, Levofloxacin, Lomefloxacin, Moxifloxacin, Nalidixic acid, Norfloxacin, Ofloxacin, Sparfloxacin, Trovafloxacin, Oxolinic acid, Gemifloxacin, and Perfloxacin.
Penicillins
[0066] Non-limiting examples of penicillins include Amoxicillin, Ampicillin, Bacampicillin, Carbenicillin Indanyl, Mezlocillin, Piperacillin, and Ticarcillin.
Penicillins and Beta Lactamase Inhibitors
[0067] Non-limiting examples of penicillins and beta lactamase inhibitors include Amoxicillin-Clavulanic Acid, Ampicillin-Sulbactam, Sulfactam, Tazobactam, Benzylpenicillin, Cloxacillin, Dicloxacillin, Methicillin, Oxacillin, Penicillin G (Benzathine, Potassium, Procaine), Penicillin V, Penicillinase-resistant penicillins, Isoxazoylpenicillins, Aminopenicillins, Ureidopenicillins, Piperacillin+Tazobactam, Ticarcillin+Clavulanic Acid, and Nafcillin.
Carbepenems
[0068] Non-limiting examples of carbepenems include Imipenem-Cilastatin and Meropenem.
Monobactams
[0069] A non-limiting example of a monobactam includes Aztreonam.
Macrolides and Lincosamines
[0070] Non-limiting examples of macrolides and lincosamines include Azithromycin, Clarithromycin, Clindamycin, Dirithromycin, Erythromycin, Lincomycin, and Troleandomycin.
Glycopeptides
[0071] Non-limiting examples of glycopeptides include Teicoplanin and Vancomycin.
Rifampin
[0072] Non-limiting examples of rifampins include Rifabutin, Rifampin, and Rifapentine.
Oxazolidonones
[0073] A non-limiting example of oxazolidonones includes Linezolid.
Tetracyclines
[0074] Non-limiting examples of tetracyclines include Demeclocycline, Doxycycline, Methacycline, Minocycline, Oxytetracycline, Tetracycline, and Chlortetracycline.
Aminoglycosides
[0075] Non-limiting examples of aminoglycosides include Amikacin, Gentamicin, Kanamycin, Neomycin, Netilmicin, Streptomycin, Tobramycin, and Paromomycin.
Streptogramins
[0076] A non-limiting example of streptogramins includes Quinopristin+Dalfopristin.
Sulfonamides
[0077] Non-limiting examples of sulfonamides include Mafenide, Silver Sulfadiazine, Sulfacetamide, Sulfadiazine, Sulfamethoxazole, Sulfasalazine, Sulfisoxazole, Trimethoprim-Sulfamethoxazole, and Sulfamethizole.
Others
[0078] Non-limiting examples of other antibiotic agents include Bacitracin, Chloramphenicol, Colistemetate, Fosfomycin, Isoniazid, Methenamine, Metronidazol, Mupirocin, Nitrofurantoin, Nitrofurazone, Novobiocin, Polymyxin B, Spectinomycin, Trimethoprine, Trimethoprine/Sulfamethoxazole, Cationic peptides, Colistin, Iseganan, Cycloserine, Capreomycin, Pyrazinamide, Para-aminosalicyclic acid, and Erythromycin ethylsuccinate+sulfisoxazole.
[0079] Antiviral agents include, but are not limited to: zidovudine, acyclovir, ganciclovir, vidarabine, idoxuridine, trifluridine, ribavirin, interferon alpha-2a, interferon alpha-2b, interferon beta, interferon gamma).
[0080] Anifungal agents include, but are not limited to: amphotericin B, nystatin, hamycin, natamycin, pimaricin, ambruticin, itraconazole, terconazole, ketoconazole, voriconazole, miconazole, nikkomycin Z, griseofulvin, candicidin, cilofungin, chlotrimazole, clioquinol, caspufungin, tolnaftate.
Dosages
[0081] The dosage of any compositions of the present invention will vary depending on the symptoms, age and body weight of the patient, the nature and severity of the disorder to be treated or prevented, the route of administration, and the form of the subject composition. Any of the subject formulations may be administered in a single dose or in divided doses. Dosages for the compositions of the present invention may be readily determined by techniques known to those of skill in the art or as taught herein.
[0082] In certain embodiments, the dosage of the subject compounds will generally be in the range of about 0.01 ng to about 10 g per kg body weight, specifically in the range of about 1 ng to about 0.1 g per kg, and more specifically in the range of about 100 ng to about 10 mg per kg.
[0083] An effective dose or amount, and any possible affects on the timing of administration of the formulation, may need to be identified for any particular composition of the present invention. This may be accomplished by routine experiment as described herein, using one or more groups of animals (preferably at least 5 animals per group), or in human trials if appropriate. The effectiveness of any subject composition and method of treatment or prevention may be assessed by administering the composition and assessing the effect of the administration by measuring one or more applicable indices, and comparing the post-treatment values of these indices to the values of the same indices prior to treatment.
[0084] The precise time of administration and amount of any particular subject composition that will yield the most effective treatment in a given patient will depend upon the activity, pharmacokinetics, and bioavailability of a subject composition, physiological condition of the patient (including age, sex, disease type and stage, general physical condition, responsiveness to a given dosage and type of medication), route of administration, and the like. The guidelines presented herein may be used to optimize the treatment, e.g., determining the optimum time and/or amount of administration, which will require no more than routine experimentation consisting of monitoring the subject and adjusting the dosage and/or timing.
[0085] While the subject is being treated, the health of the patient may be monitored by measuring one or more of the relevant indices at predetermined times during the treatment period. Treatment, including composition, amounts, times of administration and formulation, may be optimized according to the results of such monitoring. The patient may be periodically reevaluated to determine the extent of improvement by measuring the same parameters. Adjustments to the amount(s) of subject composition administered and possibly to the time of administration may be made based on these reevaluations.
[0086] Treatment may be initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage may be increased by small increments until the optimum therapeutic effect is attained.
[0087] The use of the subject compositions may reduce the required dosage for any individual agent contained in the compositions (e.g., the FabI inhibitor) because the onset and duration of effect of the different agents may be complimentary.
[0088] Toxicity and therapeutic efficacy of subject compositions may be determined by standard pharmaceutical procedures in cell cultures or experimental animals, e.g., for determining the LD 50 and the ED 50 .
[0089] The data obtained from the cell culture assays and animal studies may be used in formulating a range of dosage for use in humans. The dosage of any subject composition lies preferably within a range of circulating concentrations that include the ED 50 with little or no toxicity. The dosage may vary within this range depending upon the dosage form employed and the route of administration utilized. For compositions of the present invention, the therapeutically effective dose may be estimated initially from cell culture assays.
Pharmaceutical Formulation
[0090] The pharmaceutical formulation of the antiinfective may be comprised of either an aqueous dispersion of liposomes and free antiinfective, or a dehydrated powder containing liposomes and free antiinfective. The formulation may contain lipid excipients to form the liposomes, and salts/buffers to provide the appropriate osmolarity and pH. The dry powder formulations may contain additional excipients to prevent the leakage of encapsulated antiinfective during the drying and potential milling steps needed to create a suitable particle size for inhalation (i.e., 1-5 μm). Such excipients are designed to increase the glass transition temperature of the antiinfective formulation. The pharmaceutical excipient may be a liquid or solid filler, diluent, solvent or encapsulating material, involved in carrying or transporting any subject composition or component thereof from one organ, or portion of the body, to another organ, or portion of the body. Each excipient must be “acceptable” in the sense of being compatible with the subject composition and its components and not injurious to the patient. Suitable excipients include trehalose, raffinose, mannitol, sucrose, leucine, trileucine, and calcium chloride. Examples of other suitable excipients include (1) sugars, such as lactose, and glucose; (2) starches, such as corn starch and potato starch; (3) cellulose, and its derivatives, such as sodium carboxymethyl cellulose, ethyl cellulose and cellulose acetate; (4) powdered tragacanth; (5) malt; (6) gelatin; (7) talc; (8) excipients, such as cocoa butter and suppository waxes; (9) oils, such as peanut oil, cottonseed oil, safflower oil, sesame oil, olive oil, corn oil and soybean oil; (10) glycols, such as propylene glycol; (11) polyols, such as glycerin, sorbitol, and polyethylene glycol; (12) esters, such as ethyl oleate and ethyl laurate; (13) agar; (14) buffering agents, such as magnesium hydroxide and aluminum hydroxide; (15) alginic acid; (16) pyrogen-free water; (17) isotonic saline; (18) Ringer's solution; (19) ethyl alcohol; (20) phosphate buffer solutions; and (21) other non-toxic compatible substances employed in pharmaceutical formulations.
Inhalation Device
[0091] The pharmaceutical formulations of the present invention may be used in any dosage dispensing device adapted for intranasal administration. The device should be constructed with a view to ascertaining optimum metering accuracy and compatibility of its constructive elements, such as container, valve and actuator with the nasal formulation and could be based on a mechanical pump system, e.g., that of a metered-dose nebulizer, dry powder inhaler, soft mist inhaler, or a nebulizer. Due to the large administered dose, preferred devices include jet nebulizers (e.g., PARI LC Star, AKITA), soft mist inhalers (e.g., PARI e-Flow), and capsule-based dry powder inhalers (e.g., PH&T Turbospin). Suitable propellants may be selected among such gases as fluorocarbons, hydrocarbons, nitrogen and dinitrogen oxide or mixtures thereof.
[0092] The inhalation delivery device can be a nebulizer or a metered dose inhaler (MDI), or any other suitable inhalation delivery device known to one of ordinary skill in the art. The device can contain and be used to deliver a single dose of the antiinfective compositions or the device can contain and be used to deliver multi-doses of the compositions of the present invention.
[0093] A nebulizer type inhalation delivery device can contain the compositions of the present invention as a solution, usually aqueous, or a suspension. In generating the nebulized spray of the compositions for inhalation, the nebulizer type delivery device may be driven ultrasonically, by compressed air, by other gases, electronically or mechanically. The ultrasonic nebulizer device usually works by imposing a rapidly oscillating waveform onto the liquid film of the formulation via an electrochemical vibrating surface. At a given amplitude the waveform becomes unstable, whereby it disintegrates the liquids film, and it produces small droplets of the formulation. The nebulizer device driven by air or other gases operates on the basis that a high pressure gas stream produces a local pressure drop that draws the liquid formulation into the stream of gases via capillary action. This fine liquid stream is then disintegrated by shear forces.
[0094] The nebulizer may be portable and hand held in design, and may be equipped with a self contained electrical unit. The nebulizer device may comprise a nozzle that has two coincident outlet channels of defined aperture size through which the liquid formulation can be accelerated. This results in impaction of the two streams and atomization of the formulation. The nebulizer may use a mechanical actuator to force the liquid formulation through a multiorifice nozzle of defined aperture size(s) to produce an aerosol of the formulation for inhalation. In the design of single dose nebulizers, blister packs containing single doses of the formulation may be employed.
[0095] In the present invention the nebulizer may be employed to ensure the sizing of particles is optimal for positioning of the particle within, for example, the pulmonary membrane.
[0096] A metered dose inhalator (MDI) may be employed as the inhalation delivery device for the compositions of the present invention. This device is pressurized (pMDI) and its basic structure comprises a metering valve, an actuator and a container. A propellant is used to discharge the formulation from the device. The composition may consist of particles of a defined size suspended in the pressurized propellant(s) liquid, or the composition can be in a solution or suspension of pressurized liquid propellant(s). The propellants used are primarily atmospheric friendly hydroflourocarbons (HFCs) such as 134a and 227. Traditional chloroflourocarbons like CFC-11, 12 and 114 are used only when essential. The device of the inhalation system may deliver a single dose via, e.g., a blister pack, or it may be multi dose in design. The pressurized metered dose inhalator of the inhalation system can be breath actuated to deliver an accurate dose of the lipid-containing formulation. To insure accuracy of dosing, the delivery of the formulation may be programmed via a microprocessor to occur at a certain point in the inhalation cycle. The MDI may be portable and hand held.
EXEMPLIFICATION
Example 1
[0097] Pharmacokinetics of amikacin delivered as both free and encapsulated amikacin in healthy volunteers. The nebulized liposomal amikacin contains a mixture of encapsulated (ca., 60%) and free amikacin (ca., 40%). Following inhalation in healthy volunteers the corrected nominal dose was 100 mg as determined by gamma scintigraphy. FIG. 1 depicts the lung concentration of amikacin and TOBI® (administered 100% free), based on pharmacokinetic modeling of serum concentrations over time. Both curves assume a volume of distribution for aminoglycosides in the lung of 200 ml. Interestingly, the peak levels of antiinfective in the lung are approximately equivalent for the 100 mg dose of liposomal amikacin, and the 300 mg dose of TOBI®. This is a consequence of the rapid clearance of the free tobramycin from the lung by absorption into the systemic circulation with a half-life of about 1.5 hr. These results serve as a demonstration of the improved lung targeting afforded by liposomal encapsulation. The presence of free and encapsulated antiinfective in the amikacin formulation is demonstrated by the two component pharmacokinetic profile observed. Free amikacin is rapidly absorbed into the systemic circulation (with a half-life similar to TOBI), while the encapsulated drug has a lung half-life of approximately 45 hr. The free amikacin is available to provide bactericidal activity, while the encapsulated drug provides sustained levels of drug in the lung, enabling improved killing of resistant bacterial strains. The measured lung concentrations for the liposomal compartment are significantly above the MIC 50 of 1240 clinical isolates of Pseudomonas aeruginosa, potentially reducing the development of resistance.
Example 2
[0098] Impact of free amikacin on the percentage of amikacin encapsulated in liposomes following nebulization. Liposomal preparations of amikacin may exhibit significant leakage of encapsulated drug during nebulization. As detailed in Table 1 below, the presence of free amikacin in solution was shown to surprisingly decrease the leakage of antiinfective by about four-fold from the liposome. While not wishing to be limited to any particular theory, it is hypothesized that liposomes break-up and re-form during nebulization, losing encapsulated antiinfective in the process. Alternatively, encapsulated antiinfective is lost during nebulization because the liposome membrane becomes leaky. When an excess of free antiinfective is present in solution, the free antiinfective is readily available in close proximity to the liposome, and is available to be taken back up into the liposome on re-formation.
[0000]
TABLE 1
Effect of free amikacin on the leakage of amikacin from liposome-
encapsulated amikacin.
Formu-
% Free Amikacin
% Free Amikacin
% Free Amikacin
lation
(Pre-nebulization)
(Post-nebulization)
(Due to nebulization)
A
3.3 (n = 1)
42.4 ± 3.2 (n = 3)
39.1 ± 3.2 (n = 3)
B
53.6 ± 5.4 (n = 9)
63.3 ± 4.7 (n = 9)
9.8 ± 5.8 (n = 9)
Wherein n is the number of measurements.
INCORPORATION BY REFERENCE
[0099] All of the patents and publications cited herein are hereby incorporated by reference.
EQUIVALENTS
[0100] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims.
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A system for treating or providing prophylaxus against a pulmonary infection is disclosed comprising: a) a pharmaceutical formulation comprising a mixture of free antiinfective and antiinfective encapsulated in a lipid-based composition, and b) an inhalation delivery device. A method for providing prophylaxis against a pulmonary infection in a patient and a method of reducing the loss of antiinfective encapsulated in a lipid-based composition upon nebulization comprising administering an aerosolized pharmaceutical formulation comprising a mixture of free antiinfective and antiinfective encapsulated in a lipid-based composition is also disclosed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional of application Ser. No. 11/508,891, filed Aug. 24, 2006, now U.S. Pat. No. 8,323,347 issued Dec. 4, 2012, which claims the benefit of U.S. Provisional Application Ser. No. 60/710,943, filed Aug. 25, 2005, the disclosures of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The present invention relates to surgical reconstitution of the shoulder and, in particular, to prosthetic replacement of the humerus.
BACKGROUND OF THE INVENTION
The shoulder joint is a ball-and-socket joint with unique features that allow for exceptional freedom of movement. The hemispherical head of the humerus and the glenoid capsule of the scapula support the articular surfaces of the shoulder joint. The head of the humerus is significantly large relative to the shallow glenoid cavity. In addition, ligaments in the shoulder act largely to limit the degree of movement allowed in the joint: They do not act to maintain apposition of the joint surfaces. As a consequence of these and other special characteristics, the shoulder joint exhibits every variety of movement: flexion, extension, abduction, adduction, circumduction, and rotation. The range of movements comes as some cost to joint stability, however.
Shoulder instability and other maladies of the shoulder joint, such as arthrosis or fracture, can be sufficiently acute that prosthetic replacement of compromised joint features may be indicated. Replacement of the humeral head involves resecting the humeral head from the humerus and installing a humeral prosthetic at the resection.
Early shoulder prostheses attempted to mimic the upper portion of the humerus and extending to include the humeral head. They typically were unitary structures that included a stem to be anchored in the humeral canal and a hemispherical head to be positioned within the glenoid cavity of the scapula.
Later developments allowed for adjustments to the geometry of the prostheses. Differences in patient anatomy and surgical techniques necessitated maintaining large inventories of the early, unitary prostheses. Prostheses were kept on-hand with heads and stems of different sizes and various relative tilt angles and radial offsets.
The more-recently devised modular prostheses generally are modular systems. Their modularity allows flexibility with respect to either the tilt angle or the radial offset between the head and stem. Although some of these prior art modular systems utilize either a “standard” head or a “standard” stem, most still require a plurality of either the heads or the stems to provide complete tilt angle and radial offset flexibility. None of the prior art systems provides complete tilt angle and radial offset flexibility without requiring different modular head or stem components of each given size. As a result, substantial inventories are maintained of either the stems or heads, which are the most expensive components. Moreover, most of the known systems provide incomplete adjustability of prosthetic geometry.
FIG. 1 illustrates a modular humeral-prosthesis 1 disclosed in DE 19509037 to Habermeyer. The humeral-prosthesis 1 allows for adjustment of radial offset, inclination angle, and version (anteversion/retroversion). Humeral-prosthesis 1 includes a stem-module 3 that features a shank 5 having an upper-shank portion 7 and a tongue/tab 9 that supports a pin 11 . Pin 11 hinges an angle-adapter 13 to the rest of the stem-module 3 . Angle-adapter 13 fits over tongue/tab 9 and pivots on pin 11 through an inclination angle a as shown in FIG. 2 . The angle-adapter 13 can be locked in place to retain a desired inclination angle.
Humeral-prosthesis 1 also includes a coupling adapter 17 , shown in FIGS. 1-4 . The coupling adapter 17 is shown in FIG. 3 separated from other prosthetic components. The coupling adapter 17 includes an adapter plate 27 . A male Morse taper 29 extends from one side of adapter plate 27 . A ball joint 31 extends from the adapter plate 27 on the side opposite the male Morse taper 29 . The ball joint 31 is located eccentrically on the adapter plate 27 . The eccentricity of the ball joint 31 on the adapter plate 27 allows for adjustment of a radial offset between the prosthetic stem 3 and a spherical cap 27 secured to the male Morse taper 29 , as described further below. Once established, the radial offset is fixed using set screw 23 ( FIG. 4 ).
Referring to FIG. 5 , adjustment of anteversion/retroversion is provided by the angle-adaptor 13 . As discussed above, the angle adaptor 13 pivots on the axis 11 at the top end 7 of the stem 3 to adjust the inclination angle a. In the view of FIG. 5 it can be seen that the angle adapter 13 is beveled at its interface with coupling adapter 17 . The beveling allows the adapter 13 , and hence the stem 3 , to pivot by way of ball joint 31 with respect to the coupling adapter 17 . The stem 3 and coupling adapter 17 rock through an angle b to one face 15 or the other of coupling adapter 17 . Faces 15 on coupling adapter 17 act as stops to define the maximum pivot to either side. Set screw 23 , used to retain the desired radial offset, also fixes the desired version.
A need exists in the prior art for a modular shoulder prosthesis that features universal setting of radial-offset, inclination angle, and anteversion/retroversion, with independent fixing of each setting.
SUMMARY OF THE INVENTION
The present invention provides a humeral prosthetic and surgical methods for reconstitution of a shoulder joint. The humeral prosthetic allows universal adjustment to the prosthetic inclination angle, radial offset, and version. In an exemplary embodiment, the humeral prosthetic includes three components: (i) a stem for attachment to the humerus, (ii) a spherical head for replacing the humeral head, and (iii) a coupling adapter joining the stem and the spherical head. At least one of the settings for the three adjustments noted above may be fixed independently of the other two settings. Preferably, a setting for each of the three adjustments is fixed independently.
In an exemplary embodiment, each modular component includes means for setting and fixing a respective one of the three adjustments noted above. More specifically, the exemplary prosthetic stem includes means for setting and fixing the inclination angle of the prosthesis. The exemplary spherical head includes means for setting and fixing the radial offset. The coupling adapter includes means for setting and fixing version.
The present invention also provides a method of conducting surgery by: (i) providing a humeral prosthetic comprising a humeral attachment; an adapter comprising a plate, a taper extending from a first side of the plate, a concavity formed along a diameter on a second side of the plate, and an expandable locking component extending from the second side of the plate; and a spherical head; (ii) providing the humeral prosthetic within a patient's humerus; and (iii) independently adjusting at least one of the radial offset of the spherical head, the inclination angle of the humeral attachment, and the version of the adapter, relative to the other two.
These and other features and advantages of the invention will be more apparent from the following detailed description that is provided in connection with the accompanying drawings and illustrated exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art prosthesis shown in anterior/posterior elevation;
FIG. 2 is a detailed view of the upper portion of the prior art prosthesis illustrating adjustment of the inclination angle;
FIG. 3 is a side view of an adapter portion of the prior art prosthesis shown in FIGS. 1 and 2 ;
FIG. 4 is a partial cut-away view illustrating details of the upper portion of the prior art prosthesis shown in FIG. 2 ;
FIG. 5 is a detailed view from above the prosthesis illustrating the beveled faces allowing adjustment of version in the prior art prosthesis shown in FIGS. 1-4 .
FIG. 6 illustrates a humeral prosthesis according to an exemplary embodiment of the present invention;
FIG. 7 illustrates an angle adapter and a coupling adapter enlarged to show detail;
FIG. 8 shows a coupling adapter viewed in elevation according to the invention;
FIG. 9 shows the coupling adapter of FIG. 8 viewed in side elevation;
FIG. 10 shows details of the coupling adapter of FIGS. 8 and 9 ;
FIG. 11 illustrates a locking screw according to the invention;
FIG. 12 illustrates another locking screw according to the invention;
FIG. 13 illustrates an exploded view of the prosthesis of the present invention, including an inclination component, a coupling adapter, a screw and a spherical head;
FIG. 14 illustrates a perspective view of the coupling adapter of FIG. 13 ;
FIG. 15 illustrates a perspective cross-sectional view of the coupling adapter of FIG. 14 ;
FIG. 16 illustrates a perspective view of the screw of FIG. 13 ;
FIG. 17 illustrates a perspective view of the spherical head of FIG. 13 ;
FIG. 18( a ) illustrates an exploded schematic view of the prosthesis of the present invention, including an inclination component, a coupling adapter, a screw and a spherical head;
FIG. 18( b ) illustrates the prosthesis of FIG. 18( a ) ;
FIGS. 19( a )-( c ) illustrate schematic views of the prosthesis of FIG. 18( b ) ;
FIGS. 20( a )-( d ) illustrate schematic views of the inclination component of the prosthesis of FIG. 18( b ) ;
FIGS. 21( a )-( e ) illustrate schematic views of the coupling adapter of the prosthesis of FIG. 18( b ) ; and
FIGS. 22( a )-( e ) illustrate schematic views of the spherical head of the prosthesis of FIG. 18( b ) .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention provides a humeral prosthetic and surgical methods for reconstitution of a shoulder joint. The humeral prosthetic allows universal adjustment to the prosthetic inclination angle, radial offset, and version. In an exemplary embodiment, the humeral prosthetic includes three components: a stem for attachment to the humerus, a spherical head for replacing the humeral head, and a coupling adapter joining the stem and the spherical head, wherein at least one of the settings for the three adjustments noted above may be fixed independently of the other two settings. Preferably, a setting for each of the three adjustments is fixed independently.
In an exemplary prosthesis and as detailed below, each modular component includes means for setting and fixing a respective one of the three adjustments noted above. More specifically, the exemplary prosthetic stem includes means for setting and fixing the inclination angle of the prosthesis. The exemplary spherical head includes means for setting and fixing the radial offset. The coupling adapter includes means for setting and fixing version.
The invention also provides a method of surgical reconstruction of shoulder by: (i) providing a humeral prosthetic comprising a humeral attachment; an adapter comprising a plate, a taper extending from a first side of the plate, a concavity formed along a diameter on a second side of the plate, and an expandable locking component extending from the second side of the plate; and a spherical head; (ii) providing the humeral prosthetic within a patient's humerus; and (iii) independently adjusting at least one of the radial offset of the spherical head, the inclination angle of the humeral attachment, and the version of the adapter, relative to the other two.
Referring now to the drawings, where like elements are designated by like reference numerals, FIG. 6 illustrates an exemplary humeral prosthesis according to an exemplary embodiment of the invention. FIG. 6 illustrates modular humeral-prosthesis 30 including a stem-module 33 that features a shank 35 having an upper-shank portion 37 and a tongue/tab 39 that supports a pin 41 . Pin 41 hinges an inclination component 43 to the rest of the stem-module 33 . Inclination component 43 fits over tongue/tab 39 and pivots on pin 41 through an inclination angle a as shown in FIG. 2 illustrating the prior art prosthesis. The inclination component 43 includes an opening 44 ( FIG. 7 ) that provides access to a screw (not shown) threaded between a pair of spreadable leaves formed in a portion of the tongue/tab 39 . The spreadable leaves are spread progressively further apart by advancement of the screw and into locking frictional engagement with opposing inside surfaces of the inclination component 43 . The screw is advanced by turning sufficient to fix the position of the inclination component 43 at a desired inclination angle.
Humeral-prosthesis 30 also includes coupling adapter 47 , shown in FIGS. 6-10 . The coupling adapter 47 is shown in FIG. 7 paired with the inclination component 43 . The coupling adapter 47 includes an adapter plate 57 . An access opening 48 through the adapter plate 57 corresponds to the opening 44 in the inclination component 43 and provides access to the inclination-angle locking screw discussed above. A male Morse taper 59 extends from one side of adapter plate 57 . Morse taper 59 locks into a female Morse taper 49 a formed in spherical head 49 . A shallow, elongate concavity 55 extends along a diameter of adapter plate 57 on a side opposite the male Morse taper 59 . The elongate concavity 55 complements an elongate convex surface 56 formed on inclination component 43 , discussed in further detail below.
FIGS. 8-10 further illustrate details of coupling adapter 47 . A pair of clothespin tabs 61 extends from adapter plate 57 . The clothespin tabs are accepted into a rectangular opening 63 formed in inclination component 43 . A pre-installed locking screw 65 ( FIG. 11 ) or 67 ( FIG. 12 ) is urged within tapped hole 69 between clothespin tabs 61 . The locking screw 65 , 67 wedges between clothespin tabs 61 . The clothespin tabs 61 spread apart to frictionally-engage inner walls of rectangular opening 63 with sufficient force to fix a relative versional position between inclination component 43 and coupling adapter 47 . In an exemplary embodiment, clothespin tabs 61 may have a square configuration to lock within rectangular opening 63 and to prevent rotation within the inclination block. However, the invention is not limited to this exemplary embodiment, and contemplates additional shapes and geometries for the clothespin tabs 61 , for example, a rectangular or trapezoidal configuration among many others.
More specifically, version is adjusted by pivoting adapter plate 57 with respect to inclination component 43 . The components will pivot through angles b of retroversion and anteversion as illustrated in FIG. 5 showing a prior art prosthesis. Instead of pivoting around a bevel, however, elongate concavity complements convex surface 45 so that the two are mutually engaged throughout the range of motion from +b to −b, the range being determined by the fit of clothespin-tabs 61 within rectangular opening 63 . Once the desired version is achieved, one of the locking screws 65 , 67 is used to spread the clothespin tabs into locking engagement with inside surfaces delimiting rectangular opening 63 .
Referring again to FIG. 6 , the female Morse taper socket is formed eccentric to a central axis of the spherical head 49 . Radial offset is adjusted by rotating the spherical head 49 around male Morse taper 59 with respect to coupling adapter 47 . The radial offset is fixed in position by the locking interaction of the complementary Morse taper features.
FIG. 13 illustrates a an exploded view of the prosthesis of the present invention, comprising inclination component 43 , coupling adapter 47 with clothespin tabs 61 , locking screw 65 and spherical head 49 . Coupling adapter 47 is further detailed in FIGS. 14 and 15 , which illustrate a perspective view and a perspective cross-sectional view, respectively, of the coupling adapter. FIG. 16 illustrates a perspective view of locking screw 65 while FIG. 17 illustrates a perspective view of the spherical head 49 .
FIGS. 18-22 illustrate additional schematic views of the prosthesis of the present invention, comprising inclination component 43 , coupling adapter 47 with clothespin tabs 61 , locking screw 65 and spherical head 49 .
The above description and drawings illustrate preferred embodiments which achieve the objects, features and advantages of the present invention. It is not intended that the present invention be limited to the illustrated embodiments. Any modification of the present invention which comes within the spirit and scope of the following claims should be considered part of the present invention.
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A humeral prosthesis includes a stem component and a head component joined by an inclination component. The inclination component is provided with an opening that is designed to accommodate a pair of expandable tabs extending from a side of a plate. The plate is also provided with a taper extending opposite to the pair of expandable tabs. Inclination angle, radial offset, and version are adjustable and are separately and independently set and fixed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, generally to stairway structures. More particularly, the invention relates to a stairway step assembly for use as an aid in climbing a stairway. The invention is particularly useful to elderly and handicapped users who have difficulty climbing a standard stairway due to the height or rise of the steps thereof The invention provides a means of quickly, economically, and safely altering the step arrangement of the standard stairway with minimal or no modification to the permanent structure of the stairway.
2. Background Information
In the past, various devices have been used and/or proposed to aid the elderly, handicapped and special needs individuals in climbing stairways or stairs. However, these devices have significant limitations and shortcomings. Specifically, prior art devices are believed to be difficult and expensive to construct and deploy, lack adjustability, and require substantial modification to the existing stairway structure.
Despite the need in the art for a stairway climbing aid device or assembly which overcomes the disadvantages, shortcomings and limitations of the prior art, none insofar as is known has been developed or proposed.
Accordingly, it is an object of the present invention to provide a stairway step assembly which serves as an aid in climbing the stairway. It is a further object of this invention to provide an assembly which is easy and inexpensive to construct and deploy, fully adjustable, and requires little or no modification to the existing stairway structure, and which overcomes the limitations and shortcomings of the prior art.
BRIEF SUMMARY OF THE INVENTION
The apparatus of the present invention provides an improved stairway step assembly for use in aiding climbing of the stairway by the user.
The basic assembly comprises a plurality of step members, the step members having predetermined horizontal dimensions and a predetermined height which is approximately one-half the height of a step of a standard stairs. The assembly further comprises means for connecting each the step member in a fixed position on a top, horizontal section of the standard stairs step.
The features, benefits and objects of this invention wilt become clear to those skilled in the art by reference to the following description, claims and drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a front view of a portion of a first embodiment of the stairway step assembly of the present invention operatively deployed on a section of a stairway.
FIG. 2 is a left side view of the assembly.
FIG. 3 is a right side view of the assembly.
FIG. 4 is a top view of the assembly.
FIG. 5 is a front view of a portion of a second embodiment of the assembly.
FIG. 6 is a left side view of the assembly shown in FIG. 5.
FIG. 7 is a front view of a portion of a third embodiment of the assembly.
FIG. 8 is a right side view of the assembly shown in FIG. 7.
FIG. 9 is front view of a portion of a fourth embodiment of the assembly.
FIG. 10 is a right side view of the assembly shown in FIG. 9.
FI. 11 is a perspective view of a fifth embodiment of the assembly.
FIG. 12 is a detailed view of a portion of the assembly shown in FIG. 11.
FIG. 13 is a perspective view of one step member of the assembly.
FIG. 14 is a perspective view of one connection member of the assembly.
FIG. 15 is a perspective view of one extension member of the assembly.
FIG. 16 is a front view of the step member.
FIG. 17 is a top view of the step member. FIG. 18 is a side view of the step member.
FIG. 19 is a side view of the connection member.
FIG. 20 is a front view of the extension member.
FIG. 21 is a side view of the extension member.
FIG. 22 is a front view of one step member of a sixth embodiment of the assembly.
FIG. 23 is a front view of one step member of a seventh embodiment of the assembly of the present invention.
FIG. 24 is a side view of an eighth embodiment of the assembly.
FIG. 25 is a front view of the assembly.
FIG. 26 is a side view of an upper unit of the assembly.
FIG. 27 is a front view of the upper unit.
FIG. 28 is a side view of a lower unit of the assembly.
FIG. 29 is a front view of the lower unit.
FIG. 30 is a side view of an upper unit of a ninth embodiment of the assembly.
FIG. 31 is a front view of the upper unit.
FIG. 32 is a side view of a lower it of the assembly.
FIG. 33 is a front view of the lower unit.
FIG. 34 is a side view of a tenth embodiment of the assembly.
FIG. 35 is a front view of the assembly.
FIG. 36 is a side view of an upper unit of the assembly.
FIG. 37 is a front view of the upper unit.
FIG. 38 is a side view of a lower unit of the assembly.
FIG. 39 is a front view of the lower unit.
FIG. 40 is a side view of an upper unit of an eleventh embodiment of the assembly.
FIG. 41 is a front view of the upper unit.
FIG. 42 is a side view of a lower unit of the assembly.
FIG. 43 is a front view of the lower unit.
DETAILED DESCRIPTION
Referring to the drawings, wherein like reference numerals designate like or similar elements throughout, several embodiments of the stairway step assembly of the present invention are illustrated.
Referring to FIGS. 1-4, one embodiment of the stairway step assembly 10 of the present invention comprises a plurality of step members 11a-c and a plurality of connection members 12a-d. A portion of the assembly 10 is shown operatively deployed on a standard stairs 13 which have a series of horizontal steps 14 of a predetermined depth "a" of approximately 8-12 inches (20.5-30 cm.) and interspaced vertical risers 15 of a predetermined height "b" of approximately 6-8 inches (15.25-20.5 cm). The lateral width "c" of the steps 14 and risers 15 are equivalent. Only a portion of the assembly 10 is shown for purposes of describing the features of the invention, and the number of step members 11 and connectors 12 may be varied depending upon the size of the stairs 13 on which the assembly 10 is deployed.
The step members 11 of the assembly 10 have a box-shaped configuration with a predetermined depth "a", height "b" and width "c". Step member 11 depth "a" is preferably equivalent to the depth "a" of a stairs step 14. Step member 11 height "b" is preferably approximately one-half the height "b" of a stairs riser 15. And, step member 11 width "c" is approximately one-third the width "c" of the stairs step 14. In use, the step members 11 are placed on the top surface of successive steps 14 of the stairs 13 at a far side thereof so as to be closely spaced from a wall or other surface (not shown) adjoining the stairs 13. The right side of each step member 11 has a pair of apertures 16 which are vertically aligned with respect to each other for attachment of the connection member 12. Apertures 16 may alternatively or additionally be placed on the left side of the step members 11 for deployment of the step members 11 on the left side of the stairs 13. The step members 11 have a top surface 17 upon which the user places their feet while climbing the stairs 13. The top surface 17 is preferably fitted with a non-slip member such as (not shown). The step members 11 provide an intermediary step between the stair steps 14. They decrease the height or reach a user must raise or lower their feet while ascending or descending the stairs 13. The step members 11 may optionally be fitted with a heating pad or strip (not shown) to melt ice when deployed on an exterior stairs, and/or lighting means such as a reflector or an electrolumnescent strip for improved visibility during nighttime or low light use.
The connection members or connectors 12 are rectangular, flat plate structures. They have a preferred length which is equivalent to the combined heights of a single step riser 15 and a single step member 11. The connectors 12 have a set of two apertures or slots 18a-b disposed near each of its ends. The apertures 18a-b are vertically aligned with respect to each other when viewed in an operative orientation, and are preferably elongated in such vertical dimension. In use, the connectors 12 link adjacent step members 11 by bolts or equivalent fastening means 19 disposed through connector apertures 18a-b and into step apertures 16. The elongated nature of apertures 18a-b permits a predetermined degree of vertical adjustment (commonly referred to as "rise") of the step members 11 with respect to the connectors 12. The connectors 12 maintain the step members 11 in place on the stairs 13, without the need to physically connect the step members 11 to the side wall and without the need to permanently connect the members 11 to the stairs itself.
Referring to FIGS. 5 and 6, a second embodiment of the stairway step assembly 25 is shown deployed on stairs 26 of equivalent dimensions to that of stairs 13 discussed above. The assembly 25 comprises a plurality of step members 27a-c and a plurality of connection members 28. The step member 27 have a box shaped upper portion 29 and a unitary flat, front facing lower portion 30 which extends downwardly from the upper portion 29 for connection to the lower successive step member 27. The bottom edge 31 of the lower portion 30 is thickened and has a laterally disposed, cylindrical channel therein. The upper portion 29 of each step farther has a pair of connection extensions 32a-b connected to its top surface at the rearward comers thereof. The extensions 32a-b permit coupling with the next higher step member 27. The connection member 28 is an elongated bolt that extends through one extension 32a, the channel in portion 31 and through the other extension 32b to connect adjacent step members 27.
Referring to FIGS. 7 and 8, third embodiment of the stairway step assembly 35 is shown deployed on stairs 36 of equivalent dimensions to that of stairs 13 discussed above. The assembly 35 comprises a plurality of step members 37a-c and a plurality of connection members 40. The step members 37 have a box shaped configuration. The separate, flat, connector 40 is connected to the front face of each step member 37 by bolts or other fasteners 45 through adjustable connection slots 46, and extends downwardly for connection to the lower successive step member 37. The bottom edge 41 of the connection member 40 is thickened and has a laterally disposed, cylindrical channel therein. The upper portion 39 of each step further has a pair of connection extensions 42a-b connected to its top surface at the rearward comers thereof for coupling with the next higher step member 37. An elongated bolt extends through one extension 42a, the channel in portion 41 and through the other extension 42b to connect adjacent step members 37.
Referring to FIGS. 9 and 10, a fourth embodiment of the stairway step assembly 50 is shown deployed on stairs 51 of equivalent dimensions to that of stairs 13 discussed above. The stairs 51 abuts left side wall 54. The assembly 50 comprises a plurality of step members 52a-c and a plurality of connection members 53a-c which are interlocked with respect to each other and are further each attached to the wall 54. The step members 52 each have a box-type configuration with a pair of apertures 55 disposed near the upper front and back corner on the right side wall thereof The connection members 53 each has an angled member 56, a short front vertical member 57 and a longer rear vertical member 58. The bottom end of each angled member 56 has a connection aperture 59, while the top end has a connection pin 60 which is inserted in the connection aperture 59 of the next higher member 53. The connection pins 60 further extend through a circular aperture 61 of a wall bracket 62, which is fastened to the wall 54. This structure permits the stairs 52 to be pivoted upwardly away from the stairs 51 and towards the wall 54.
Referring to FIGS. 11-21, a fifth embodiment of the stairway step assembly 70 is shown deployed on stairs 71 of equivalent dimensions to that of stairs 13 discussed above. The assembly 70 comprises a plurality of step members 72a-f, a plurality of connection members 73a-e, and preferably a plurality of extension members 80. The step members 72 of the assembly 70 have a box shaped configuration and are constructed of aluminum. Alternative construction materials include other lightweight, strong metals, plastic, composites, and wood. The right side of each step member 72 has a pair of apertures 74 which are horizontally aligned with respect to each other. The left side of each member 72 also has a pair of horizontally aligned apertures 75.
The connection members or connectors 73 are flat, generally L-shaped plate structures with a vertical member 76 and a horizontal member 77. The connectors 73 have a set of three apertures or slots 78 disposed near the bottom end of the vertical member 76 two of which are aligned with the apertures 74 of the step 72 for connection via a bolt or other fastening means (not shown). The extra or third aperture 78 permits horizontal adjustment of the position of the step 72 with respect to the connector 73. An elongated slot 79 is disposed at the end of the horizontal member 77, aligned horizontally. This slot 79 is used to connect the step 72 to an extension member 80 as is described further below.
The extension members 80 are connected to the steps 72 and enable them to be adjusted (longitudinally) to fit the size, depth-wise (commonly referred to as the "run", of the top horizontal surface of the stairs 71 steps. The extension members 80 are flat, relatively thin, U-channel shaped elements having a top, horizontal plate 81 and a pair of side, vertical plates 82. Each member 80 fits snugly over a step 72 and is connected there to by a bolts or other fastening members 83 disposed through an elongated, horizontally oriented slot 84 in the left side plate 82, which further extend into apertures 75 of step 72. Right side plate also has a slot 85 to accommodate the fasteners used to couple the connector 73 to the step 72. In use, the extension member 80 is slid laterally to fit the full size of the stairs 71 step and the fasteners 83 are tightened. The other embodiments of the step members may be modified to provide run adjustment utilizing this design.
Referring to FIG. 22, a sixth embodiment of the present invention wherein at least one individual step 90 having a box-like configuration with a top member 91, at least two side members 92 and a bottom member 93. The step 90 is attached to the top surface of a stairs step by a hook and loop style connector, for example VELCRO. As shown, a layer 94 of hook-type material of a predetermined size, is attached to the bottom member 93 of the step 90. When place on a carpeted stairs surface, the layer 94 couples with the carpet fibers to secure the step 90 in place. When placement on a smooth, not carpeted stairs surface, such as wood, vinyl, tile or the like, is desired a layer of loop-style material (not shown) is attached to the stair step, in alignment with the layer 94 of hook-style material.
Referring to FIG. 23, a seventh embodiment comprises at least one step 100 which is substantially similar to the step 90 described above except that it has a plurality of prong members 101 for gripping carpeted or other surfaces on a stairs step.
FIGS. 24-29 show an eight embodiment of the assembly 105. The assembly includes a box-like lower or base member 106 and a channeled upper member 107 which is slidably disposed over the lower member 106 for step run adjustment. The upper member 107 has horizontal slots 108 which receive connectors 109 extending through apertures 110 in the bottom member 106. The upper member 107 further has a front plate 111 which extends downwardly for connection to the next lower bottom member, and providing step rise adjustability, via connectors 112 disposed in apertures 113 and 114. The bottom end of the front plate 111 is shown abutting the back surface of the base member 106, but it may alternatively be connected in a vertically oriented slot (not shown) disposed in the back end of the base member 106.
FIGS. 30-33 show members of a ninth embodiment of the assembly which includes a box-like lower member 120 and a channeled upper member 121. The upper member 12 1 has horizontal slots 122 which receive connectors (not shown) which extend through apertures 123 in the bottom member 120. The bottom member 120 further has a front plate 124 which extends downwardly for connection to the next lower bottom member for step rise adjustment, via connectors (not shown) disposed in apertures 125 and 126.
FIGS. 34-39 show a tenth embodiment of the assembly 130. The assembly includes a box-like lower or base member 131 and a channeled upper member 132 which is slidably disposed over the lower member 131 for step run adjustment. The upper member 132 has horizontal slots 133 which receive connectors 134 extending through apertures 135 in the bottom member 131. The upper member 132 farther has a back wall 136 which extends upwardly for connection to the next higher bottom member, and providing step rise adjustability, via connectors 137 disposed in apertures 138 and 139.
FIGS. 40-43 show members of an eleventh embodiment of the assembly which includes a box-like lower member 145 and a channeled upper member 146. The upper member 146 has horizontal slots 147 which receive connectors (not shown) which extend through apertures 148 in the bottom member 145. The bottom member 145 further has a back wall 147 which extends upwardly for connection to the next higher bottom member for step rise adjustment, via connectors (not shown) disposed in apertures 149 and 150.
The descriptions above and the accompanying drawings should be interpreted in the illustrative and not the limited sense. While the invention has been disclosed in connection with the preferred embodiment or embodiments thereof, it should be understood that there may be other embodiments which fall within the scope of the invention as defined by the following claims. Where a claim is expressed as a means or step for performing a specified function it is intended that such claim be construed to cover the corresponding structure, material, or acts described in the specification and equivalents thereof, including both structural equivalents and equivalent structures.
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A stairway step assembly for use as an aid in climbing a stairway. The assembly is particularly useful to elderly and handicapped users who have difficulty climbing a standard stairway due to the height or rise of the steps thereof. The assembly provides a means of quickly, economically, and safely altering the step arrangement of the standard stairway with minimal or no modification to the permanent structure of the stairway. The assembly comprises a plurality of step members having predetermined horizontal dimensions and a predetermined height which is approximately one-half the height or rise distance of a standard step. The assembly further comprises an attachments mechanism for connecting the step members in place on the top or horizontal section of standard steps.
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RELATED CASES
This invention is described in my copending Provisional Application, Ser. No. 60/381,080, filed May 17, 2002.
FIELD OF INVENTION
This invention relates to barbeque grills and is particularly directed to improved barbeque grills having a plurality of cooking surfaces.
PRIOR ART
Outdoor cooking has long been a popular pastime and, in recent years, the development of barbeque grills has greatly increased the appeal of this practice. This has been especially true since the introduction of barbeque grills fueled with propane and the like. However, it is often necessary or desirable to cook several different types of foods for a single meal. Thus, some may prefer steaks, while others prefer chicken or seafood. Unfortunately, each of these different foods must be cooked at a respective temperature, whereas most gas-fueled grills only provide one burner. Consequently, it is necessary to cook the different foods sequentially, which greatly increases the amount of time required to prepare a meal and necessitates feeding the guests sequentially as their desired foods are cooked. Some multiple burner barbeque grills have been provided. However, these provide the burners is side-by-side arrangement which greatly increases the size of the grill and makes storage much more difficult. Thus, none of the prior art barbeque grills have been entirely satisfactory.
BRIEF SUMMARY AND OBJECTS OF INVENTION
These disadvantages of the prior art are overcome with the present invention and an improved barbeque grill is provided which enables a user to cook several different types of foods simultaneously at respective temperatures, yet is compact and convenient to store when not in use.
These advantages of the present invention are preferably attained by providing a barbeque grill having a plurality of cooking surfaces which store in stacked relation, yet which can be moved into essentially side-by-side relation for cooking and which can quickly and easily be returned to the stacked position when no longer needed.
Accordingly, it is an object of the present invention to provide an improved barbeque grill.
Another object of the present invention is to provide an improved barbeque grill having a plurality of cooking surfaces.
An additional object of the present invention is to provide an improved beabeque grill having a plurality of gas-fueled cooking surfaces.
A further object of the present invention is to provide an improved barbeque grill having a plurality of gas-fueled cooking surfaces, yet which can be stored conveniently in a minimum of space.
A specific object of the present invention is to provide an improved barbeque grill having a plurality of gas-fueled cooking surfaces which can be stored in stacked relation, yet can be moved into essentially side-by-side relation for cooking.
These and other objects and features of the present invention will be apparent from the following detailed description, taken with reference to the figures of the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front view showing a barbeque grill embodying the present invention, shown with the cooking surfaces in the stored position;
FIG. 2 is a side view of the barbeque grill of FIG. 1 ;
FIG. 3 is a front view of the barbeque grill of FIG. 1 , showing the cooking surfaces extended for use.
DETAILED DESCRIPTION OF THE INVENTION
In that form of the present invention chosen for purposes of illustration, FIG. 1 show a barbeque grill, indicated generally at 10 having a base 12 supported by a plurality of legs 14 supporting a plurality of cooking surfaces 16 , 18 and 20 . Each of the cooking surfaces 16 , 18 and 20 comprises a burner 22 and a food supporting surface 24 , such as a grill, griddle or the like. A fuel source, such as propane tank 26 may be stored in the base 12 and may be connected to supply the burners 22 in a conventional manner. Cooking surface 16 is mounted between several of the legs 14 , while cooking surfaces 18 and 20 are pivotally mounted on respective ones of the legs 14 and are swingable between a stored position, in line with cooking surface 16 , and an extended position, as seen in FIG. 3 . If desired, the cooking surfaces 18 and 20 may be mounted so that in the extended position, they may be lowered to lie in the same plane with cooking surface 16 , as shown in dotted lines at 18 ′ and 20 ′.
In use, cooking surfaces 18 and 20 are normally located in the stored position, as seen in FIG. 1 , which allows the barbeque grill 10 to be stored conveniently in a minimum of space. When the user desires to do some cooking, they move the grill 10 to a desired location and swing cooking surfaces 18 and 20 to their extended positions. This provides the user with a plurality of cooking surfaces whose cooking temperatures may be individually controlled by temperature controllers 21 . Thus, cooking surface 16 may be adjusted to a high heat for cooking steaks or the like, while cooking surfaces 18 and 20 may be set to lower cooking temperatures for cooking chicken, fish or other items. Also if desired, the food supporting surface 24 of cooking surface 16 may be a grill, while the food supporting surface 24 of cooking surface 18 may be a griddle and the food supporting surface 24 of cooking surface 20 may be ribbed or otherwise formed for cooking specialized items. If desired, recesses 28 may be provided to receive beverage containers or the like and hooks 30 may be provided to allow cooking utensils or the like to be hung thereon.
Obviously, numerous variations and modifications can be made without departing from the spirit of the present invention. Therefore, it should be clearly understood that the form of the present invention described above and shown in the figures of the accompanying drawing is illustrative only and is not intended to limit the scope of the present invention.
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An improved barbeque grill having a plurality of gas-fueled cooking surfaces which can be stored in stacked relation, yet can be moved into essentially side-by-side relation for cooking.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation application and claims priory of U.S. application Ser. No. 09/681,005, filed Nov. 13, 2000.
BACKGROUND OF THE INVENTION
The present invention relates generally to diagnostic systems for fuel injected engines and, more particularly, to an apparatus and method to adjust the fuel quantity delivered to each cylinder of a fuel injected engine.
Fuel injected engines inject a known quantity of fuel into each cylinder during engine operation based on engine speed, load, engine temperature, air temperature, barometric pressure, and other measurable parameters. This known quantity of fuel is determined for each engine operating point by technicians skilled in the art of internal combustion engines and design, and is a sufficient quantity to cause the engine to run well at each operating point despite numerous manufacturing tolerances that may be encountered. If the engine is not functioning properly, it could be that the wrong quantity of fuel is being delivered to one or more of the cylinders due to a malfunctioning component. It could also be the case that for some other unknown malfunctioning component, the engine requires more or less fuel at a given operating point than a properly functioning engine. While this is not catastrophic, if operated over time with an insufficient amount of fuel being delivered to the engine cylinders, excessive wear and/or breakdown of the engine can occur.
When an engine is not functioning properly, it is most often brought to a knowledgeable and skilled technician for diagnosis and repair. It is often very helpful in the diagnosis of a malfunctioning engine to know if one or more of the engine cylinders is not receiving the desired quantity of fuel. Unlike a carbureted engine, there are no screws in a fuel injected engine for the technician to use to adjust the air/fuel mixture that is delivered to each cylinder. At present, there are no tools which allow technicians to make adjustments to the fuel quantity of a fuel injected engine. Thus, it is very difficult to determine whether the quantity of fuel each cylinder is receiving is the correct amount.
The present invention is for use in an unique diagnostic system for fuel injected engines. Such a system must allow a technician to temporarily adjust the quantity of fuel delivered to each cylinder of the engine. However, it is important to maintain only a temporary change in fuel delivery as a permanent change could violate EPA emission guidelines. It is also important for a technician to be able to precisely adjust the amount of fuel being delivered to the engine cylinder.
It would therefore be advantageous to have a diagnostic system that allows for temporary adjustment of the fuel quantity being delivered to a fuel injected engine.
SUMMARY OF THE INVENTION
The present invention provides a system for adjusting the fuel quantity delivered to each cylinder of a fuel injected engine. The present invention also provides a means for increasing or decreasing the on-time of a fuel injector of the engine. Further, the present invention provides for storing any change in the operating parameters in the internal memory of the engine's electronic control unit (ECU). All of which overcome the aforementioned shortcomings.
In accordance with one aspect of the invention, a diagnostic system is provided for use with a fuel injected engine. A service computer is connected to an engine control unit of the fuel injected engine. The service computer has a computer readable storage medium having thereon a computer program that when executed receives operating data of the fuel injected engine from the engine's ECU. The ECU receives the operating data from a plurality of sensors connected thereto. The plurality of sensors provide operating data of the fuel injected engine including engine speed, load, engine temperature, air temperature, and barometric pressure. The ECU is further connected to a plurality of engine components including a number of fuel injectors. Upon receipt of data from the service computer, the ECU alters the fuel quantity being delivered to the fuel injected engine.
In accordance with another aspect of the invention, a diagnostic machine for use with a fuel injected engine of an outboard motor is provided. The diagnostic machine includes a communications interface connectable to an ECU of a fuel injected engine. The communications interface transmits fuel injector data from the ECU to a processor. The processor is connected to a computer readable storage medium of the diagnostic machine having thereon a computer program that when executed causes the processor to determine an adjustment to fuel injector firing time and further transmit that adjustment to the ECU.
In accordance with yet another aspect of the invention, a method to adjust fuel quantity being delivered to a fuel injected engine is disclosed. The method includes the steps of connecting a diagnostic machine to an ECU of a fuel injected engine. Fuel injector data of the fuel injected engine is then transmitted from the ECU to the diagnostic machine. Next, the method selects at least one engine fuel injector controlled by a control signal having a corresponding pulse width. The method next modifies the injector pulse width based upon at least one user input wherein modification of the injector pulse width results in an adjustment to the fuel quantity being delivered to the fuel injector. The method then transmits the modified injector pulse width of the fuel injector to the ECU of the fuel injected engine where, ultimately, the modified injector pulse width is stored in memory of the ECU.
Another aspect of the present invention provides a system and method for adjusting the fuel quantity being delivered to a fuel injected engine of an outboard marine motor. The method includes the steps of receiving operating parameters of a fuel injected engine, determining the fuel flow of at least one fuel injector based on the operating parameters of the fuel injected engine, modifying the fuel flow of the fuel injector thereby temporarily adjusting the amount of fuel being delivered to the fuel injected engine.
Various other features, objects and advantages of the present invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate one embodiment presently contemplated for carrying out the invention.
In the drawings:
FIG. 1 is a block diagram of a fuel injected engine incorporating the present invention.
FIG. 2 shows a family of performance curves of fuel injectors which follow a second order polynomial.
FIG. 3 shows a family of performance curves of complex fuel injectors which follow a third order of polynomial.
FIG. 4 is a perspective view of a fuel injected outboard marine engine having an ECU in communication with a portable processing unit, incorporating the present invention.
FIG. 5 is a flow chart showing an implementation of the present invention for use with the apparatus of FIGS. 1 and 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The operating environment of the present invention will be described with respect to a 2-cycle outboard marine engine as best shown in FIG. 4 . However, it will be appreciated that this invention is equally applicable for use with a 4-cycle engine, a diesel engine, or any other type of fuel injected engine.
It is well known in the art that the torque of an engine, the engine speed, engine emissions, and engine temperature can be optimized by adjusting the amount of the fuel applied to the cylinders and the time at which that fuel is ignited by using fuel injectors such as that disclosed in U.S. Pat. No. 5,687,050. The amount of fuel injected into an engine cylinder is typically controlled by a width of a control signal pulse applied to the fuel injector to hold it open for a predetermined period of time and then allowing it to close, thus allowing only a particular quantity of fuel to be injected into the cylinder. However, unlike a carbureted engine which has fuel/air mixture screws, there is no mechanism to adjust the amount of fuel delivered to each cylinder of a fuel injected engine. Adjusting the width of the control pulse applied to the fuel injector either results in an increase or decrease in the quantity of fuel delivered to the engine cylinder.
Referring now to FIG. 1, a block diagram is shown of an internal combustion engine assembly 20 having a central ECU 30 which receives inputs such as engine speed from RPM sensor 32 and throttle position from sensor 34 . It will also be appreciated, that one of the primary purposes of an ECU in an engine application is to control the ignition firing and timing of the ignition circuit 36 by receiving a control signal from ECU 30 on line 38 . As shown, the control signal from ECU 30 also controls the firing of each cylinder as indicated by lines 40 , 42 , 44 , 46 and 48 . ECU 30 further provides a control signal by means of line 50 to the fuel injectors via fuel injector solenoids as indicated at 52 , 54 , 56 , 58 , 60 , and 62 . Thus, each cylinder of an internal combustion engine receives both an ignition firing signal and a fuel injection signal from the ECU 30 .
In addition to those functions provided by an engine ECU in the past, the ECU used in current engines will further include a memory which may typically be a read-only memory 64 for storing a third-order equation such as ax 3 +bx 2 +cx+d=0 and a read/write memory 66 having storage locations associated with each cylinder of the engine for storing the coefficient data specifically associated with each fuel injector to provide fuel to that particular cylinder. The coefficient data is used in the aforementioned third-order equations stored in read-only memory 64 . Thus, depending upon the throttle setting and the corresponding RPM, the equation in read-only memory 64 is provided to microprocessor or calculator 68 of ECU 30 along with the appropriate coefficient data of the third-order equation associated with the cylinder for which the volume of fuel is being determined. Microprocessor 68 then uses the equation and the corresponding coefficient data to calculate the necessary pulse width and provide the requisite amount of fuel to the appropriate fuel injection 52 - 62 to achieve efficient engine operation.
To aid in understanding the operation of these complex fuel injectors and the requirement of using advanced calculations to determine pulse width, over those fuel injectors used in the past, reference is made to the set of curves illustrative of fuel injector performance of earlier less complex fuel injectors. As shown in FIG. 2, an increase in pulse width results in an increase in fuel flow in a rather predictable manner as shown by the second-order polynomial curves 70 , 72 , 74 , and 76 representing four individual fuel injectors, as used in a four-cylinder engine. It is clear from each of these curves that if the fuel flow associated with a particular pulse width is known at several different, but known, pulse widths, because of the simple nature and the predictability, the fuel flow at any other pulse width which is not at a known point can be predicted or easily extrapolated with a fair amount of accuracy. Thus, in the prior art fuel injector control calculations it was only necessary to store a few data points which associated fuel flow with pulse width for each fuel injector and then quickly extrapolate for pulse widths for which points were not available.
However, the advanced complex fuel injectors which can be used with the present invention do not have such predictable pulse width versus fuel flow performance curves. For example, referring to FIG. 3, there is shown a set of four fuel injector performance curves 78 , 80 , 82 , and 84 which clearly cannot be described by a second-order polynomial. Such curves require a third-order polynomial for controlling the performance of these advanced complex fuel injectors. Because of the unpredictability and complexity of these performance curves, it will be appreciated that one cannot simply extrapolate between two desired fuel flow levels and determine the necessary pulse width with any degree of accuracy. The curves shown are exemplary of a third-order polynomial and one skilled in the art will readily understand that the injector fuel flow vs. pulse width curve is coincident with a portion of a third order polynomial curve for a range of pulse widths where the third order polynomial has a positive slope.
Consequently, the basic form of a third-order polynomial is stored in read-only memory 64 of ECU 30 and then for each cylinder the unique and specific coefficients which define a performance curve associated with each specific fuel injector are calculated. Then, as discussed above, by using the third-order polynomial, the necessary pulse width for a desired fuel flow can be determined.
Referring now to FIG. 4, a perspective view of an outboard marine engine 100 having a fuel injected internal combustion engine 102 , controlled by an ECU 104 is shown connected to a service computer 106 . In a preferred embodiment, the service computer 106 is connected to the ECU 104 with a serial cable 108 . However, it is contemplated that the service computer 106 can communicate with the ECU 104 in any number of ways, including but not limited to, a SCSI (Small Computer System Interface) cable and card, a USB (Universal Serial Bus) cable and port, standard parallel connection, or with wireless technology, such as by infrared transmissions. The service computer 106 may be a transportable laptop, a desktop computer, a diagnostic machine, specialized service computer, or any other processing unit capable of executing and running a computer program. The service computer 106 has a keyboard 110 , a monitor 112 , and at least one disk drive 114 . The disk drive 114 can receive an external disk or CD, or any other computer readable storage medium 116 . The ECU 104 is individually connected to each of a number of fuel injectors 118 to control the performance of the engine 102 , as previously described.
The invention includes a system to replace fuel injector data in the ECU 104 . The system includes a service computer 106 connectable to transmit data to the ECU 104 . The service computer 106 has a computer readable storage medium 116 associated therewith and having thereon a computer program that when executed receives a series of user inputs through the keyboard 110 or other input interface that upon receipt and analysis ultimately leads to a change in the fuel injector firing time. A computer program is also supplied and will be described further with reference to FIG. 5 . In general, the computer program includes a set of instructions which, when executed by a computer, such as the service computer 106 , causes the service computer 106 to download an identification characteristic from the ECU 104 , and read existing fuel injector coefficient data from the ECU for the fuel injectors. The replacement fuel injector coefficient data from the computer readable storage medium 116 is then written to the ECU 104 for the specific fuel injector selected by the user.
Referring now to FIG. 5, the method steps of the present invention, together with the acts accomplished by the instructions of the computer program, are depicted in flow chart form. Upon initialization 120 , a user, typically a service person, is prompted for an input at 122 . If, for some reason, the user does not wish to proceed, the user can exit the program 124 by pressing a key on the keyboard, such as the ESC key on the service computer 106 . This branch may also be followed if a time-out feature is added in case the user does not respond to the inquiry at 122 . Further, this exit path is also desirable in the event a user wants to just confirm that the service computer 106 is preferably communicating with a given ECU 104 even if adjustment of the pulse width of an injector for that particular engine 102 is not desired.
Once the user selects a cylinder 126 to adjust fuel delivery thereto by adjusting a pulse width of a corresponding fuel injector, the service computer 106 receives an increase/decrease command at 128 from the user. The increase/decrease command indicates to the service computer 106 that the user wishes to increase or decrease fuel delivery to the identified cylinder. The service computer then will lengthen or shorten the pulse width, respectively, of the fuel injector associated with the engine cylinder selected. The service computer 106 then receives the degree of adjustment to be implemented at 130 . In a preferred embodiment, the user effectuates a change in the fuel quantity delivered to the fuel injectors by changing the injector pulse width, positively or negatively, in 5 μs intervals. To facilitate additional ease of effectuating the change in injector pulse width, the present invention allows the user to make adjustments in large increments, typically 50 μs, or in smaller increments, approximately 5 μus. For example, to increase the pulse width by 45 μs, the user would select a large increment increase of 50 μs followed by a small increment decrease of 5 μs, rather than selecting a small increase repeatedly or, as in this example, nine times.
Once the service computer 106 receives the degree of adjustment at 130 from the user, the service computer 106 modifies the pulse width of the fuel injector of the engine cylinder accordingly at 132 . After the pulse width is modified at 132 , the service computer 106 adjusts the injector data at 134 to reflect the modified pulse width. The adjusted injector data is then written to the ECU of the engine at 136 .
After the new injector data is written to the ECU at 136 , the user is prompted to select another cylinder at 138 . If the user desires to select another cylinder at 138 , 140 the diagnostic loop returns to 126 wherein the user is prompted to identify which cylinder should next be modified. Alternatively, the user may select to adjust the cylinders an equal amount simultaneously. If the user chooses to not select another cylinder 138 , 142 the diagnostic loop 120 is terminated and the user is exited from the program at 124 .
The present invention contemplates the use of a fuel injector of a type commonly referred to as single fluid pressure surge direct delivery fuel injector used in gasoline engines, and more specifically, in 2-stroke gasoline engines. One application of such an injector is a 2-stroke gasoline outboard marine engine, as shown in FIG. 4 . These fuel injectors typically do not entrain the gasoline in a gaseous mixture before injection. However, it will be appreciated by those skilled in the art that the above-described invention is equally suited for use with other types of injectors. Another type of direct fuel delivery uses a high pressure pump for pressuring a high pressure line to deliver fuel to the fuel injector through a fuel rail that delivers fuel to each injector. A pressure control valve may be coupled at one end of the fuel rail to regulate the level of pressure of the fuel supplied to the injectors to maintain a substantially constant pressure. The pressure may be maintained by dumping excess fuel back to the vapor separator through a suitable return line. The fuel rail may incorporate nipples that allow the fuel injectors to receive fuel from the fuel rail. Thus, in this case, a substantially steady pressure differential, as opposed to a pressure surge, between the fuel rail and the nipples cause the fuel to be injected into the fuel chamber. Another example of direct fuel injection is a direct dual-fluid injection system that includes a compressor or other compressing means configured to provide a source of gas under pressure to affect injection of the fuel to the engine. That is, fuel injectors that deliver a metered individual quantity of fuel entrained in a gaseous mixture. It is to be understood, however, that the present invention is not limited to any particular type of direct fuel injector.
Accordingly, the invention includes a method of servicing an engine requiring adjustment to the fuel injector firing time that includes identifying a fuel injector in need of adjustment by cylinder number and establishing communication between a service computer and an ECU of the engine. The method next includes downloading identification of the ECU, the engine cylinder, and the fuel injector from the ECU to the service computer, and writing adjusted fuel injector data into the ECU for a given fuel injector for the cylinder number identified.
The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.
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The present invention provides a system and method to adjust temporarily the quantity of fuel delivered to the cylinders of a fuel injected engine. The present invention allows a service technician to temporarily adjust the quantity of fuel being delivered to each cylinder or all cylinders of an internal combustion engine. The system includes an internal combustion engine having therein an electronic control unit capable of controlling the fuel quantity delivered to each cylinder and a general service computer connectable thereto and capable of transmitting data to the ECU. When instructed by the service technician, the service computer sends signals to the ECU to adjust fuel injector data to the fuel injectors of so as to increase or decrease the amount of fuel being delivered to the fuel injected engine.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to PCI International Application No. PCT/GB2014/052857 filed on Sep. 19, 2014, which claims priority to British Patent Application No. GB1316703.6 filed Sep. 20, 2013, the entirety of the disclosures of which are expressly incorporated herein by reference.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] This invention relates to a vehicle, device and method for loading a vehicle. More specifically, but not exclusively, this invention relates to a mobility scooter, device and method for loading a mobility scooter into a larger vehicle.
[0004] Mobility scooters are typically used by the elderly and infirm as a mode of transport. They axe usually powered by an electric motor and a battery, and therefore have a range limited by the power output of the motor and the capacity of the battery. The mobility scooter design is therefore a compromise between the weight and size of the scooter, and its Potential range. The range of many mobility scooters is such that only local trips from the user's home are viable.
[0005] If the user wants to take his/her mobility scooter to a destination which is outside the range of the mobility scooter, then he/she must transport the mobility scooter to the destination. As mobility scooter users are often elderly or infirm, the process of transporting the mobility scooter is problematic. One prior art device for solving this problem is a ramp.
[0006] An example of a ramp 110 of the prior art is shown in FIG. 1 . The ramp 110 includes two angled platforms 112 , which extend from the rear of the vehicle to the ground such that a mobility scooter may drive up the angled platforms 112 into the rear of the vehicle.
[0007] There are problems with the ramp 110 . The ramp 110 can be dangerous to use, as the angled platforms 112 must be aligned carefully for the mobility scooter to drive up safely. If the angled platforms 112 are misaligned, or if the angled platforms 112 slide off the rear of the vehicle, then the mobility scooter may fall to the ground, potentially causing serious damage to the mobility scooter and injury to the elderly or infirm person.
[0008] The ramps 110 are large to reduce the angle of the angled platforms 112 . The size of the ramp 110 can therefore be difficult and cumbersome for the elderly or infirm to use, and can take up a lot of space inside the vehicle when not in use and stored in the vehicle.
[0009] Furthermore, as it is prohibited for the elderly or infirm person to ride the mobility scooter up the angled platforms 112 , the person must stand to one side of the angled platforms 112 and operate the mobility scooter's accelerator. This is a difficult and dangerous operation, particularly as mobility scooters may accelerate very quickly when unloaded. Also, the mobility scooter may drive off the ramp if the steer angle is off-centre.
[0010] Clearly, the ramp was not an appropriate solution. Therefore, alternatives were developed, including a lift, a hoist, and a “take-apart” scooter.
[0011] The lift 120 is illustrated in FIG. 2 . The lift 120 , which is similar to a “tail lift” as used on a lorry, includes a fixing member 122 , a pillar 124 and a platform 126 . The platform 126 may be moved along an axis of the pillar 124 . The lift 120 is fixed to the rear of a vehicle by the fixing member 122 , which typically includes large bolts and steel plates such that the lift 120 is secured to the chassis of the vehicle.
[0012] In use, the platform 126 is lowered to the ground along the pillar 122 (achieved by an electric motor in the pillar 122 ), and the mobility scooter is driven onto the platform 126 . The platform 126 is then raised off the ground.
[0013] The lift 120 may be adapted such that the platform 26 is rotatable between a stowed position, such that the platform 126 is parallel with the rear of a vehicle, and a deployed position, such that the platform 126 is parallel with the ground.
[0014] There are problems associated with the lift. When the lift 120 is in the stowed position, the platform 126 blocks the rear door from opening. This can prohibit access to, for example, the boot of a car, or the hack of a van. Also, when the mobility scooter is loaded on the deployed lift 120 , the mobility scooter may become very dirty and wet in adverse weather conditions (this may also damage the mobility scooter's electronics). The scooter also has a tendency to bounce off the lift 120 if it is not secured, which is obviously dangerous.
[0015] The lift 120 also affects the weight distribution of the vehicle, and makes it difficult for the driver to park it.
[0016] Another option is the hoist, illustrated in FIG. 3 . The hoist 130 includes a fixing member 132 , a mast 134 , a boom 136 , an attachment 137 and a winch 138 . The winch 138 and the attachment 137 are connected through a cable 139 , which runs alone the boom 136 .
[0017] The hoist 130 is fixed to the interior of a vehicle via the fixing member 132 , which typically includes large bolts and steel plates such that the hoist 130 is secured to a chassis of the vehicle. The attachment 137 , such as a hook, is used to attach the mobility scooter to the hoist 130 . The winch 38 then winds up the cable 139 such that the mobility scooter is lifted towards the boom 136 .
[0018] The mobility scooter can then be moved into the vehicle. This can be achieved by having a retractable boom 136 , such that the boom 136 can be retracted into the vehicle.
[0019] There are problems associated with the hoist. For example, if the vehicle is parked on a hill, then the mobility scooter will swing under gravity as it is lifted off the ground. This is obviously dangerous. Also, the hoist 130 is fixed to the inside of the vehicle, which takes up interior space. The hoist 130 can therefore decrease the boot space of a car.
[0020] There are problems associated with both the lift 120 and the hoist 130 . The lift 120 and the hoist 130 use the vehicle as a counterbalance when lifting the mobility scooter. If the vehicle is small and/or light, it may experience a force when using the lift 120 or hoist 130 to move a vehicle causing the vehicle to tip. This is a health and safety risk, and can cause damage to the vehicle and/or mobility scooter.
[0021] The lift 120 and the hoist 130 are therefore normally used on larger vehicles, such as large vans or 4×4s, or when the mobility scooter is very light.
[0022] There are further problems associated with both the lift 120 and the hoist 130 . The lift 120 and the hoist 130 require specialist fitting, as they normally require steel plates and large bolts to be fitted properly. This is expensive work, and requires the vehicle to be modified which reduces the second hand value of the vehicle.
[0023] Another option is a “take-apart” mobility scooter. The “take-apart” mobility scooter can be dissembled into its constituent parts, which are small enough to be lifted into a vehicle.
[0024] A first problem with the “take-apart” mobility scooter is that some of the constituent parts are heavy. For example, the part including the battery may have a mass of around 20 kg, which is very heavy for an elderly or infirm person. Furthermore, as the “take-apart” mobility scooter is designed to be as light as possible, they are relatively small and unsafe to drive, and the battery is typically smaller which reduces its range.
[0025] Furthermore, it is undesirable to spend a lot of time dissembling and assembling the “take-apart” mobility scooter outside the vehicle, for example when it is raining. It can also be difficult for some elderly or infirm people to dissemble or assemble the “take-apart” mobility scooter, for example, if they have arthritis.
[0026] All these solutions are clearly unsatisfactory. There has been a long-felt need in the industry for a device that safely and effectively loads a mobility scooter into a larger vehicle.
[0027] There are also further problems when a user of a mobility scooter wants to travel via aircraft. A user may transport their mobility scooter to the airport using one of the methods above, which is then loaded onto the plane. However, the user cannot take the adapted car or large ramps onto the aircraft with them, and so must rely on the rental car company at their destination having suitable cars and/or equipment for transporting their mobility scooter. This complication often deters mobility scooter users from international travel.
[0028] It is therefore desirable to alleviate some or all of the above problems.
BRIEF SUMMARY
[0029] According to a first aspect of the invention, there is provided a device for moving a mobility vehicle into a larger vehicle, comprising a platform for positioning inside the larger vehicle; a ramp having a sidewall; and a mobility vehicle including a guide which is movable such that it is lowered below the floor of the mobility vehicle body, the guide and sidewall being arranged to such that, as the mobility vehicle ascends the ramp, the front wheels are lifted off the ramp, and the guide steers the mobility vehicle up the ramp and into the larger vehicle.
[0030] The device may include a bridging member connectable between the platform and ramp, wherein the bridging member and ramp are configured to move to a deployed position in which the bridging member extends between the platform and the ramp such that the bridging member and platform are substantially coplanar, and the ramp extends at an angle from the bridging member. The device of the present invention includes a platform which may be positioned in the larger vehicle (e.g. a car), and the ramp and bridging member may extend out of a boot of the car (i.e. over the boot lip). The device may be positioned such that the bridging member extends over the boot lip such that the bridge and platform are substantially coplanar, and the ramp may extend downwardly to the ground. This allows the ramp to adopt a shallower gradient (compared to a gradient of a ramp extending between the ground and the platform, which would join the platform inside the boot). The skilled person will understand that the shallower gradient reduces the power required for a smaller vehicle (e.g. a mobility vehicle) to ascend the ramp, and allows the mobility vehicle to enter the car boot at a more acute angle (which reduces the chances of the mobility vehicle grounding and increases the range of larger vehicles the device may operate with, e.g. hatchbacks).
[0031] The device may also include a platform sidewalk bridging member sidewall and ramp sidewall, which may allow a smaller vehicle (e.g. a mobility vehicle of a second aspect of the invention) to ascend the ramp without grounding. In cooperation with a guide wheel on the scooter, the side-wall may help with alignment of the scooter as it travels along the ramp and/or bridging member.
[0032] The angle between the ramp and the bridging member is preferably less than or substantially equal to 30 degrees when in the deployed position. This further reduces the power required for a mobility vehicle to ascend the ramp. The ramp may also include a first and second ramp portion, having a telescopic connection. The skilled person will understand that the ramp may extend to its deployed position by extending the first and second ramp portion telescopically, whilst retaining a smaller volume when in its stowed configuration.
[0033] The bridging member and ramp may also be configured to move to a stowed position, in which the bridging member and ramp are stowed underneath the platform.
[0034] The device may further comprise an indicator of the angle between the ramp and the bridging member, and the indicator may differentiate between above and below 30 degrees (for example by a coloured indicator showing green for less than 30 degrees and red for more than 30 degrees). This helps users quickly determine if the device is set up safely.
[0035] The device may also include a central channel. The central channel may be suitable for receiving a central front wheel of a mobility vehicle. The platform, bridging member and ramp may also be provided in first and second rails (rather than a single piece), wherein each rail is for aligning with a first and second rear wheel of a mobility vehicle. The device may include first and second handles between the first and second rails and the central channel, which may aid moving the device between the stowed and deployed positions.
[0036] According to a second aspect of the invention, there is provided mobility vehicle comprising a body having a floor, wherein the floor has an upper side and a ground-facing side; at least ne front Wheel and a plurality of rear wheels; and a guide attachable to the body and movable away from the floor to a deployed position on the ground-facing side of the floor.
[0037] The mobility vehicle includes a guide which is movable such that it is lowered below the floor of the body. The guide may therefore be lowered such that it is positioned between the floor and the ground and such that it abuts the ramp sidewall as the mobility vehicle ascends the ramp. Accordingly, as the mobility vehicle ascends the ramp, the front wheels are lifted off the ramp, and the guide steers the mobility vehicle up the ramp and into the larger vehicle. This ensures the front Wheels are not influencing the steer angle of the mobility vehicle, such that there is no risk of it being directed off the ramp.
[0038] The guide may be movable such that it is lowered below the floor of the body and between the first and second wheels. The skilled person will understand that the mobility vehicle adopts a pitch angle as it is ascends the ramp (wherein the pitch angle is defined by the contact points of the guide on the device's sidewalls and the rear wheel on the ground or ramp). By positioning the guide between the first and second wheels, the mobility vehicle maintains this pitch angle whilst the front portion of the vehicle enters the larger vehicle (as the pitch angle is maintained whilst the guide contacts the device's sidewalls). This reduces the likelihood of the mobility vehicle grounding as it ascends the device.
[0039] The mobility vehicle may further comprise a steering tiller including a control for driving the first or second wheels, wherein the control is disabled When the guide is lowered. In this arrangement, the mobility vehicle may be operated by other means, such as a remote control. This allows the user to operate the mobility vehicle and drive it up the ramp from a safe distance, rather than leaning over the ramp and using the mobility vehicle's controls. The mobility vehicle may be driven up the ramp at a predetermined speed. The predetermined speed may be set by the remote control to ensure the mobility vehicle is driven with adequate power to climb the ramp at a safe top speed. The torque developed by the drive motor may be automatically varied to maintain the predetermined speed across different operating conditions.
[0040] The steering tiller may be foldable, and the mobility vehicle. may also comprise a foldable seat. These features reduce the size of the mobility vehicle such that it may be loaded into a wide range of larger vehicles.
[0041] The mobility vehicle may further comprise an anti-tip wheel positioned at the rear portion of the body, and the anti-tip wheel may be movable (e.g. raised) as the guide is lowered. This ensures that the anti-tip wheel does not contact the ground as the mobility vehicle ascends the ramp, which may affect the drive of the mobility vehicle.
[0042] According to a third aspect of the invention, there is provided a method of loading a mobility vehicle into a larger vehicle, the mobility vehicle comprising a body having a floor, wherein the floor has an upper side and a ground-facing side; at least one front wheel and a plurality of rear wheels; and a guide attachable to the body and movable away from the floor to a deployed position on the ground-facing of the floor, the method comprising the steps of deploying a ramp between an opening in the larger vehicle and the ground, the ramp including a floor and a sidewall; moving the guide to the deployed position; aligning the mobility vehicle with the ramp such that the guide aligns with the sidewall; and moving the mobility vehicle up the ramp, wherein the guide abuts the sidewall and lifts the at least one front wheel off the floor.
[0043] The step of moving the first vehicle up the ramp may include using a remote control to drive the first vehicle.
[0044] The mobility vehicle may further include a foldable steering tiller and a foldable seat, and the method may further comprise the step of folding the steering tiller and seat.
[0045] The step of moving the mobility vehicle may include moving the mobility vehicle up the ramp onto a platform. Furthermore, the method may further comprise the step of stowing the ramp underneath the platform.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] Embodiments of the invention will now be described, by way of example, and with reference to the drawings in which:
[0047] FIG. 1 illustrates a ramp of the prior art;
[0048] FIG. 2 illustrates a lift of the prior art;
[0049] FIG. 3 illustrates a hoist of the prior art;
[0050] FIG. 4 is a side view of an embodiment of a device of the present invention, the device in an extended state;
[0051] FIG. 5 is a side view of the device of FIG. 4 in a stowed state;
[0052] FIG. 6 is a front view of the device of FIG. 4 in the extended state;
[0053] FIG. 7 is a side view of an embodiment of a mobility vehicle of the present invention;
[0054] FIG. 8 is a side view of the mobility vehicle of FIG. 7 , in a collapsed state;
[0055] FIG. 9 is a front view of the mobility vehicle of FIG. 7 , in the collapsed state; and
[0056] FIGS. 10 to 13 illustrate an embodiment of a method of the present invention.
DETAILED DESCRIPTION
[0057] An embodiment of a device of the present invention will now be described with reference to FIGS. 4 and 6 . FIG. 4 illustrates a device 1 in an extended state. The device 1 includes a platform 10 , a bridge 20 and a ramp 30 . The platform 10 is configured to be fitted into a larger vehicle via a fitting mechanism 40 (explained in more detail below) such that the bridge 20 and ramp 30 may extend out of an opening (e.g. fitted to the rear of a car such that the bridge 20 and ramp 30 extend out of the boot). In this extended configuration, the bridge 20 extends from a first end of the platform 10 such that it is generally coplanar with the platform 10 , and the ramp 30 extends downwardly from the bridge 20 to the ground. In this embodiment, the angle between the bridge 20 and the ramp 30 is between 20 and 30 degrees.
[0058] The ramp 30 includes a first ramp portion 31 and second ramp portion 32 . Tie platform 10 , bridge 20 and first and second ramp portions 31 , 32 are all configured for telescopic movement. The device 1 is shown in a stowed state in FIG. 5 . To move between the extended and stowed positions, the ramp portions 31 , 32 may be moved such that they are coplanar with the platform 10 and bridge 20 (i.e. the angle between the bridge 20 and ramp portions 31 , 32 is zero), and the bridge 20 and ramp 30 is moved telescopically to be stored underneath the platform 10 .
[0059] In this embodiment, the device 1 includes an indicator 25 disposed between the bridge 20 and the ramp 30 . The bridge 20 and ramp 30 are pivotally mounted such that as the angle between the bridge 20 and ramp 30 increases, a greater proportion of the indicator 25 is unveiled. The amount of indicator 25 visible to the user therefore illustrates the angle between the bridge 20 and ramp 30 . The indicator 25 includes a section of one colour (e.g. green) when the angle is less than 30 degrees, and, as the angle increases over 30 degrees, a portion of the indicator in a second colour (e.g. red) is unveiled. The skilled person will understand that the indicator 25 is a useful tool to help the user (who may be elderly) determine if the ramp 30 is deployed at a safe angle.
[0060] FIG. 6 is a front view of the device 1 in the extended position. In this embodiment, the platform 10 , bridge 20 and ramp 30 are all provided in left and right sections. These are positioned a distance apart such that the left and right sections align with the left and right wheels of a mobility vehicle.
[0061] The device also includes a central channel 35 having a floor 35 f . The central channel 35 is positioned between the left and right sections of the platform 30 and is connected thereto by handles 36 , 37 . The central channel 35 is therefore aligned with a central front wheel of a mobility vehicle (e.g. for 3 or 5 wheeled mobility vehicles). The handles 36 , 37 help the user move the device 1 between the stowed and extended positions.
[0062] Referring to FIGS. 4 and 6 , the platform 10 , bridge 20 and ramp 30 each include a floor, 10 f, 20 f, 31 f ; 32 f, and sidewall 10 s, 20 s, 31 s, 32 s. These features work in conjunction with the mobility vehicle (explained below) to ensure it ascends the ramp safely and effectively. The device 1 also includes a receiver 10 r acting as a stop when the mobility vehicle is loaded on the platform 10 .
[0063] Referring back to FIG. 4 , the fitting mechanism 40 includes a plurality of floor engaging hook-and-loop fasteners 41 , 42 , a plurality of side wall engaging suction pads, and a plurality of seat anchors 43 . These features ensure that the platform 10 is secured to the larger vehicle, and the bridge 20 and ramp 30 may therefore move relative to the platform and larger vehicle.
[0064] An embodiment of a mobility vehicle 50 will now be described with reference to FIGS. 7 to 9 . In this embodiment, the mobility vehicle 50 is a mobility scooter having a plurality of front wheels 51 , a plurality of rear wheels 52 , a guide 53 , a foldable steering tiller 54 including a control 55 , a foldable seat 56 , anti-tip castor wheels 57 , and a storage compartment 58 containing, a remote control 59 .
[0065] The guide 53 includes a guide arm 53 a, guide wheel 53 b, lever 53 c and guide disc 53 d. Guide arms and guide wheels are provided on both sides of the vehicle 50 (but are operated by a single lever 53 c ), but only one guide will be described for simplicity.
[0066] FIG. 7 illustrates the mobility scooter in an arrangement for normal use. The user may sit on the foldable seat 56 , steer the vehicle using the steering tiller 54 , and control the speed of the vehicle using the control 55 . The mobility scooter 50 is driven by the rear wheels 52 and steered via a central front wheel. In this arrangement, the guide is in a disabled state such that it does not interfere with normal operation of the mobility vehicle 50 .
[0067] The mobility scooter 50 has a collapsed state shown in FIG. 8 . In this arrangement, the foldable steering tiller 54 and seat 56 are folded into the collapsed state, which reduces the height and effective volume of the scooter 50 . The user may operate a lever 53 c on the guide 53 , which causes the guide as 53 a to move about a pivot and tower the guide wheel 53 a. The guide wheel 53 a therefore moves away from the floor body towards the ground.
[0068] When in this lowered state, the guide wheel 53 a is positioned such it abuts the sidewalls 10 s, 20 s, 31 s , 32 s of the device 1 as the mobility scooter 50 ascends the ramp. This has the effect of lifting the front portion of the mobility vehicle 50 relative to its rear portion (i.e. increasing the pitch angle), thereby lifting the front wheels 51 away from the floor 10 s , 20 s, 30 s of the device 1 (this is explained in more detail below). As shown in FIG. 9 , the guide wheel 53 a has a grooved section. The grooved section helps the guide wheels 53 a capture the sidewalls 10 s, 20 s, 31 s, 32 s of the device 1 .
[0069] When in the collapsed state, the mobility scooter 50 also raises the anti-tip castor wheels 57 . This ensures that the castor wheels 57 do not contact the ramp as it ascends, such that only the guide wheel 53 b and driven rear wheels 52 contact the device 1 .
[0070] The mobility scooter 50 is also configured to disable the control 55 when in the collapsed state. The mobility scooter 50 may therefore only be driven by the remote control 59 . Accordingly, the user may stand a safe distance away from the scooter and drive it up the ramp using the remote control 59 .
[0071] An embodiment of a method of loading a mobility vehicle 50 into a larger vehicle will now be described with reference to FIGS. 10 to 13 . Firstly, the user opens an opening on a large vehicle (e.g. a boot of a car) and extends the bridge 20 and ramp 30 from the device 1 to the ground. The bridge 20 therefore extends over the boot lip of the car and the ramp 30 extends at an angle of less than 30 degrees to the ground.
[0072] The user then drives the mobility vehicle 50 to the device 1 such that the central front wheel aligns with the central channel 35 and the left and right front wheels align with the left and right sections of the ramp 30 . The user then steps off the mobility vehicle 50 and folds the steering tiller 54 and seat 56 such that it is in the collapsed state shown in FIG. 10 . The mobility vehicle 50 is no longer drivable by the control 55 .
[0073] The user then operates the lever 53 c to lower the guide wheel 53 a. This also raises the anti-tip castor wheels 57 . The user then removes the remote control 59 from the storage compartment 58 and moves the mobility vehicle 50 forward.
[0074] As shown in FIG. 11 , the mobility vehicle 50 therefore begins ascending the ramp 30 . Initially, the front wheels 51 contact the floor of the ramp 30 and central channel 35 . However, as the mobility scooter 50 moves further up the ramp 30 , the guide wheels 53 contact the ramp sidewalls 31 s , 32 s. This causes the front portion of the mobility vehicle 50 to lift, thus lifting the front wheels 51 off the floor of the ramp 30 and central channel 35 (as shown in FIG. 12 ). The front wheels 51 therefore cannot influence the steer angle of the mobility vehicle 50 , and the mobility vehicle 50 is directed by the guide wheel 53 and sidewalk 31 s along and up the ramp 30 .
[0075] The mobility vehicle 50 adopts a particular pitch angle when the guide wheels 53 abut the sidewalls 31 s , 32 s. The mobility vehicle 50 retains this pitch angle until the guide wheels 53 move from the ramp sidewalls 31 s, 32 s to the bridge sidewalk 20 s. As the guide wheels 53 are positioned between the front and rear wheels of the mobility vehicle 50 , the front portion of the mobility vehicle 50 is therefore lifted over the bridge 20 before the guide wheels 53 contact the bridge sidewalls 20 s and the pitch angle begins to decrease. This ensures the mobility vehicle 50 does not ground as it ascends the device 1 .
[0076] The mobility vehicle 50 continues being driven until it is positioned on the platform 10 as shown in FIG. 11 . To prevent any forward motion of the mobility vehicle 50 , the guide disc 53 d enters the receiver 10 d on the platform 10 , and the automatic brakes on the rear wheels 52 prevent any backward motion of mobility vehicle 50 .
[0077] The user may then move the bridge 20 and ramp 30 to the stowed position and close the boot of the car.
[0078] In the embodiment above, the device 1 is constructed out of a plurality of parts having left and right sections (for aligning with the left and right wheels of the mobility vehicle). However, the skilled person will understand that this is non-essential. The device may include a platform, bridging member and ramp each constructed from a single piece of material. The sidewalls may be disposed on the outer edge of the device and mobility vehicle's guide may then be positioned at a corresponding width.
[0079] in the description above, the platform, bridging member and ramp all have sidewalls. However, the skilled person will understand that it is not essential for the platform and bridging member to have sidewalls.
[0080] The mobility vehicle described above includes a guide movable to a deployed position below the floor of the vehicle and between the front and rear wheels. However, the skilled person will understand that this particular position is not essential. The deployed position and the device's sidewalls are arranged such that the front portion of the mobility vehicle is lifted off the ground, but this may include (for example) the guide being deployed in front of the front wheels of the mobility vehicle. Furthermore, it is not essential for the guide to be a guide wheel.
[0081] The skilled person will also understand that it is not essential for the mobility vehicle to be a mobility scooter. The mobility vehicle may be any form of vehicle suitable for transporting an elderly or infirm person, such as a wheelchair.
[0082] The skilled person will understand that any combination of features is possible without departing the scope of the invention, as claimed.
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A device ( 1 ) for loading a vehicle ( 50 ) includes a platform for positioning inside the larger vehicle, a ramp having a sidewall, and a bridging member connectable between the platform and ramp, wherein the bridging member and ramp are configured to move to a deployed position in which the bridging member extends between the platform and the ramp such that the bridging member and platform are substantially coplanar, and the ramp extends at an angle from the bridging member. A mobility vehicle includes a body having a floor, wherein the floor has an upper side and a ground-facing side, at least one front wheel and a plurality of rear wheels, and a guide ( 53 ) attachable to the body and movable away from the floor to a deployed position on the ground-facing side of the floor. The mobility vehicle may ascend the ramp of the device and the guide contacts the sidewall and lifts the at least one front wheel off the floor of the device.
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FIELD OF THE INVENTION
This invention relates to a blood conservation system, and more particularly to a system for the collection, filtration and reinfusion of a patient's own blood or blood products, as a part of the treatment of vascular, cardiac, orthopedic, trauma, and the like patients.
BACKGROUND OF THE INVENTION
An absolutely safe and dependable homologous blood supply is currently unattainable. Proper technique can reduce the associated risks of homologous blood infusion, but complete safety is not yet attainable. Autotransfusion (the collection, filtration and reinfusion of the patient's own blood or blood products) is rapidly becoming an accepted adjunct in the treatment of vascular, cardiac, orthopedic and trauma patients. The American Medical Association, American Red Cross, and American Association of Blood Banks promote autologous blood transfusion as the "method of choice" in blood transfusion.
A known blood conservation system is marketed under the trade name "SULCOTRANS" by Sulco Basle, Inc. of Rockland, Md. This known system utilizes a rigid graduated collection reservoir and sterile single use drainage tube sets. However, reinfusion is direct from the collection reservoir. This prior art system collects liquid from the patient body by vacuum or gravity. However, the suction source is the conventional hospital wall suction outlet regulated to 80-100 mm. of mercury suction. Reinfusion is by gravity or handbulb attachment and a standard blood administration set can be used for reinfusion. The prior system uses a 260 micron pre-filter to clean liquid coming into the collection reservoir and uses a 40 micron post filter for liquid coming out of the collection reservoir and going toward the patient. The prior device is intended for use in post operative collection of surgical site drainage blood for auto-infusion.
U.S. Pat. Nos. 4,569,674 and 4,655,754 assigned to assignee of the present invention, disclose wound drainage apparatus usable during and after surgery, wherein a portable base unit includes a battery pack, a vacuum pump, and means for controlling operation of the vacuum pump. A portable reservoir is releasably insertable into the base unit. Upon insertion into the base unit, the reservoir is connected to the vacuum pump through a check valve and hydrophobic filter to prevent the vacuum pump from ingesting liquid from the reservoir. The reservoir in turn is connectable through a check valve to a draining wound on a patient. The vacuum pump responds to the physical presence of the reservoir in the base unit and to the gas pressure within the reservoir for maintaining the gas pressure in the reservoir at a desired range below atmospheric pressure. The reservoir is releasable from the base unit and, upon such release, maintains vacuum (sub-atmospheric pressure) therein. Thus, the reservoir, whether or not connected to the base unit, when at a sub-atmospheric pressure, can draw liquid from a wound. In one unit a flexible member atop the reservoir visually indicates the presence of a sub-atmospheric pressure in the reservoir by its physical shape (it dimples when the reservoir is at sub-atmospheric pressure).
The present inventors have recognized that the wound drainage system of above-mentioned U.S. Pat. Nos. 4,569,674 and 4,655,754 could desirably be adapted to, or form the basis for, a blood conservation system.
Accordingly, the objects and purposes of the invention include provision of the blood conservation system which is usable for receiving blood from a patient and for returning the blood or components thereof at some time thereafter to the patient, which is capable of separating lipids and the like from the patient's blood before returning it to the patient, which can draw liquid from a surgical site on a patient after a surgical procedure by suction and without need for connection to the conventional fixed suction sources incorporated in hospitals, which can be implemented with a liquid reservoir capable of connection to and disconnection from a portable base unit incorporating a battery source and vacuum pump, in which the reservoir can be at sub-atmospheric pressure for drawing liquid from the surgical site both when connected to the portable base unit and for a time following disconnection therefrom, and in which the reservoir is usable with a known and readily available portable base unit.
Further objects and purposes of the invention will be apparent to persons acquainted with apparatus of this general type upon reading the following description and inspecting the accompanying drawings.
SUMMARY OF THE INVENTION
A blood conservation system capable of receiving liquid, including blood, from a patient and comprising a reservoir connectable to the patient, transfusion means for receiving blood from the reservoir, and valve means for controlling the transfer of liquid from the reservoir.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary pictorial view of a blood conservation system embodying the invention.
FIG. 2 is a further pictorial view, taken from a different angle, of the reservoir of FIG. 1.
FIG. 3 is an enlarged, central cross-sectional view, taken substantially along the line III--III of FIGS. 2 and 6, and with the liquid outlet valve closed.
FIG. 4 is a view similar to FIG. 3 but with the outlet valve open.
FIG. 5 is a view substantially taken along the line V--V of FIG. 3 and particularly showing the liquid inlet line to the reservoir.
FIG. 6 is a sectional view substantially taken on the line VI--VI of FIG. 3 and showing the vent/suction passage from the valve stem to the top of the hydrophobic filter of FIG. 3.
DETAILED DESCRIPTION
A blood conservation system 10 (FIG. 1), embodying the invention, comprises a reservoir 11 releasably connectable to a portable base unit 12 for reducing the pressure within the reservoir to a sub-atmospheric pressure. The reservoir 11 is connectable to a surgical site (wound) not shown by a disposable tube set 13.
The tube set 13 comprises a drain tube, indicated in broken lines at 14, insertable in a conventional manner in a wound, usually at the time of surgery, to remove, by gravity or suction, liquid and other fluid materials to be drained from the wound, at the time of surgery and/or thereafter. Plural drain tubes (for example as at 14 and 14') may be joined by a Y-shaped fitting 15 to the remainder of the tube set 13 served by a single reservoir 11. The tube set 13 further comprises a first tube 16 connecting the Y-fitting to a prefilter 17. In the embodiment shown, the prefilter 16 is preferably a 160 to 260 micron prefilter provided for removal of bone chips, clotted blood and similar debris. A second tube 20 connects the prefilter 17 to an anti-reflux valve 21 (a check valve or one way valve, conveniently a so-called duckbill valve) oriented to permit liquid flow from the drain tube 14 to the reservoir 11 but prevent positively any reverse flow. A third tube 22 connects anti-reflux valve 21 to the top of the reservoir 11 for draining liquid from the drain tube 14 into the reservoir 11.
The blood conservation system 10 further includes a transfusion bag 23 connected by a fourth tube 24 to the bottom of the reservoir 11 for receiving blood therefrom. The transfusion bag 23 has at least one outlet 25 connectable in a conventional manner to a conventional blood administration set (not shown) for further handling of the blood therein, for example for immediate readministration to the patient, for processing in a conventional manner to readminister only certain components of the blood to the patient, for temporary storage prior to readministration to the patient, etc.
The drain tube 14, Y-fitting 15, tubes 16, 20 and 22, pre-filter 17, anti-reflux valve 21, tube 24, and transfusion bag 23 are all conventional parts which are readily and widely available commercially, and so are believed not to require further comment.
The base unit 12 may be of a kind commercially available from the assignee of the present invention. The internal structure and operation of an early version of the base unit 12 are disclosed in substantial detail in above-mentioned U.S. Pat. No. 4,569,674 assigned to the assignee of the present invention. A later version of the base unit 12, similar in configuration to that in present FIG. 1, is disclosed in later above-mentioned U.S. Pat. No. 4,655,754 (see particularly FIGS. 6 and 7), the relevant disclosures of both of the aforementioned patents being incorporated herein by reference.
The portable base unit 12 (FIGS. 1 and 3) includes an electric supply in the form of an upwardly slidably removable, rechargeable, battery pack 30. As schematically indicated in FIG. 3, the base unit 12 further includes a vacuum pump and a control circuit. The control circuit turns on the vacuum when a contact sensor signals that a reservoir (here for example the reservoir 11) has been downwardly inserted into the base unit 12 and a pressure sensor signals simultaneously that the pressure in the reservoir is above the desired sub-atmospheric range. Both conditions are needed to turn on the vacuum pump. The vacuum pump is off when no reservoir 11 is plugged into the base unit 12. The vacuum pump is also off when the reservoir 11 plugged into the base unit 12 is at a sub-atmospheric pressure in the desired preset range. The desired preset range may for example occupy a portion of the range between atmospheric pressure and at least 2.4 PSI below atmospheric pressure, which is within the range of capability of the vacuum pump in one form of the base unit 12.
Aforementioned U.S. Pat. No. 4,655,754 discloses a reservoir usable with the base unit 12 of present FIG. 1 and adapted for wound drainage but not for use in a blood conservation (e.g. auto-transfusion) system. The drain reservoir 11 of the present application, as can be seen from FIG. 3 for example, may be similar to the drain reservoir of aforementioned U.S. Pat. No. 4,655,754 to the extent of having a cover 35 (FIG. 3) cantilevered at 36 beyond the left end of the upward opening bottle 36 of the reservoir 11. To adapt the present reservoir 11 to use with the base unit 12 above described, the leftward portion of the cover 35, including the leftward, overhanging portion 37 may be structured much like that of the corresponding portion of the reservoir in aforementioned U.S. Pat. No. 4,655,754. Thus, in present FIG. 3, the leftward portion of the cover 35 has an upward opening recess 41 (FIG. 3) which extends from the central portion of the cover 35 nearly to the left end 37 thereof. A plate-like enclosure 42 is sealingly fixed in the recess 41 to close the top thereof. A vacuum, or suction, passage 43 is formed by the recess 41 and plate-like closure 42. A leg 44 integrally depends from the left end of the cover 35 in close spaced relation to the left side of the bottle 36. Approximately midway down the leg 44, a wall 45 extends laterally within the leg to separate the hollow interior of the leg 44 into an upper chamber 46 communicating with the vacuum passage 43 thereabove, and a downwardly opening recess 47 communicable with the pressure sensor and vacuum pump in the base unit 12.
A check, or one way, valve 50 here comprises a conventional resilient umbrella valve head 51 depending from a coaxial stem 52 fixed in a central opening in the overlying wall 45, the stem 52 being enlarged adjacent its free end to firmly hold the radially enlarged head 51 normally in sealing contact against the wall 45. The valve 50 may for example be a Part No. VA 3123, available from Vernay, Inc., of Yellow Springs, Ohio. Holes through the wall 45 are closed by the overlapping umbrella valve head 51 when the air pressure in the recess 47 is higher than that in the upper chamber 46, i.e , when there is a sub-atmospheric pressure in the bottle 36. On the other hand, the valve head 51 is capable of opening by deflecting downward at its periphery for drawing air from the bottle 36 through the vacuum passage 43 and past the check valve 50 into the vacuum pump in the base unit 12. If desired, the opening of the umbrella valve 50 may be merely in response to an above-limit pressure in the reservoir 11. Alternately, it is contemplated that the valve 50 can be mechanically opened by insertion of the reservoir 11 into the base unit 12. For example, upward bending of a radially intermediate portion of the umbrella valve head 51 into a downward facing annular groove in the bottom of the wall 45 (radially closely surrounding the stem 52), by a fork-like prod 49, fixed on and upstanding from the base unit 12, bends the periphery of the head 51 down away from the wall 45 to open the holes in the wall 45.
The reservoir 11, embodying the present invention, departs from the reservoir of aforementioned U.S. Pat. No. 4,635,754 as hereafter described.
The vacuum passage 43, in the embodiment of the present invention shown in present FIG. 3, communicates with a nipple 53 which depends from the cover 35 into the interior of the bottle 36, for purposes appearing hereinafter.
The reservoir 11 is substantially greater in fore/aft thickness (right to left in FIG. 5) than the drainage reservoir of aforementioned U.S. Pat. No. 4,635,654. The greater fore/aft thickness provides additional volume for greater liquid storage and provides room for the additional internal structure of the reservoir 11 hereafter discussed.
Along its rearward (rightward in FIG. 5) edge and generally centrally of the bottle 36, as seen from right to left in FIGS. 3, 4 and 6, the cover 35 is provided with coaxial, communicating, upstanding and depending nipples 54 and 55 (FIG. 5). The outlet end of the tube 22 of the drainage tube set 13 is sealingly sleeved over the upstanding nipple 54 and thereby communicates with a liquid inlet tube 56 which is sealingly sleeved over the depending nipple 55. The inlet tube 56 depends downward into the bottle 36 to within about one-quarter inch of the bottom wall 57 of the bottle 36. Blood and other fluid material drawn into the bottle 36 through the tube set 13 and liquid inlet tube 56, exits from the bottom of the latter to progressively fill the bottle 36. Location of the outlet end of the liquid inlet tube 56 near the bottom wall 57 of the bottle 36 reduces splashing of the incoming blood and other liquid and reduces the possibility of physical injury to the incoming blood cells due to violent collision with each other or with the hard internal surfaces of the bottle 36.
A tubular valve guide 60 (FIG. 3) is fixed to and depends vertically from the cover 35 and substantially centrally down into the interior of the bottle 36. In the embodiment shown, the valve guide 60 is somewhat less than about one-half the vertical height of the bottle 36. The top end portion 61 of the guide 60 is stepped to a reduced diameter and received through a snug opening 62 in the cover 35 where it is fixedly secured, by any convenient means such as a suitable adhesive. To firmly fix the depending guide 60 with respect to the cover, the cover is provided with a depending annular flange 63 which receives and fixedly supports the stepped top end portion 61 of the guide 60.
A tubular standpipe 67 extends in a fixed, sealed manner centrally through the bottom wall 57 of the bottle 36. The standpipe 67 is preferably centered on the bottom wall 57. The tube 24 of FIG. 1 is sealingly sleeved over a nipple 68 depending from the bottle bottom wall 57 and defining the lower end of the standpipe 67. The standpipe 67 extends from the bottle floor 57 upward to a height above the floor 57 (in the embodiment shown about an inch) which will exceed the likely thickness of a layer of unwanted fatty materials, such as lipids, which may enter the reservoir 11 with blood from the wound and tend to form a layer floating on top of the blood.
A vertically elongate valve stem 65 is vertically slidably supported in a longitudinal, central, through bore 66 of the tubular valve guide 60. The guide 60 and valve stem 65 are coaxially aligned above the standpipe 67. Fixed to the bottom end of the stem 65 is a flat, resilient valve disk 70 which, in the lower position of the valve stem 65 shown in FIG. 3, seats upon and closes the open top of the standpipe 67. Fixed to the bottom of the stem 65 is a depending hood 71. The hood 71 defines a downwardly opening recess 72 of diameter somewhat exceeding the diameter of the standpipe 67, for radially loosely receiving the standpipe 67 therein. In FIG. 3, the hood 71 extends downward from the valve disk 70 to within a short distance, for example a quarter inch, from the bottom wall 57 of the reservoir 11. Thus, the hood 71 is somewhat shorter vertically than the standpipe 67.
At one side of the stem 75, the hood 71 is provided with an upstanding nipple 73, which extends above the level of the valve disk 70. The lower end of a flexible gas vent tube 74 sealingly sleeves over the nipple 73. The gas vent tube 74 extends upward from the hood 71 and is fixed, by any convenient means not shown (such as an adhesive or a clamp) to the side of the guide 60. The upper end of the gas vent 74 opens upward near, but spaced slightly downward from the underside of the cover 35, for example about three quarters of an inch therebelow. The top of the tube 74 is above the level to which liquid is allowed to rise in the bottle 36.
Raising of the valve stem 65, from its FIG. 3 position to its elevated FIG. 4, position lifts the valve disk 70 from the top of the standpipe 67 and thus permits communication between the standpipe 67 and the interior of the bottle 36, past the bottom of hood 71. To accommodate the upward displacement of the stem 65, the gas vent tube 74 flexes laterally as indicated in FIG. 4.
Even in the uppermost position of the valve stem 65, shown in FIG. 4, the hood 71 still extends below the top of the standpipe 67. Thus, a layer of unwanted lipids and the like, floating atop the blood in the reservoir, is blocked by the depending hood 71 from access to the open top of the standpipe 67 and therefore cannot escape from the reservoir 11 into the tube 24 leading to the transfusion bag 23. Thus, floating contaminants, such as lipids, are prevented from passing from the reservoir 11 to the transfusion bag 23 (FIG. 1), but the heavier blood in the reservoir 11 is allowed to pass under the hood 71 (FIG. 4) and down into the open top of the standpipe 67 and thence through the tube 24 into the transfusion bag 23, at least until the level of liquid in the reservoir 11 drops to a level even with the top of the standpipe 67.
Where liquid drains from the reservoir by gravity (as it would in FIG. 1, for example, where the transfusion bag 23 is located below the level of the reservoir 11) the gas vent tube 74 vents the upper end of the hood 71 to the top portion of the interior of the bottle 36 so that the pressure in these two locations is the same. Accordingly, liquid passing from the bottle 36 downward through the standpipe 67 and tube 24 into the transfusion bag 23 cannot itself drop the pressure within the hood 71 to less than the pressure within the bottle 36, and so cannot itself suck liquid from the bottle 36 and thereby cause the minimum liquid level in the bottle 36 to drop below the top of the standpipe 67. Thus, the vent tube 74 prevents sucking of any part of the floating layer of lipids or other unwanted materials under the hood 71 and down through the standpipe 67. Thus, the standpipe 67, hood 71 and gas vent tube 74 act in concert to prevent unwanted floating materials, particularly lipids, to be drawn with the blood from the reservoir 11 into the transfusion bag 23, when the valve 70 is opened by lifting of the stem 65 to its upper FIG. 4 position.
A downward opening recess 80 in the valve guide 60 is coaxial with and enlarges the diameter of the bottom portion of the bore 66. The recess 80 forms a downward facing step 81 in the bore 66. A radially outwardly extending flange 82 is fixed on the valve stem 65 intermediate the ends thereof. The flange 82 is of sufficiently small diameter to be freely slidable within the recess 80 in the valve guide 60. The diameter of the stem 65 above the flange 82 is less in diameter than the recess 80, and a spiral compression spring 83 is axially freely slidably disposed in the elongate annular space between the periphery of the stem 65 and the inner peripheral wall of the recess 80. The spring 83 is axially trapped between the flange 82 on the stem 65 and the downward facing step 81 of the valve guide 60. Thus, the spring 83 resiliently urges the valve stem 65 downward with respect to the valve guide 60 and overlying cover 35, so as to urge the valve disk 70 firmly against the top of the standpipe 67 to seal the latter against escape of liquid from the reservoir 11.
The valve stem 65 has an upward facing step 84 opposed to the downward facing step 81 in the valve guide 60. In the lower position of the stem 65, shown in FIG. 3, the steps 81 and 84 are spaced vertically by a distance substantially less than the height of the hood 71. Thus, the valve stem 65 can move upward only to a limited extent, until the two steps 81 and 84 collide, at which position the hood 71 still substantially vertically overlaps the standpipe 67, as seen in FIG. 4.
The reduced diameter, upper portion of the stem 65, above the step 84 thereof, cooperates with and is snugly vertically slidable in the portion of the through bore 66 above the recess 80, for providing further valve functions as hereafter discussed. These functions include, in the FIG. 3, downward position of the valve stem 65, connecting the upper portion of the interior of the bottle 36 to the suction leg 44 to draw gases from and thereby reduce the pressure in the bottle 36 to sub-atmospheric pressure. Alternately, with the valve stem 65 in its FIG. 4, upper position, these valve functions include disconnecting the interior of the bottle 36 from the suction leg 44 and instead opening the interior of the bottle 36 to the atmosphere above the cover 35 to permit drainage of liquid in the bottle 36 through the standpipe 67.
To accomplish these valving functions, annular seals 90, 91, 92 and 93 (FIG. 3) are spaced along the valve stem 65 and seal against the reduced diameter upper portion of the through bore 66 above the step 81. In the embodiment shown, the annular seals 90-93 are conveniently resilient O rings received in corresponding annular grooves spaced along the length of the reduced diameter upper portion of the valve stem 65.
As seen in FIG. 3, a flexible tube 94 sleeves over the suction nipple 53 and at its other end is fixed in a recessed hole 95 communicating through the sidewall of the valve guide 60, to open into the through bore 66 in spaced relation vertically between the spring recess 80 and the cover 35.
The ends of the tube 94 are sealingly fixed over the nipple 53 and in the recessed hole 95 to communicate the vacuum passage 43 with the through bore 66 of the tubular valve guide 60.
A further recessed hole 96 (FIGS. 3 and 6) communicates with the bore 66 of the valve guide 60 at a location spaced axially between the hole 95 and the cover 35. In the embodiment shown, the hole 96 extends laterally away from the hole 95.
Spaced to the right and rear of the tubular valve guide 60, and depending from the underside of the cover 35, is a protective unit 100 (FIG. 4) comprising a generally circular casing 101. The casing 101 is covered by a reduced diameter upper end portion 102 (FIGS. 3 and 6) fixed by any convenient means, such as adhesive bonding, to the underside of the cover 35. A recessed hole 103 in the upper end portion 102 communicates with a central opening 104 in the casing 101. The recessed hole 103, in the embodiment shown, faces generally leftward. A flexible tube 105 (FIG. 6) has opposite ends sealingly fixed in the recessed holes 96 and 103 respectively, the tube 105 extending generally in a S-shape therebetween.
Returning to the valve stem 65, the topmost O-rings 92 and 93 are spaced axially along the stem 65 at opposite ends of an axially elongate annular groove 106 in the stem. With the stem 65 in its normal downward position of FIG. 3, the annular groove 106 communicates the recessed holes 95 and 96 in the valve guide 60 and thereby connects the suction leg 44 to the vacuum passage 43 and tube 94 through the recessed hole 96, tube 105 (FIG. 6) and central opening 104 in the upper end portion 102 of the protective unit 100.
An axial depression 107 (FIG. 3) in the interior surface of the bore 66 extends from a point just above the upper O-ring 93, with the latter in its downward position of FIG. 3, upward along the periphery of the upper end portion of the stem 65, to open through the top surface of the cover 35 to the atmosphere surrounding the reservoir 11. In the lower, FIG. 3 position of the stem 65, the upper O-ring 93 prevents venting of the reservoir 11 to the atmosphere. On the other hand, in the upper position of the valve stem 65 shown in FIG. 4, the upper O-ring 93 is lifted above the bottom of the axial depression 107 to communicate the atmosphere surrounding the reservoir 11 through the axial depression 107, annular groove 106, the recessed hole 96, the tube 105 (FIG. 6), the central opening 104 in the upper end portion 102 of the protective unit 100, with the interior of the bottle 36.
The lower O-rings 90 and 91 are, in both the upper and lower positions of the stem 65, located below the tube 94 and thus provide a redundant seal to insure that liquid within the bottle 36 cannot reach the vacuum passage 43 and suction leg 44 by seeping between the valve stem 65 and valve guide 60. Also, the lowermost O-ring 90 is spaced below the adjacent O-ring 91 by a distance greater than the stroke length of the valve stem 65. Thus, there is a short vertical segment of the valve guide bore 66, between the O-rings 90 and 91, that neither of the O-rings 90 and 91 can contact. This prevents possible contaminants from entering the reservoir 11 through the air vent 107 and passing down the bore 66 into contact with liquid in the bottle 36.
The protective unit 100 (FIGS. 2 and 4) has a washerlike, horizontally extending divider 110 (FIG. 4) which separates the hollow interior of the casing 101 into upper and lower chambers. The upper chamber contains a conventional hydrophobic filter 111 (for example of the kind shown in the above-referenced U.S. Pat. No. 4,655,754) which substantially fully occupies the upper chamber except for a vertically thin space 112 immediately above the divider 110. The hydrophobic filter has a central, upstanding nipple 113 snugly and sealingly received in the bottom portion of the central opening 104. The hydrophobic filter 111 permits a suction source, connected to the depending suction leg 44, to draw air and other gases from the interior of the bottle 36 upward therethrough (with the valve stem 65 in its normal lowered position FIG. 3) but prevents liquid from passing therethrough. On the other hand, with the valve stem 65 in its raised FIG. 4 position, the very small pore size (for example about 2 microns) of the pores in the hydrophobic filter 111 are small enough to in effect sterilize ambient air drawn from the atmosphere, through the axial depression 107 and thus eventually downward through the hydrophobic filter 112 into the bottle 36. This prevents airborne bacteria and the like from entering the bottle 36 and contacting, and possibly contaminating, blood therein.
Below the annular divider 110, a casing 101 has a lower chamber which is loosely occupied by a float valve 114. In the embodiment shown, the float valve 114 comprises an annular float 115 loosely disposed in the lower chamber for rising and falling therein. A stub shaft 116 is fixed to and extends up through the bottom 117 of the protective unit casing 101. The float 115 has a downwardly opening central recess in which the stub shaft 116 is snugly but axially slidably located, to positively guide the rise and fall of the float 115. Extending upward from the float 115 is a central peg 120 which fixedly supports a resilient, washer shaped valve member 121. The cup shaped casing 101 has openings 125 in the side wall thereof for admitting liquid into contact with the float 115, so that the float rises and falls in response to corresponding changes in liquid level in the bottle 36.
With the liquid in the bottle 36 below a desired maximum level, the float 115 is not lifted by such liquid but rather remains at or near its lowermost position shown in FIG. 4. In this way, the valve means 121 are not lifted into contact with the central opening (valve seat) 122.
On the other hand, when the liquid level in the bottle 36 rises to a sufficient level, to float the float 115 (as seen in FIG. 3), the float 115 rises until the annular valve member 121 rises up into contact with the downwardly flared valve seat 123 in the washer-like divider 110, to close and seal the valve seat 123 and thereby isolate the interior of the bottle 36 both from the atmosphere 107 and from the vacuum passage 43 and suction leg 44.
Fixed atop the stem 65 and protruding upward through the cover 35 is a hook 130 by means of which the stem 65 can be raised and lowered between its FIGS. 3 and 4 positions. To facilitate raising and lowering of the valve stem 65, an inverted L-shaped cross section handle 131 (FIGS. 3 and 4) has a cross shaft 132 over which the hook 130 is hooked. The handle 131 has depending side walls 133. The side walls 133 at their lower right corner define a fulcrum 134 about which the handle 131 is pivotable, by depressing and raising the rightward end of such handle.
A flexible disk 136 (FIG. 2) is fixed in an opening in the cover 35 and visibly flexes, to change contour (dimples) in response to application of sub-atmospheric pressure to the interior of the bottle 36, so that a person can, by inspecting the shape of the disk 136, tell whether there is a sub-atmospheric pressure in the bottle 36.
The apparatus may be constructed of any desired material. In one embodiment constructed according to the invention, and by way of example, the flexible tubes were of PVC, and the rigid parts of the reservoir were of molded plastics material, for example polycarbonate.
OPERATION
The reservoir 11 can be assembled as follows. The protective unit 100 preferably is assembled by upwardly inserting the stub shaft 116 through a snug central opening in the bottom of the upwardly opening, cup shaped casing 101, whereupon the float 115 (with attached resilient valve washer 121) is dropped into the casing 101 to loosely sleeve over the upper end of the stub shaft 116, so as to be free to rise and fall with changes in liquid level.
The washer-like horizontal divider 110 is then fixed within the cup shaped casing 101 (for example by seating upon an unnumbered, narrow, upward facing step shown in FIG. 3). The hydrophobic filter 111 has its upstanding central nipple 113 plugged into the central opening 104 in the upper end portion 102. The upper end portion 102, with the underlying hydrophobic filter 111, is then plugged into the open top of the casing 101. The parts fixed together as above described are held together by any convenient means, such as adhesive bonding. The top of the upper end portion 102 of protective unit 100 is secured, as by adhesive bonding, to the underside of the cover 35.
The valve guide 60 is pendently fixed to the underside of the cover 35 by upward insertion of its top end portion 61 snugly and fixedly into the central hole 62 in the cover 35. The spring 83 is slid down over the top portion of the valve stem 65 and the latter, with the valve disk 70 fixed, as by adhesive bonding, to the bottom thereof, is upwardly inserted into the valve guide 60 so that its hooked upper end 130 protrudes out above the top cover 35. The O rings 90-93 are preassembled on the upper portion of the stem 65 in the manner shown in the drawings
With the handle 131 sitting atop the cover 35 slightly to the right of its position of FIG. 3, the valve stem 65 is manually pushed up as far as possible in the valve guide 60. The handle 131 is then slid leftward to side the shaft 132 therein under the hook 130 at the upper end of the valve stem 65. The valve stem 65 is then allowed to drop, so that the hook 130 drops over and captures the shaft 132 of the handle 131. Thus, the valve stem and handle are connected releasably in the manner shown in FIGS. 3 and 4.
The tube 105 (FIG. 6) then has its ends inserted into the recessed holes 96 and 103 in a fixed, sealed manner. The tube 94 can then similarly be snugly and fixedly sleeved over the nipple 53 and snugly and fixedly inserted into the recessed hole 95 in the valve guide 60. The gas vent tube 74 can then similarly be fixedly and snugly sleeved over the nipple 73 and fixedly secured near its upper end to the side of the valve guide 60.
The above-mentioned fixed connections between the valve guide 60 and tubes 74, 94 and 105 can be secured, as by adhesive bonding, as can be the securement of the tube 94 to the nipple 53.
The umbrella shaped check valve 50 can at this point be upwardly inserted through the central opening of the wall 45 within the hollow suction leg 44. The plate-like closure 42 can be fixed to cover the flat recess 41 in the cover 35 by adhesive bonding along its edges.
The liquid inlet tube 56 can, at its upper end, be sleeved over the depending nipple 55, and if desired, secured thereto by adhesive bonding. Also, the standpipe 67 can be inserted upward through the central opening 76 in the bottom 57 of the bottle 36. The standpipe 67 here has a radially outwardly extending flange spaced intermediate its ends, which flange is fixedly received in the opening 76 and may be secured thereto by adhesive bonding.
At this point, the cover 35, carrying the above-named parts fixed thereto, can be placed atop the bottle 36 with the valve stem 65 coaxially aligned above the standpipe 67. The cover 35 can then be fixed to the top of the bottle 36 by any convenient means, such as adhesive bonding. This completes assembly of the reservoir 11
To ready the reservoir 11 for collecting blood, a tube set 13 is secured thereto. More particularly, the tube 22 of the tube set is snugly and sealingly sleeved over the upstanding nipple 54 atop the cover 35. The drain tube 14 (or 14 and 14' if a Y fitting 15 is provided) can then be inserted into a wound to be drained. The inlet tube 24 of the transfusion bag 23 is intended to be permanently sealingly sleeved over the downwardly protruding nipple 68 on the underside of the bottle 36, as shown in FIG. 1.
With a charged battery 30 inserted into the base unit 12 (FIG. 1), the reservoir 11 can be downwardly inserted into the base unit in the manner shown in above-mentioned U.S. Pat. No. 4,655,754. If the gas pressure in the reservoir 11 is not in its preset sub-atmospheric pressure operating range, the vacuum pump in the base unit 12 turns on. With the valve stem 65 in its lower, FIG. 3 position, the vacuum pump in the base unit 12 draws gases (normally air) from the interior of the bottle 36 through the openings 125 in the protective casing 101, up past the open valve seat 123, through the hydrophobic filter 111, central opening 104, recessed hole 103, tube 105 (FIG. 6), recessed hole 96, annular groove 106, tube 94, vacuum passage 43, and the check valve in the suction leg 44 and thence to the base unit 12 and its vacuum pump. In this downward position of the valve stem 65 shown in FIG. 3, the valve stem 65 shuts off any communication of bottle 36 with the axial depression 107 (the vent to the atmosphere) and standpipe 67. Thus, the base unit 12 can reduce the pressure within the bottle 36 to a sub-atmospheric pressure in a desired range. A typical sub-atmospheric pressure range to which the base unit 12 can be set is, for example, 0.5 PSI to 2.4 PSI below atmospheric pressure.
The sub-atmospheric pressure in the bottle 36 draws blood, and in many instances some unwanted flowable materials such as lipids or other fatty substances, from the wound, through the tube set 13 (FIG. 1) toward the reservoir 11. As above described, the pre-filter 17 acts to remove solid particles such as bone chips and the like from the flow.
Although the base unit 12 is portable, it may be desired to remove the reservoir 11 from the base unit, since the reservoir 11 is lighter, more compact and hence even more portable when not attached to the base unit 12. After release from the base unit 12, the sub-atmospheric pressure in the reservoir 11 is preserved against loss by automatic closure of the check valve 50, so that the reservoir can continue to draw fluid from the wound through the tube set 13.
As a result, the level of liquid in the reservoir begins to rise. The entering liquid rises past the top of the hood 71 (FIG. 3). The vent tube 74 allows the liquid to rise within the hood 71 as it rises outside the hood.
As above stated, the hydrophobic filter 111 permits gases, such as air, to be withdrawn from the bottle 36 the base unit 12, but blocks liquids from passing therethrough. Thus, if liquid enters the protective unit 100, due to splashing, tilting of the reservoir, normal rise, or any other reason, and the float valve 121, 123 should unexpectedly fail to close, the hydrophobic filter 111 prevents contamination of the vacuum pump in the base unit 12.
Should the liquid rise enough, it will contact and lift the float 115 until the rising float 115 pushes the annular valve means 121 against the valve seat 123 to close the float valve and thus prevent any further exit of gases and liquid upward to the hydrophobic filter 111. Once the float valve 121, 123 is closed, and assuming the reservoir 11 is plugged into the base unit 12, the central opening 104, holes 103 and 96, tube 94, vacuum passage 43, and suction leg 44 rapidly drop in pressure, until below the desired, preset range and this shuts off the vacuum pump in the base unit 12, in the manner discussed in the aforementioned U.S. Pat. No. 4,655,754. At the same time, the closed float valve 121, 123 and high liquid level prevent any significant additional amount of liquid from being drawn into the reservoir 11.
Liquid, particularly blood, can be emptied from the bottle 36 when desired. For example, blood in the bottle 36 can be emptied through the tube 24 into a transfusion bag 23 as follows. The handle 131 is depressed from its FIG. 3 to its FIG. 4 position, by the hand of the operator, to lift the valve stem 65 with respect to the valve guide 60. As seen in FIG. 4, this has several effects.
First, the vacuum path through the tube 94 is cut off from the recessed hole 96 by the correspondingly raised 0 ring 92. Thus, after the liquid level within the bottle 36 falls sufficiently (as hereafter discussed) and the float 115 falls and opens the float valve 121, 123, the interior of the bottle 36 remains disconnected from the vacuum passage 43.
Second, the valve disk 70 is lifted off the top of the standpipe 67. The heavier liquids, such as blood, pass under the bottom of the hood 71 and over the top of the standpipe 67 to exit through the tube 24. Lighter liquids, such as lipids and the like, float in a more or less discreet layer atop the blood. Blood continues to drain from the reservoir 11 until the top of the liquid mass lies about level with the top of the standpipe 67, as shown in FIG. 4. Then no more liquid flows out of the reservoir 11, such that the layer of unwanted floating material (lipids and the like) when its top is flush with the top of the standpipe 67, its bottom does not extend downward to the bottom of the hood 71, so that no appreciable portion of this unwanted floating material layer L can escape from the bottle 36 and enter the transfusion bag 23, thus keeping the transfusion bag 23 free of it. The venting of the top of the hood 71 by the flexible tube 74 keeps the gas pressure under the hood 71 equal to that in the rest of the bottle 36. Thus, the pull of gravity downward on the liquid within the exit tube 54 cannot stuck, or siphon, the unwanted floating lipids layer L down under the bottom of the hood 71, up into the hood 71 and then down through the standpipe 67.
As a result, the aforementioned apparatus permits removal of the blood (or most of it) from the bottle 36 into the transfusion bag 23 for subsequent transfusion back to the patient, while eliminating the unwanted lipids.
Third, the valve stem 65 in its upward position of FIG. 4 vents the interior of the bottle 36 past the float valve 121, 123, hydrophobic filter 111, holes 103 and 96, thence through the annular groove 106 and axial depression 107 to the atmosphere surrounding the reservoir 111. Such venting permits the aforementioned drainage of the bottle 36 through the standpipe 67.
When the bottle 36 has been sufficiently drained of liquid, the operator can then pivot the handle 131 counterclockwise back to its rest position at FIG. 3, thus allowing the spring 83 to return the valve stem 65 to its downward position of FIG. 3, thereby closing the top of the standpipe 67 and the passage through the axial vent depression 107 and restoring the connection of the vacuum passage 43 through the hydrophobic filter and float valve into the bottle 36 to once again enable production of the pressure in the bottle 36 to the desired atmospheric range.
During venting of the upper portion of the bottle 36 to the atmosphere as seen in FIG. 4, the hydrophobic filter 111, due to its very small effective pore size, for example an effective pore size of one micron or less for example 0.45 microns, acts to sterilize the incoming air entering the bottle 36 by mechanically blocking entry of bacterial agents and the like.
The tubes 14, 16, 20, 22, 24 and 56 are preferably of a flexible resilient material such as PVC.
Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
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A blood conservation system capable of receiving blood and lipids from a patient. A reservoir is releasably connectable to a patient for receiving body liquids, including blood. A transfusion unit is attached for receiving blood from the reservoir. The reservoir includes a valve unit actuable for transferring blood to the transfusion unit but preventing transfer of lipids. The valve unit also controls venting of the reservoir.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2013-0138142, filed on Nov. 14, 2013, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to a method for preparing a disubstituted urea and carbamate compounds by reacting an amine, carbon dioxide and an alkylene oxide compound in the presence of an ionic liquid-based catalyst system, more particularly to a method for preparing a disubstituted urea and carbamate compounds simultaneously through a one-pot reaction of an amine, carbon dioxide and an alkylene oxide compound in the presence of an ionic liquid-based complex catalyst system containing indium.
BACKGROUND
[0003] Disubstituted ureas are usefully used as starting materials or intermediates of agrichemicals, herbicides, insecticides and carbamates and various methods for their preparation are being studied.
[0004] The existing method of preparing urea by reacting an amine with phosgene is disadvantageous in that the highly toxic and corrosive phosgene is used and a large amount of the pollutant HCl is produced as byproduct. Accordingly, methods for preparing urea without using the harmful phosgene have been studied in the US, Japan and Europe.
[0005] U.S. Pat. No. 2,877,268 discloses a method for preparing urea by reacting an amine with carbonyl sulfide (COS) in the absence of a catalyst, and the literature “ J. Org. Chem . (R. A. Franz, 26, p. 3309, 1961)” discloses a method for preparing urea by reacting an amine with carbon monoxide (CO) and sulfur (S) using a tertiary amine as a catalyst. However, these methods are problematic in that byproducts difficult to handle such as H 2 S are produced because sulfur is used.
[0006] Japanese Patent Publication No. S62-59253 discloses a method for preparing urea from a nitro compound using a catalyst such as rhodium, ruthenium, etc. Although this method allows preparation of urea with relatively high conversion rate and selectivity, the expensive noble metal catalyst may be easily decomposed because of high reaction temperature and pressure.
[0007] European Patent No. 0 319 111 discloses a method for preparing urea from a mixture of an amine and nitrobenzene using a noble metal catalyst palladium with a salt of copper, iron, manganese, vanadium, chromium, etc. added to maintain the activity of the palladium catalyst. As described in Example 1 of the EP 0 319 111, this method is problematic in that the maximum yield of urea is low as 73% (turnover frequency, i.e., the number of moles of urea produced per unit time, per a mole of catalyst <4) when reacted for 20 hours under the condition of 140° C. and 50 atm.
[0008] A method for synthesizing aliphatic urea by carbonylation of an amine in the presence of a selenium catalyst is described in “ Chemistry Letters (Koyoshi Kondo, p. 373, 1972)”. This method is problematic in that a large amount of the catalyst is spent since the selenium is used in an equimolar amount with respect to the starting material amine and that the reaction hardly proceeds if an aromatic amine is used as the starting material.
[0009] U.S. Pat. No. 4,052,454 discloses a method for synthesizing urea by reacting a nitro compound with water and carbon monoxide in the presence of a selenium metal catalyst. This method is economically unfavorable since, as described in Example 1 of the U.S. Pat. No. 4,052,454, nitrobenzene conversion rate and urea yield are only 66.3% and 33.8% (turnover frequency, i.e., the number of moles of urea produced per unit time, per a mole of catalyst <2) when reacted for 1 hour under the condition of 150° C. and 53 atm, with a molar ratio of the catalyst to the starting material nitrobenzene of about ⅛.
[0010] As described above, the existing methods for preparing substituted urea are inappropriate for preparation of the substituted urea in industrial scale because of byproduct formation, reaction condition with high temperature and pressure, and low yield, and are problematic in that it is difficult to prepare urea in high yield when a less reactive aromatic amine is used as a starting material in spite of the reaction condition with high temperature and pressure. And, the method for preparing urea using selenium as a catalyst also has a problem because of the characteristic unpleasant odor of selenium after the reaction under the condition with high temperature and pressure.
[0011] Hydroxyalkyl carbamates are synthetic intermediate useful in various fields, including drug synthesis and agrichemical production, and as precursors of polyurethane.
[0012] As an existing method for preparing a hydroxyalkyl carbamate, Korean Patent No. 10-0050365 discloses preparation of 2-hydroxypropyl carbamate by reacting propylene carbonate with a primary or secondary aliphatic amine.
[0013] Also, U.S. Pat. No. 4,268,684 (Arthur E. Gurgiolo) discloses a method for preparing an aromatic carbamate by reacting an aromatic amine, e.g., aniline, with dimethyl carbonate, and U.S. Pat. No. 4,550,188 discloses a catalyst for reacting an aromatic amine with an organic carbonate, including a mercury salt and iodine. However, there are problems of the toxicity of mercury and low performance of the catalyst. Also, the aromatic polyurethane derived from the aromatic carbamate synthesized from the aromatic amine has unsatisfactory physical and chemical properties as compared to aliphatic polyurethane due to yellowing.
[0014] Meanwhile, Korean Patent Publication No. 1991-0009114 relates to a novel hydroxyalkyl carbamate having one or more secondary amine groups in the molecule and a method for preparing same, and describes preparation of a hydroxyalkyl carbamate from a polyfunctional amine having at least one primary amine group and at least one hindered secondary amine group, wherein the primary amine group(s) react(s) selectively with a cyclic carbonate and the secondary amine group(s) remain(s) unreacted.
[0015] Korean Patent No. 10-0576404 relates to a β-hydroxyalkyl carbamate-modified resin for pigment dispersion and a cationic electrodeposition paint composition containing same, and describes preparation of a β-hydroxyalkyl carbamate from reaction of a cyclic carbonate with a polyepoxide-amine resin.
[0016] U.S. Pat. No. 6,165,338 relates to a cathodic electrodeposition coating composition and describes preparation of a hydroxyalkyl carbamate from reaction of a primary or secondary amine or diamine with a cyclic carbonate such as ethylene carbonate.
SUMMARY
[0017] The present disclosure is directed to providing a method for preparing a disubstituted urea and carbamate compounds simultaneously with high yield from an amine as a starting material, more particularly a method for preparing a disubstituted urea and carbamate compounds simultaneously through a one-pot reaction of an amine, carbon dioxide and an alkylene oxide compound in the presence of an ionic liquid-based complex catalyst system containing indium.
[0018] In one general aspect, there is provided a method for preparing a disubstituted urea represented by Chemical Formula 1 and carbamate compounds represented by Chemical Formula 2 and Chemical Formula 3 simultaneously by reacting an amine, carbon dioxide and an alkylene oxide compound in the presence of an ionic liquid-based catalyst system containing indium:
[0000]
[0019] wherein
[0020] R 1 is a C 2 -C 10 aliphatic alkyl group, a C 4 -C 10 alicyclic alkyl group or a C 5 -C 6 aryl group, wherein the terminal of the alkyl group or aryl group may be either substituted with a hydroxyl group, an acyl group, a carboxyl group, a halogen atom or an —NH 2 group or unsubstituted; and
[0021] R 2 is a C 2 -C 10 aliphatic alkyl group, a C 4 -C 10 alicyclic alkyl group, a C 5 -C 6 aryl group or a halogen atom.
[0022] The ionic liquid-based catalyst system containing indium is a complex catalyst system represented by Chemical Formula 6 consisting of a main catalyst represented by Chemical Formula 4 and an alkali metal halide represented by Chemical Formula 5 as a promoter:
[0000] [Q][InX (4-n) Y n ] [Chemical Formula 4]
[0000] MZ [Chemical Formula 5]
[0000] [Q][InX (4-n) Y n ]-MZ [Chemical Formula 6]
[0023] wherein
[0024] [Q] stands for a cation of an ionic liquid, [InX (4-n) Y n ] stands for an anion of the ionic liquid and MZ stands for an alkali metal halide, wherein Q is imidazolium, phosphonium, ammonium or pyridinium, X is Cl, Br or I, Y is Cl or Br, M is an alkali metal, Z is Cl, Br or I, and n is an integer from 0 to 3.
[0025] The cation of the ionic liquid may be selected from a group consisting of 1-butyl-3-methylimidazolium (Bmim), tetra-n-butylphosphonium (TBP), tetra-n-butylammonium (TBA), tetra-n-butylpyridinium (C 4 Py) and choline (Chol).
[0026] The anion of the ionic liquid may be selected from a group consisting of InCl 4 , InCl 3 Br, InCl 3 I, InBr 3 Cl and InBr 4 .
[0027] And, the alkali metal halide may be selected from a group consisting of NaI, NaBr, NaCl, KI, KBr, KCl, RbI, RbBr, RbCl, LiI, LiBr, LiCl, CsI, CsBr and CsCl.
[0028] Specifically, the compound represented by Chemical Formula 4 may include but is not limited to [Bmim][InCl 4 ], [Bmim][InCl 3 Br], [Bmim][InCl 3 I], [Bmim][InBr 3 Cl], [Bmim][InBr 4 ], [Bmim][InI 4 ], [TBP][InCl 4 ], [TBP][InBr 4 ], [TBP][InI 4 ], [C 4 Py][InCl 4 ], [C 4 Py][InBr 4 ], [C 4 Py][InI 4 ], [Chol][InCl 4 ], [Chol][InBr 4 ] and [Chol][InI 4 ].
[0029] The main catalyst may be used in an amount of 1/5000- 1/50 equivalent, specifically 1/2500- 1/100 equivalent, based on the moles of the amine.
[0030] The main catalyst and the promoter may be added at an equivalence ratio of 1:1-1:5.
[0031] The alkylene oxide may be used in an amount of 0.5-2 equivalents based on the moles of the amine.
[0032] The amine may be a compound represented by Chemical Formula 7 and the alkylene oxide may be a compound represented by Chemical Formula 8 or Chemical Formula 9:
[0000] R 1 —NH 2 [Chemical Formula 7]
[0033] wherein
[0034] R 1 is a C 2 -C 10 aliphatic alkyl group, a C 4 -C 10 alicyclic alkyl group or a C 5 -C 6 aryl group, wherein the terminal of the alkyl group or aryl group may be either substituted with a hydroxyl group, an acyl group, a carboxyl group, a halogen atom or an —NH 2 group or unsubstituted;
[0000]
[0035] wherein
[0036] R 2 is a C 2 -C 10 aliphatic alkyl group, a C 4 -C 10 alicyclic alkyl group, a C 5 -C 6 aryl group or a halogen atom;
[0000]
[0037] wherein
[0038] n is an integer from 1 to 5.
[0039] The amine may be selected from a group consisting of methylamine, ethylamine, isopropylamine, butylamine, isobutylamine, hexylamine, dodecylamine, hexadecylamine, octadecylamine, benzylamine, phenylamine, cyclobutylamine, cyclohexylamine, 1,4-diaminocyclohexane, 4,4′-methylenebis(cyclohexylamine), aniline, benzylamine and phenylenediamine.
[0040] And, the alkylene oxide may be selected from a group consisting of ethylene oxide, propylene oxide, butylene oxide, cyclopentene oxide and cyclohexene oxide.
[0041] The reaction may be performed for 1-4 hours at 40-200° C. under a carbon dioxide pressure of 300-1500 psig, specifically for about 2 hours at 60-170° C. under a carbon dioxide pressure of 800-1200 psig.
[0042] The reaction may be performed either in the absence of a solvent or in the presence of a solvent.
[0043] When the reaction is performed in the presence of a solvent, it may be performed in the presence of one or more solvent selected from a group consisting of C 1 -C 6 alcohol, tetrahydrofuran (THF), dimethylformamide (DMF), N-methylpyrrolidinone (NMP), dimethyl sulfoxide (DMSO), acetonitrile, toluene and dioxane.
[0044] In accordance with the present disclosure, a disubstituted urea and carbamate compounds can be prepared simultaneously at high yield by reacting an amine, carbon dioxide and an alkylene oxide compound in the presence of an ionic liquid-based catalyst system containing indium.
[0045] The disubstituted urea and carbamate compounds prepared by the present disclosure can be easily converted to isocyanates, and the isocyanates can be used as important precursor compounds that can be converted to polyurethane through reaction with polyols.
[0046] Since the method of the present disclosure allows use of an aliphatic amine as a starting material, the yellowing problem of the polyurethane derived from aromatic amines can be resolved and the physical and chemical properties of the polymer can be improved.
[0047] In addition, the ionic liquid-based catalyst containing indium according to the present disclosure is economical because it can be reused several times.
DETAILED DESCRIPTION OF EMBODIMENTS
[0048] The advantages, features and aspects of the present disclosure will become apparent from the following description of the embodiments with reference to the accompanying drawings, which is set forth hereinafter.
[0049] The reaction of the present disclosure described above is described in the following scheme.
[0000]
[0050] In Scheme 1,
[0051] R 1 and R 2 are the same as defined in Chemical Formulas 1-3 and Chemical Formulas 7-8,
[0052] cat. stands for the ionic liquid-based catalyst system of the present disclosure, T for reaction temperature, P for pressure, t for reaction time and S for organic solvent. The catalyst system and the reaction conditions are the same as described above.
[0053] Although the reaction of the present disclosure is a one-pot reaction, the reaction pathway may be represented by Scheme 2.
[0000]
[0054] In Scheme 2, cyclohexylamine (CHA) and propylene oxide were used as starting materials and cat. stands for the ionic liquid-based catalyst system of the present disclosure.
[0055] As can be seen from Schemes 1 and 2, in the present disclosure, the starting materials, i.e., an amine (the compound represented by Chemical Formula 7 in Scheme 1, CHA in Scheme 2), carbon dioxide and an alkylene oxide (the compound represented by Chemical Formula 8 in Scheme 1, propylene oxide in Scheme 2) are reacted to produce a disubstituted urea, i.e., dicyclohexylurea (the compound represented by Chemical Formula 1 in Scheme 1, DCU in Scheme 2) and carbamate compounds, i.e., hydroxypropyl N-(cyclohexyl)carbamate (the compound represented by Chemical Formula 2 in Scheme 1, HPCC in Scheme 2) and 3-cyclohexyl-4-methyloxazolidone (the compound represented by Chemical Formula 3 in Scheme 1, CMOxz in Scheme 2).
[0056] Also, as can be seen from Scheme 2, aminoalcohol (CyNHCH 2 CHCH 3 OH, AmA) is produced as a byproduct. If byproducts such as AmA are produced in large amount, the conversion rate of CHA and the yield of DCU may decrease.
[0057] After the reaction of the present disclosure is completed, the insoluble urea may be weighed after filtration and drying to calculate its yield. The conversion rate of the amine may be calculated through gas-liquid chromatography. And, the yield of the carbamate compounds may be calculated by analyzing the residue remaining after separating the urea through gas chromatography.
[0058] In addition, the major target compound DCU can be easily separated through filtration and the catalyst can be reused by adding the starting materials to a solution in which the catalyst of the present disclosure is dissolved.
[0059] Hereinafter, the present disclosure will be described in more detail through examples. However, the following examples are for illustrative purposes only and not intended to limit the scope of this disclosure.
Example 1
Synthesis of Catalyst
[0060] [Bmim]Cl (6.2 g, 35.5 mmol) and InCl 3 (7.85 g, 35.5 mmol) were added to a 20-mL vial. After irradiating 600-W microwaves 3 times for 5 seconds and removing undissolved solid from the resulting liquid using a syringe filter, [Bmim][InCl 4 ] in liquid state was obtained with a yield of 98%. Also, [Bmim][InBr 4 ], [Bmim][InI 4 ], [TBP][InCl 4 ], [TBA][InCl 4 ] and [C 4 Py][InCl 4 ] were respectively prepared by the same method. [Chol][InCl 4 ] was prepared by refluxing for 2 hours using methanol as a solvent instead of the microwave irradiation.
Example 2
Preparation of DCU and HPCC Through Reaction at High Pressure
[0061] Cyclohexylamine (CHA, also “CyNH 2 ”) (4.26 g, 43 mmol), propylene oxide (PO) (43 mmol, 2.5 g), [Bmim][InCl 4 ] (0.085 g, 0.215 mmol), NaI (0.161 g, 1.075 mmol) and tetrahydrofuran (THF) (15 mL) as a solvent were added to a 100-mL high-pressure reactor equipped with a magnetic stirrer. After performing reaction for 2 hours under a CO 2 pressure of 1200 psig at 150° C., the reaction mixture was cooled to room temperature. After adding a predetermined amount (2 mL) of external standard, the solid product was separated. The separated solid product was washed 2-3 times with distilled water to remove cyclohexyl carbamate salt (CyNH 3 + CyNHCOO − ). After further washing 2-3 times with THF, the product was completely dried in a vacuum oven. After the drying, the produced dicyclohexylurea (N,N′-dicyclohexylurea, DCU) was weighed to calculate the production yield of DCU. The conversion rate (%) of CHA and the yield of DCU were calculated according to Equation 1 and Equation 2.
[0000] CHA conversion rate (%)=(Moles of reacted CHA )/(Moles of added CHA )×100 [Equation 1]
[0000] DCU yield (%)=(Moles of actually produced DCU )/(Moles of theoretically producible DCU )×100 [Equation 2]
[0062] The residue remaining after the separation of the solid product was analyzed by gas chromatography (GC) equipped with a flame ionization detector (FID) to confirm the production of hydroxypropyl N-(cyclohexyl)carbamate (HPCC), aminoalcohol (CyNHCH 2 CHCH 3 OH, AmA) and 3-cyclohexyl-4-methyloxazolidone (CMOxz). The yields of HPCC, AmA and CMOxz were calculated using the external standard. According to the GC analysis result, the CHA conversion rate was 85.9%, the DCU yield was 47.1%, the HPCC yield was 26.7%, the CMOxz yield was 9.9%, and the AmA yield was 2.1%.
Comparative Examples 1-9
[0063] Experiment was conducted under the same condition as in Example 2 while varying the catalyst and solvent in the absence of the promoter NaI. The result is shown in Table 1. As seen from Table 1, there was no significant difference in HPCC and CMOxz yields as compared to Example 2, but CHA conversion rate and DCU yield were lower and the production of reaction byproducts such as AmA was increased.
[0000] TABLE 1 CHA DCU HPCC/CMOxz AmA Comp. conversion yield yield yield Ex. Catalyst Solvent rate (%) (%) (%) (%) 1 None THF 68.9 0 25.6/32.9 10.3 2 InCl 3 THF 55.8 0.7 11.8/0.4 42.7 3 [Bmim]Cl THF 64.6 2.3 25.6/4.3 31.4 4 [Bmim][InCl 4 ] THF 73.1 23.8 27.4/1.7 15.7 5 [Bmim] 2 [ZnBr 2 Cl 2 ] THF 67.5 3.4 29.8/21.4 9.7 6 [Bmim][InCl 4 ] Toluene 75.5 25.8 15.1/6.2 28.5 7 [Bmim][InCl 4 ] Dioxane 68.4 19.8 19.3/3.3 25.6 8 [Bmim][InCl 4 ] Methanol 64.3 tr. 22.1/1.7 40.6 9 [Bmim][InCl 4 ] IPA 72.8 tr. 20.6/2.4 49.3
In Table 1, tr. stands for trace amount.
Comparative Examples 10-15
[0064] Experiment was conducted under the same condition as in Example 2 while varying the promoter. The result is shown in Table 2. As seen from Table 2, when NaI was used as the promoter, there was no significant difference in HPCC and CMOxz yields, but CHA conversion rate and DCU yield were increased and the production of reaction byproducts such as AmA was suppressed. However, when other promoters were used, no ionic liquid-based catalyst was used (Comparative Example 14), or no main catalyst was used and only NaI was used (Comparative Example 15), DCU yield was very low and the production of reaction byproducts such as AmA was increased.
[0000]
TABLE 2
CHA
DCU
HPCC/
AmA
conversion
yield
CMOxz
yield
Cat-Promoter
rate (%)
(%)
yield (%)
(%)
Comparative
[Bmim][InCl 4 ]—NaNO 2
61.6
10.1
22.9/1.9
26.7
Example 10
Comparative
[Bmim][InCl 4 ]—NaOH
67.9
14.1
27.6/2.0
24.3
Example 11
Comparative
[Bmim][InCl 4 ]—K 2 CO 3
73.5
13.4
14.1/4.1
41.8
Example 12
Comparative
[Bmim][InCl 4 ]—KOAc
60.6
7.2
10.2/1.3
41.0
Example 13
Example 2
[Bmim][InCl 4 ]—NaI
85.9
47.1
26.7/9.9
2.1
Comparative
InCl 3 —NaI
78.5
16.2
17.1/19.3
25.9
Example 14
Comparative
NaI
73.4
0
26.2/7.5
39.6
Example 15
Examples 3-16
[0065] Experiment was conducted under the same condition as in Example 2 while varying the promoter, i.e., the alkali metal halide. The result is shown in Table 3. As seen from Table 3, when LiI, NaI, KI, RbI or CsI was used as the promoter, there was no significant difference in HPCC and CMOxz yields, but CHA conversion rate and DCU yield were increased and the production of reaction byproducts such as AmA was suppressed. The DCU yield was the highest when NaI was used as the promoter.
[0000]
TABLE 3
CHA
DCU
HPCC/
AmA
conversion
yield
CMOxz
yield
Example
Promoter
rate (%)
(%)
yield (%)
(%)
3
LiCl
81.3
21.6
14.8/9.0
35.6
4
LiBr
70.6
25.6
28.2/2.5
13.9
5
LiI
74.3
28.9
25.5/6.8
12.9
6
NaCl
83.1
18.6
18.5/14.8
30.2
7
NaBr
76.7
20.9
16.6/8.5
30.6
2
NaI
85.9
47.1
26.7/9.9
2.1
8
KCl
75.8
16.9
24.4/3.5
30.8
9
KBr
75.6
20.1
24.6/0.4
30.2
10
KI
85.8
41.2
25.2/4.5
14.4
11
RbCl
73.8
25.3
28.2/3.1
17.1
12
RbBr
72.3
30.7
19.5/3.4
18.1
13
RbI
75.5
34.3
28.1/9.8
3.0
14
CsCl
68.6
19.7
31.1/2.1
15.6
15
CsBr
79.2
22.8
27.9/1.4
26.5
16
CsI
76.8
26.1
22.9/12.9
14.5
Examples 17-23
[0066] Experiment was conducted under the same condition as in Example 2 while varying the ionic liquid. The result is shown in Table 4. As seen from Table 4, when [Bmim]-based ionic liquid was used, CHA conversion rate and DCU yield were increased and the production of reaction byproducts such as AmA was suppressed. In Example 23, the amount of CHA was 2 times that of Example 2. It can be seen that the result was better when the equivalence ratio of CHA to PO was 1 than when it was 2.
[0000]
TABLE 4
CHA
DCU
HPCC/
AmA
conversion
yield
CMOxz
yield
Example
Catalyst
rate (%)
(%)
yield (%)
(%)
2
[Bmim][InCl 4 ]—NaI
85.9
47.1
26.7/9.9
2.1
17
[Bmim][InBr 4 ]—NaI
84.5
45.9
9.0/8.6
20.4
18
[Bmim][InI 4 ]—NaI
88.5
33.0
19.9/26.1
7.4
19
[TBP][InCl 4 ]—NaI
82.6
39.3
13.9/10.2
17.7
20
[TBA][InCl 4 ]—NaI
86.1
36.7
6.9/36.3
12.2
21
[C 4 Py][InCl 4 ]—NaI
82.1
40.6
14.5/10.2
16.8
22
[Chol][InCl 4 ]—NaI
82.3
35.5
26.2/15.9
3.8
23
[Bmim][InCl 4 ]—NaI
43.2
8.3
21.5/0
6.8
Examples 24-27
[0067] Experiment was conducted under the same condition as in Example 2 while varying the equivalence ratio of [Bmim][InCl 4 ] to NaI from 1:1 to 1:5. The result is shown in Table 5. As seen from Table 5, when the equivalence ratio was 1:5, CHA conversion rate and DCU yield were increased and the production of reaction byproducts such as AmA was suppressed.
[0000]
TABLE 5
CHA
DCU
HPCC/
AmA
conversion
yield
CMOxz
yield
Example
Catalyst
rate (%)
(%)
yield (%)
(%)
24
[Bmim][InCl 4 ]—1NaI
79.4
39.0
12.7/9.4
18.3
25
[Bmim][InCl 4 ]—2NaI
75.5
39.8
16.8/8.3
10.6
26
[Bmim][InCl 4 ]—3NaI
86.9
44.2
12.1/14.6
19.9
27
[Bmim][InCl 4 ]—4NaI
79.9
44.0
15.4/8.7
16.8
2
[Bmim][InCl 4 ]—5NaI
85.9
47.1
26.7/9.9
2.1
Examples 28-32
[0068] Experiment was conducted under the same condition as in Example 2 while varying the amine. The result is shown in Table 6. As seen from Table 6, when various amine compounds were used, amine conversion rate and urea yield were high and the production of reaction byproducts such as AmA was suppressed.
[0000]
TABLE 6
Conversion
Urea
HPCC
AmA
Example
Amine
rate (%)
yield (%)
yield (%)
yield (%)
28
80.5
50.6
33.4
6.4
29
90.4
66.4
20.6
3.4
30
50.5
33.4
18.0
6.1
31
80.5
49.5
20.4
2.3
32
48.4
20.6
20.4
4.4
[0069] While the present disclosure has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the disclosure as defined in the following claims.
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The present disclosure relates to a method for preparing a disubstituted urea and carbamate compounds simultaneously through a one-pot reaction of an amine, carbon dioxide and an alkylene oxide compound in the presence of an ionic liquid-based complex catalyst system containing indium. In accordance with the present disclosure, a disubstituted urea and carbamate compounds can be prepared simultaneously at high yield. In addition, the ionic liquid-based catalyst containing indium according to the present disclosure is economical because it can be reused several times.
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BACKGROUND OF THE INVENTION
[0001] The subject-matter of the invention is a personal document in book form, for example, a passport having a personalized page that together with the other pages of the personal document is bound by means of a seam and attached in a book cover.
[0002] The personalized page of a personal document normally comprises a plurality of strata. In particular, when integrating an RFID element for complying with ISO 9303 standards for machine-readable travel documents and for inscribing personal data and the passport photo, sandwich-type layer structures that have long service lives, which are temperature stable, and are protected against falsification are required. Such thermoplastic films and film combinations in general do not provide good articulation properties in the area of the seam. When using polycarbonate (PC) films or polyethylene therepththalate (PET) films, the reverse bending strength is generally limited. In particular, integrating an RFID element into the personalized page requires very thick sandwich-like structures. When using transparent laser-capable polycarbonate (PC) films or transparent laser-capable PET/PE-HD films, the graphic and electronic personalization can be performed in a finished passport document. Existing passport solutions have the problem that they open poorly and do not stay closed well because the stiffness of the personalized page causes the passport not to remain closed or open without the exertion of force.
[0003] DE 198 14 420 A1 cites an identification document, such as a passport or the like, that comprises a plurality of sheets that are bound on a seam to make a book. At least one of the sheets forms a data sheet that is provided with information and comprises at least two layers, whereby at least one of the layers is transparent. The format of the layers is selected such that they project beyond the area of the seam, and thus in the area of the seam, connect the data sheet to the other sheets of the identification document. In the area of the information the layers are joined to an inseparable laminate, In the area of the seam, however, they do not adhere to one another.
[0004] Thus, the number of bending cycles is intended to be increased and the stiffness of the laminate page is intended to be sharply reduced by the more flexible individual films in the area of the seam. Moreover, in the area of the data sheet, the passport pops open less than with passports that include a data sheet that is laminated across its entire surface. Plastic films made of PC, PETG, or HDT-PETG are preferably used for the films.
[0005] EP 1 008 459 B1 refers to a method for producing a booklet, such as, for example, an ID. A band is attached in the same manner as the other sheets of the booklet, and the band is attached to a plate in a special manner, whereby the plate is produced at least partially from a plastic material and has a front side and a reverse side, each side including one page. The aforesaid band is selected, for example, from a synthetic material that is suitable for being sewn in and for frequent bending and is preferably made of polypropylene.
[0006] EP 0 936 976 B1 discloses a passport with an information page that contains information about, and an image of, the passport holder, whereby the information page comprises a thermosetting plastic material such as, for example, polycarbonate, and is personalized with laser inscriptions, and whereby this page has a plurality of layers that are laminated to one another using heat and pressure. In the bending area, the output page has a separating layer between the outside layers so that these layers are not laminated, and in this manner, a bendable, long-lived bending location is provided on the information page in the passport.
[0007] EP 1 245 407 A2 describes a multi-layer personalized page in a passport that has a plastic layer into which data can be inscribed with the laser. This laser-capable layer made of polycarbonate is laminated by means of PE foam to a flexible backing made of HDPE and is sewn in the area of an excess length of the backing.
[0008] The goal of the present invention is to provide an improved personal document in book form that has a longer service life and is less susceptible to falsification.
SUMMARY OF THE INVENTION
[0009] The goal is attained in accordance with the invention with a personal document in book form including a book cover, a multi-layer personalized page that contains personal data, and interior pages, whereby the personalized page and the interior pages are attached in the book cover by means of a seam. The multi-layer personalized page has a core stratum comprising a textile layer, and is joined on both sides to at least one thermoplastic layer, which cover the core stratum up to a section of excess length. An RFID element with an IC element for contactless transmission of biometric data from the personalized document is integrated in the core stratum. The personalized page is sewn by means of the seam to the other pages and the book cover in the area of the excess length.
[0010] The textile layer of the personal document is preferably a fabric, in particular a polyester fabric and/or a polyester satin fabric. This results in a particularly bendable, long-lived articulation in the area of the seam in the personal document.
[0011] Another advantageous embodiment results when the textile layer is a cotton fabric and/or a cotton blend fabric or a microfiber fabric made of thermoplastic fibers. However, it is also possible for the textile layer to be a non-woven fabric.
[0012] Particular advantages result in that the textile layer can contain machine-readable security elements, which enhances protection against falsification. Such security elements include added security pigments and/or security prints that are used during authentication of the personal document.
[0013] The textile layer in accordance with the invention is provided, on at least one page, with a bonding agent layer that can be applied, for example, in the form of a film, in particular a perforated film, in the form of a random fabric, a coating, or print.
[0014] The bonding agent layer preferably comprises a thermoplastic adhesive, in particular a hotmelt, that joins the textile layer to the plastic layer covering the core stratum in a manner that cannot be released without visibly damaging the layers. It is particularly advantageous when a reactive resin or a partially reactive resin mixture is used with which the textile layer and the plastic layer covering the core stratum are joined permanently. Preferably, the plastic layers on the front side and on the back side of the personalized page are joined to one another by lamination.
[0015] Preferably, the core stratum has recesses through which the plastic layers of the front side and the back side can join one another in a fused compound. Thus it is practically impossible for a forger to subsequently separate the layers.
[0016] In accordance with the invention, the plastic layers covering the core stratum include a first opaque thermoplastic film, for example, a white thermoplastic film, and at least one transparent laser-capable film into which the personalized data, in particular the passport photo, are inscribed with laser irradiation. These layers preferably comprise polycarbonate (PC) and/or polyethylene therepththalate (PET) and/or high-density polyethylene (HDPE) or a blend of these materials. The transparent laser-capable film is covered with a protective layer that is laminated thereto in the same manner and cannot be removed without being destroyed.
[0017] The personal document in accordance with the invention has a coil integrated into the personalized page, in particular into its core stratum, for contactless reading of biometric data for the holder of the personal document.
[0018] Advantageously, diffractive elements can also be laminated in between the layers of the multi-layer personalized page. Moreover, a photopolymer layer can be arranged there, into which layer a “shadow image” of the photo of the holder of the personal document is inscribed. In addition, as an additional security measure during the laser processing of the personalized page, lasered perforation numbering can be added and thus the protection against falsification is further enhanced.
[0019] Additional features and advantages of the invention can be found in the following description of the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic representation of an inventive personal document, partially opened;
[0021] FIG. 2 is the top view of the personalized page; and
[0022] FIG. 3 is a section through the personalized page with an RFID element in the textile layer.
DETAILED DESCRIPTION OF THE INVENTION
[0023] FIG. 1 is a schematic representation of an inventive personal document 1 , partially opened.
[0024] The passport binder 2 , 2 ′ is bound by means of the seam 15 , with the personalized page 3 , 4 , 5 , 19 and the interior strata 12 , 12 ′, 13 , 13 ′, 14 , 14 ′ into a book, so that a sort of articulation 15 is formed. The number of interior strata can be selected according to the design desired. In this case, only six interior strata are shown for the sake of simplicity.
[0025] The personalized page comprises a laminate with a core stratum 3 between plastic layers on the front side 4 and the back side 5 . The excess length 19 of the personalized page 3 , 4 , 5 in the area of the seam 19 comprises only the core stratum 3 , which is embodied bendable and made of a textile material such that a personal document produced in this manner can be opened and closed easily without there being a high restoring force and in that a high bending number is possible.
[0026] On the front, the passport cover 2 , 2 ′ has a projection 6 and can be used with a bound design or in a design that is punched on three sides.
[0027] FIG. 2 is a top view of the personalized page 3 , 4 , 5 . In accordance with the invention, the core stratum 3 extends across the entire personalized page, including the excess length 19 . However, the plastic layers of the front side 4 of the personalized page and the back side 5 of the personalized page do not extend across the full width of the core stratum 3 , but rather end at the edge 20 and are exteriorly edged with a common contour 29 . Thus, only the flexible core 3 is to be sewn at the seam or bending site 15 , while the rest of the personalized page has substantially higher stiffness due to the laminated polycarbonate layers. The exterior contour 29 is preferably obtained by punching the bound passport 1 .
[0028] An RFID element 16 with an IC element 17 and a coil 18 is integrated into the personalized page 3 , 4 , 5 , the position shown being arbitrary. The RFID element 16 can also be designed either smaller or even larger with respect to the desired specifications.
[0029] The IC element 17 is preferably positioned in the vicinity of the seam 15 , because this location can be expected to be subjected to lower mechanical loads.
[0030] The personalized data such as the ICAO line 7 , personalized data 8 , and photo 9 are produced in the finished passport 1 by means of laser irradiation, whereby the IC element 17 is also electronically programmed with the corresponding personal data or biometric data in the same working step.
[0031] Frequently a diffractive security element 10 is required for increasing protection against falsification. In the present example it is integrated into the strata 24 , 25 . Since this diffractive element 10 is largely transparent, it can be arranged such that it covers the photo 9 in places.
[0032] Since the personalized page 3 , 4 , 5 is constructed by means of laser irradiation, the passport number can also be burned into the area of the numbering 11 in the form of a microperforation and/or the photo can be added as a so-called “shadow image” by means of microperforations in addition to or adjacent to the actual photo 9 .
[0033] FIG. 3 depicts a section through the personalized page 3 , 4 , 5 with an RFID element 16 in the core stratum 3 . The layers 24 and 26 are embodied as opaque white polycarbonate layers. Both the front side and the back side of these is inseparably joined to a laser-capable polycarbonate layer 25 , 27 .
[0034] In this sectional depiction, the core stratum 3 is formed from three strata, whereby in special cases additional strata or layers might be reasonable and even necessary. The textile layer 21 comprises a polyester fabric and/or a polyester satin fabric and/or a cotton fabric and/or a cotton blend fabric and/or a microfiber fabric and/or a non-woven fabric made of thermoplastic fibers. The thickness of the fabric 21 is 50 to 300 μm, preferably 100 to 200 μm. The fabric has security threads woven therein, or is woven from security yams, or can be printed. Preferably machine-readable marking substances are used. In particular, marking substances that can be activated in the near infrared range can be added that can be read through layers arranged thereover, since, for example, conventional printing inks and opaque thermoplastic films are penetrated by NIR radiation in the metrologically interesting range of 800 to 1100 nm.
[0035] Excitation is performed using LED or laser radiation sources with appropriate optics, and the data are preferably also read out in the NIR range, whereby the conventional silicon photo diodes can be used since they have high sensitivity up to about 1000 nm and slightly more. The responding signal can be evaluated or verified in terms of frequency and/or time, i.e., in a time-resolved manner. In particular, so-called up-conversion pigments are suitable, such as a fine-grain inorganic gadolinium oxysulfide and the like. Preferably response signals in the NIR range are evaluated when such machine-readable markings are integrated in the interior of the laminate structure 21 , 22 , 23 .
[0036] The fabric 21 is provided with one or two bonding agent layers 22 , 23 . These layers can be thermoplastic in nature and in this case must have a corresponding heat resistance or can be designed partially reactive or reactive. In each case a bond is attained that makes it impossible to separate the layers 21 , 22 , 23 , 24 , 25 , 26 , and 27 without visibly damaging or destroying them.
[0037] In terms of production engineering, the bonding agent layers 22 , 23 can cover the entire surface of the fabric 21 , that is, the excess length 19 , as well. Depending on the type and thickness of the fabric, however, the excess length 19 can be kept free of one or both bonding agent layers 22 , 23 .
[0038] In one variant, the use of the fabric 21 in the production of the articulation 15 in the area of the seam of the personalized page 3 , 4 , 5 can occur in that the fabric 21 in roll form is provided with one or both bonding agent layers 22 , 23 and are then laminated together, in a single image, in strip form, or in multiple images, with the other layers 24 , 25 , 26 , 27 to make a personalized page 3 , 4 , 5 . The lamination is normally performed in a hot and cold transfer press. Lamination temperatures ranging from about 150° C. to more than 200° C. are used, and in particular, temperatures ranging from 190° C. to about 205° C. are used for high security laminate bonds based on polycarbonate. The surface pressures in the hot press are generally 200 to 400 N/cm 2 , and the surface pressures in the cold press are generally 400 to 600 N/cm 2 . Using vacuum support for the lamination process can prevent interfering air inclusions.
[0039] Depending on the type of IC element 17 and the possible type of contacting, the RFID coil 18 can be produced using etching in copper or aluminum, or by means of silver through plating, or by means of copper wire winding or laying technique.
[0040] As stated in the foregoing, the personalized page 3 , 4 , 5 is produced in single images, in strip form, or in multiple images. The contour 29 is produced using a punch tool or cutting tool. It can be advantageous that the films 24 , 25 , 26 , 27 and any additional films are embodied such that they designed are in a size large enough to include the excess length 19 , but in the area of the excess length 19 to the bonding agent side 22 , 23 are provided with a separating coating, for example, by means of screen printing. The contour punches can then punch the entire contour 29 and at the same time produce the personalized page edge 20 , such that only the films 24 , 25 , 26 , 27 are punched on the edge, and the core strata 21 , 22 , 23 are not punched.
[0041] In all of the punch technologies, the punch edge 29 is quite essential since a fabric 21 is integrated as core layer and this fabric 21 must be edged with no fringe.
[0042] In this depiction, the transparent films 25 , 27 are conducted over the edge of the opaque plastic layers 24 , 26 , but terminate prior to the excess length 19 in which the seam 15 is provided. In addition, in this embodiment it is even possible to use a relatively thick RFID element 16 , which however makes possible a personalized page 3 , 4 , 5 that is thinner overall than would otherwise be required for relatively thick RFID elements 16 .
[0043] In addition, in this depiction, a recess 28 in the core stratum 3 is shown. A fused bond between the layers surrounding the core stratum 3 is possible with one or a plurality of such recesses 28 in the core strata 21 , 22 , 23 . The holes 28 can be lasered or punched. They have a pre-determined circular, oval, or rectangular shape and can also themselves be used as an additional security feature during authentication.
LEGEND
[0000]
1 Personal document
2 Book cover
2 ′ Book cover printed side
3 Core stratum
4 Plastic layer of front side of personalized page
5 Plastic layer of back side of personalized page
6 Book cover inside page (projection front)
7 ICAO line
8 Personalized data
9 Passport photo
10 Diffractive structure
11 Number punched
12 Inside page; 12 ′ inside page back side
13 Inside page; 13 ′ inside page back side
14 Inside page; 14 ′ inside page back side
15 Seam (personal document articulation)
16 RFID element
17 IC element (chip module, interposer)
18 Coil
19 Excess length of personalized page
20 Edge of personalized page
21 Textile layer
22 Bonding agent for personalized page front side
23 Bonding agent for personalized page back side
24 Opaque personalized page front side
25 Transparent laser-capable personalized page front side
26 Opaque personalized page back side
27 Transparent laser-capable personalized page back side
28 Recess in core stratum
29 Contour/punched edge
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The invention relates to a personal document in the form of a book, comprising a book cover, a multi-layered personalised side which contains personalised data, in addition to inner pages. The personalised side and the inner pages are secured by means of a seam to the book cover. The multi-layered personalizing side is provided with a central area which is made of a textile layer which is joined on both sides to a thermoplastic layer which covers the central area until the projecting end. A RFID element comprising an IC element is integrated into the central area for the contactless transfer of biometric data of the personal document owner. The personalised side is sewn by means of a seam in the region of the projecting end.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 09/104,502, filed Jun. 25, 1998.
BACKGROUND OF THE INVENTION
The present invention relates to a neck supporting device.
There are all kinds of situations in everyday life in which the neck of a person can suffer strain. Such a situation may, for instance, occur during a collision between cars, in which a second car collides from the rear with a first car. The passengers of the first car are then at a considerable risk of contracting so-called whiplash. Basically, the body is adjusted to move forward at approximately 5 km per hour. At a movement above 5 km/hour the neck proves to be one of the most vulnerable parts of the human body. The collision from the rear accelerates the forward movement of the car, causing the passengers who are supported by the back rest of the seats also to be accelerated forward. In nearly all cases, however, the back of the head and the neck of the passenger is not supported by the back rest or a head rest. Due to the accelerated movement forward of the torso of the person's body the head will move backward in relation to the torso.
During this event great forces are exerted on the neck and the head of the passengers. These forces can cause considerable damage to the neck and head. This damage and the ensuing complaints are called whiplash. Preventing the occurrence of whiplash can avoid much suffering, discomfort and expense.
Further, it is common practice to supply whiplash patients or patients suffering from other neck complaints with a firm, almost completely immobilizing neck collar to be worn around the throat and nape, in order to support the neck. However, this has an adverse effect on, for instance, the joints and muscles in the neck. Studies have shown that complete immobilization is not the proper treatment and that an early mobilization of the neck is very important for a successful treatment of whiplash. Another disadvantage is that such a collar is very much present. Thereby a patient's infirmity becomes obvious to his surroundings and his privacy is harmed.
Another situation in which a person's neck may be strained is when working behind a (computer) screen. This causes fatigue symptoms of the neck which after some time may lead to complaints requiring treatment. If these fatigue symptoms can be avoided, the complaints requiring treatment will also not occur.
There are neck supporting devices known, such as disclosed in U.S. Pat. No. 4,757,554, comprising a soft neck support which, in use, is held against the back of the neck by means of straps which are attached to respective ends of the neck support and run under the arm pits to the back of a wearer. However, the soft neck support does not provide a firm support to the back of the neck and the back lower part of the head, especially not when strong backward forces are involved. The neck and head are hardly prevented from moving and tilting backward with respect to the wearer's torso. Further, the neck support is not firmly and supportingly held against the back of the neck, since the straps attached to the ends of the neck support are, in use, directed to the sides of the torso. Such a configuration for the straps does also not allow for an efficient force to restrict the backward movement and tilt of the neck and the head of the wearer. Moreover, to provide some firm support, a considerable force has to be exerted on the straps, resulting in a constricting force around the chest and under the arm pits and a pressure exerted on the soft body parts of the throat, which is uncomfortable and may be harmful.
SUMMARY OF THE INVENTION
It is the object of the invention to solve the drawbacks associated with the prior art neck supporting devices. To this end the invention provides a neck supporting device comprising a neck support for supporting the back of the neck and the back lower part of the head of a wearer, said neck support including a semi-rigid member having a curvature adapted to the curvature of the back of the neck and the back lower part of the head when the head is positioned in a non-tilted position with respect to the wearer's torso, and said neck support having two ends to be positioned, in use, approximately along the sides of the neck and leaving the front of the neck uncovered; and two connecting straps for, each from a respective end of said neck support, connecting said neck support to a body harness such that, in use, said connecting straps are directed to the lower torso of the wearer.
In one preferred embodiment the neck supporting device according to the invention comprises a waist strap as the body harness, said waist strap, in use, extending at least partly and approximately around the waist of the wearer and said connecting straps being an integral part of straps adapted for, each from a respective end of said neck support, in use, crossing over each other across the chest and then across the back of the wearer, to be reciprocally fastened at least approximately on the lower torso of the wearer to simultaneously form said waist strap. For a quick and simple fastening it is preferred that the embodiment includes a coupling device for reciprocally fastening said straps.
In another preferred embodiment the neck supporting device according to the invention comprises a waist strap as the body harness, said waist strap, in use, extending at least partly and approximately around the waist of the wearer, and being a separate part of the neck supporting device, and said connecting straps being adapted for fastening to said waist strap. For a convenient fastening it is preferred that said connecting straps are adapted for fastening to said waist strap jointly, and that the neck supporting device includes a coupling device for fastening said connecting straps.
In yet another preferred embodiment of the neck supporting device according to the invention the connecting straps are adapted for fastening to a car safety belt as the body harness, one of the connecting straps being adapted for fastening, in use, to the diagonal belt of the car safety belt, and the other being adapted for fastening, in use, to the hip belt of the car safety belt. For a convenient fastening it is preferred that the neck supporting device includes coupling devices for fastening said straps to the respective belts.
In favourable embodiments the tension in the straps is variable by means of an adjustment device, so that the force by which the neck support is held against the neck, and consequently the degree of possible rearward movement of the neck, can be controlled.
In yet other embodiments the two connecting straps may be reciprocally coupled by means of a clip member which, in use, is positioned on the front of the wearer. Such a clip member further improves the stability of the neck supporting device on the body of the wearer. The clip member is preferably slidable over the straps. By sliding the clip member the course of the straps across the user can be varied as desired. In order to avoid unintended sliding of the clip member during use, it is preferable that the clip member can be secured to the straps.
It is preferred that the rear side of said neck support, in use facing away from the wearer's body, comprises said semi-rigid member and that the sides of the neck support coming into contact with the body, comprise a soft foam material. The neck support is thus able to adapt to the shape of the back of the neck and the back lower part of the head, is extremely comfortable to wear and provides yet a firm support.
It may further be advantageous that the neck support is enveloped by a covering of textile material comprising possibly towelling cotton. This material makes the feel of the neck support extremely comfortable during use and will not irritate the skin.
In a convenient embodiment the covering is in addition removable by means of closure means provided in the covering. This allows the covering surrounding the neck support to be removed for cleaning. It is also possible to use coverings of different colour and/or pattern, for instance a colour going with the clothing in order to render the device as inconspicuous as possible.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be elucidated with reference to the accompanying drawing in which similar parts are indicated by the same reference numbers. In the drawing:
FIG. 1 shows a first embodiment of the neck supporting device according to the invention;
FIGS. 2a, 2b and 2c show a schematic front view, side view and rear view respectively of the neck supporting device according to FIG. 1, as fitted on a user;
FIGS. 3a, 3b, 3c, 3d and 3e show a second embodiment of the neck supporting device according to the invention as fitted on a user;
FIG. 4 shows a third embodiment of the neck supporting device according to the invention;
FIGS. 5a and 5b show the third embodiment of the neck supporting device as fitted on a user; and
FIG. 6 shows a schematic cross section of a neck support according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Whenever the figures show the same reference numerals, they refer to the same parts.
The first embodiment of the neck supporting device according to the invention shown in FIG. 1 comprises a neck support 10 and two connecting straps 20 each attached to a different end of the neck support 10. One end of the connecting straps 20 is attached to the neck support 10 and their other end s can be reciprocally coupled by means of a coupling device 30, such as a buckle. It is also possible that the connecting straps 20 are formed by a single strap positioned around the neck support 10. This strap can be attached to the neck support at one single point, such as in the middle of the rear side, or at different points, such as at the ends. The strap could also be positioned around the neck support without being attached.
In the embodiment shown, each of the ends of the connecting straps 20 which can be reciprocally coupled, is provided with, as such known, buckle parts 31, 32 which can be coupled to form a buckle 30. It is also easy to undo this buckle 30 again. The neck supporting device according to the invention further possesses a clip member 40, reciprocally coupling the connecting straps 20 at their crossing point.
FIG. 2 shows the neck supporting device of FIG. 1 as fitted on a user. During fitting the head is passed through the opening formed by the neck support 10, the connecting straps 20 and the clip member 40. The neck support 10 is applied on the shoulders and against the neck of the user, after which the connecting straps 20 are guided over the chest, behind the back and over the belly of the user. At the belly the connecting straps 20 are coupled by means of the buckle 30. The connecting straps 20 thus also form a waist strap 50.
After coupling, the connecting straps 20 may be tightened by pulling at the end of a connecting strap 20, which connecting strap end 20 is fed through an adjustment device (not shown, but known as such), which is configured as a feed-through device and which is attached to the buckle. To allow the neck supporting device to be pulled tightly around the body, the connecting strap 20 can slide through said feed-through device in a first direction, whereas it cannot slide through in the other direction. When the buckle 30 is uncoupled, the connecting strap 20 is also able to slide in the other direction. The adjustment device may be provided at one or at both buckle parts 31, 32. A buckle with the above-mentioned adjustment device is known as such.
It is also possible to use another kind of buckle, such as a buckle which is attached to one connecting strap only and through which the other connecting strap is fed, coupling being effectuated by means of a tongue of the buckle which is inserted into an opening in the other connecting strap. The provision of a number of openings in the other connecting strap allows the neck supporting device to be fitted tighter or more loosely. However, many other embodiments of buckle couplings are feasible. It is also possible to couple the two connecting straps by means of a Velcro fastening or by means of a knot.
A second embodiment of the neck supporting device according to the invention shown in FIGS. 3a to 3e also comprises a neck support 10 and a strap positioned around the neck support 10, which strap is attached (not shown) to the ends and the rear middle of the neck support 10. This results in two connecting straps 20, each being attached to a different end of the neck support 10. In the embodiment shown, said connecting straps 20 are fed through a clip member 40. The neck support 10 with the connecting straps 20 and the clip member 40 according to the second embodiment, are fitted on a user in a similar manner as in the first embodiment.
In the application of this embodiment as shown in FIG. 3e the ends of the connecting straps 20 facing away from the neck support 10, are attached to a waist strap 50 by means of a coupling device 35. This coupling device 35 may be a buckle, but is in the embodiment shown configured as a feed-through device, which also serves as an adjustment device by which the two connecting straps 20 may be tightened between the neck support 10 and the waist strap 50. The two connecting straps 20 extend, bundled together, between the clip member 40 and the waist strap 50.
The waist strap 50 may be a trouser belt to which a (part of a) coupling device for the connecting straps 20 is attached. In the embodiment shown in FIGS. 3a to 3e the waist strap 50 is formed by a strap having two ends which can be coupled by means of a buckle 52. To the buckle 52 an adjustment device 53, which is configured as a feed-through device, is attached for tightening the waist strap 50.
The clip member 40 through which the two connecting straps 20 are fed, can slide over the connecting straps 20 of the two embodiments shown. This slidable clip member 40 allows adjustment of the course of the connecting straps 20 over the chest or belly of the user. The more the clip member 40 is slid toward the neck support 10, the firmer the neck support will fit around the neck of the user. The position of the clip member 40 may be varied as required. In order to keep the clip member 40 in a chosen position on the connecting straps 20, it may be secured on the connecting straps 20 by means which are not shown.
A third embodiment of the neck supporting device according to the invention is shown in FIG. 4. The third embodiment also comprises a neck support 10 and a strap positioned around the neck support 10, which strap is attached (not shown) to the ends of the neck support 10. This again results in two connecting straps 20, each being attached to a different end of the neck support 10.
In the third embodiment the ends of the connecting straps 20 facing away from the neck support 10 are adapted for fastening to a car safety belt 60. Such application is of course also feasible for other situations, such as use in speedboats, golf-trolleys, funcars, hydrofoils, etc. One of the connecting straps 20 includes a coupling device, such as a buckle 33, for fastening, in use, to the diagonal belt 61 of the car safety belt. The second connecting strap 20 is adapted for fastening to the hip belt 62 of the car safety belt with for instance a buckle 34. Both connecting straps 20, in use, cross each other as indicated with arrow A across the chest. They may be reciprocally coupled on the front of the wearer by a clip member as in the previous embodiments. Such a clip member is, however, not included in the embodiment shown. Further, the second connecting strap 20 may also be adapted for fastening to the diagonal belt, and both connecting straps 20 may be adapted for fastening to the diagonal belt jointly.
As in the previous embodiments the connecting straps 20 may include an adjustment device for tightening the connecting straps 20 to firmly hold the neck support 10 against the neck of the user and prevent the neck and head of the wearer from moving or tilting backwards.
FIG. 6 shows a possible schematic cross section of the neck support 10 according to the invention.
The shape of the neck support 10 is adapted to that of the neck, the shoulders and the head, as can be seen in FIG. 2, 3 and 5, and the front-, upper- and underside coming into contact with the body, are made from a soft foam material 110, as shown schematically in FIG. 6. The rear side of the neck support 10 comprises a semi-rigid member 120 the curvature of which is adapted to the back of the neck and the back of the head, ensuring that the neck support 10 provides optimal support.
The neck support 10 may be enveloped by a material layer 140 of a textile material such as towelling with a pleasant feel to the skin. In a possible embodiment said second layer 140 is provided with a closure means 150, such as for instance a zipper, to allow the layer to be removed and changed. This makes it possible to clean the second layer 140 and to choose the second layer 140 in a colour and pattern to go with the clothing of the user.
The embodiments of the neck supporting device according to the invention shown can be fitted on the body of a user easily and within a few seconds. In addition, they can be adjusted to the individual user.
A major advantage of the neck supporting device according to the invention is the great degree of freedom of movement, restricting everyday activities as little as possible and supporting the neck in the correct manner to ensure a successful treatment of whiplash. In addition, said neck supporting device is virtually inconspicuous and may be disguised completely, for instance, by wearing a shawl.
The neck supporting device according to the invention affords excellent protection against incidents in which straining of the head and neck may occur, such as in a car collision from the rear (whiplash). The device may be applied as preventive means against injury of this kind, but also as a support for people suffering from existing neck complaints stemming, for instance, from a whiplash and other strains, from a neck hernia or a neck sprain, after a neck hernia operation, for the treatment of neck injury and degeneration (arthrosis), etc.
The embodiments describe above are not to be understood as limiting the invention. The neck supporting device may be realized in a variety of embodiments, all deemed to be within the scope of the appended claims.
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A neck supporting device comprising a neck support for supporting the back of the neck and the back lower part of the head of a wearer, and two connecting straps for, each from a respective end of the neck support, connecting the neck support to a body harness such that, in use, the connecting straps are directed to the lower torso of the wearer. The neck support includes a semi-rigid member having a curvature adapted to the curvature of the back of the neck and the back lower part of the head when the head is positioned in a non-tilted position with respect to the wearer's torso. The neck supporting device may comprise a waist belt as the body harness or may be adapted for fastening to a car safety belt as the body harness.
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THE FIELD OF THE INVENTION
This invention is related to a new class of opioid peptide analogs that are δ opioid receptor antagonists as well as to their synthesis and their use as analgesic and immunosuppressive compounds.
BACKGROUND AND PRIOR ART
A known nonpeptide δ opioid antagonist is naltrindole, which is described by P. S. Portoghese, et al J. Med. Chem. 31, 281-282 (1988). Naltrindole has similar δ antagonist potency as the compounds according to this invention but is much less δ selective. Furthermore, naltrindole has also quite high μ opioid receptor affinity (K i .sup.μ =12 nM) in the receptor binding assay and potent μ antagonist properties (K e =29 nM) in the guinea pig ileum (GPI) assay, cf P. S. Portoghese, J. Med. Chem. 34, 1757-1762 (1991).
Another known δ-antagonist is the enkephalin analog (ICI 174864) described by R. Cotton, et al. in Eur. J. Pharmacol. 97, 331-332 (1984). In comparison with the δ antagonists described in this patent application, ICI 174864 is much less δ-selective (10-300 times less) and has much lower antagonist potency in the MVD assay (40-1000 times less potent).
Peptides containing the H-Tyr-Tic-Aaa-sequence (Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylic acid, Aaa=aromatic amino acid residue) at the N-terminus and which are very potent and highly selective δ antagonists have recently been disclosed by P. W. Schiller et al. in FASEB J, 6 (No. 4), A1575 (1992), at the International Narcotics Research (INRC) Meetings in Keystone, Colo., Jun. 24-29 (1992) and in Skovde, Sweden, Jul. 10-15 (1993), at the 2nd Japan Symposium on Peptide Chemistry Shi-zuoka, Japan, Nov. 9-13 (1992), at the 22nd European Peptide Symposium, Interlaken, Switzerland, Sep. 13-19 (1992), in Proc. Natl. Acad. Sci. U.S.A. 89, 11871-11875 (1992), and in J. Med. Chem. 36, 3182-3187 (1993).
Thus, the problem underlying the present invention was to find δ opioid antagonists both with high δ antagonist potency and with high δ selectivity.
THE INVENTION
It has now been found that peptides containing the H-Tyr-Tic-dipeptide segment at the N-terminus and a non-aromatic amino acid residue at the 3-position of the peptide sequence, as defined by the following formula I, have
extraordinary potency as δ antagonists
high selectivity for the δ receptor
total lack of μ antagonist properties.
The compounds according to the present invention have the general formula I ##STR2## wherein
R 1 is H; CH 3 (CH 2 ) n -- wherein n=0-12; ##STR3## --CH 2 --CH═CH 2 ; or arginine;
R 2 is H; CH 3 (CH 2 ) n -- wherein n=0-12; CH 3 --; ##STR4## or
--CH 2 --CH═CH 2 ;
R 3 , R 4 , R 5 and R 6 are all H; or
R 4 and R 5 are both H and R 3 and R 6 is each a C 1 -C 6 alkyl group; or
R 3 , R 5 and R 6 are all H and R 4 is F, Cl, Br, I, OH, NH 2 or NO 2 ;
R 7 is C═O or CH 2 ;
R 8 is H or a C 1 -C 6 alkyl group;
R 9 is selected from ##STR5## wherein m is 0-12; ##STR6## wherein p is 0-4;
R 10 is OH, NH 2 or ##STR7## wherein
R 11 is H, NO 2 , F, Cl, Br or I; q is 0-3;
R 12 is COOH, CONH 2 , CH 2 OH, or any additional amino acid or peptide segment; or
R 10 is ##STR8## wherein
R 12 is as defined above.
Preferred compounds of the invention are those compounds wherein
R 1 is selected from H or CH 3 ;
R 2 is selected from H or CH 3 ;
R 3 is selected from H or CH 3 ;
R 4 is H;
R 5 is H;
R 6 is selected from H or CH 3 ;
R 7 is selected from CO or CH 2 ;
R 8 is selected from H or CH 3 ;
R 9 is selected from ##STR9## wherein p=0-4 or ##STR10##
R 10 is selected from ##STR11## wherein R 11 is H, NO 2 , F, Cl, Br or I,
q is 1-3, and R 12 is COOH.
Especially preferred compounds of the invention are those compounds wherein
R 1 is selected from H or CH 3 ;
R 2 is selected from H or CH 3 ;
R 3 is selected from CH 3 ;
R 4 is selected from H;
R 5 is selected from H;
R 6 is selected from CH 3 ;
R 7 is selected from CH 2 ;
R 8 is selected from H or CH 3 ;
R 9 is selected from ##STR12## wherein p=0-4;
R 10 is selected from ##STR13## wherein R 11 is H, q is 1, and R 12 is COOH.
Especially preferred compounds according to the invention are those wherein R 9 is ##STR14## (containing a cyclohexylalanine Cha! residue in the 3-position of the peptide sequence). Substitution of Cha in the 3-position significantly enhances δ antagonist potency.
Further preferred compounds according to the invention are those, wherein R 4 and R 5 are hydrogen and R 3 and R 6 are both methyl groups.
Also preferred compounds according to the invention are compounds wherein R 7 is a part of a reduced peptide bond.
The best mode of carrying out the invention known at present is to use the compounds of Examples 1, 2, 5, 11, 12 and 15.
SYNTHESIS
Most Boc-amino acid derivatives used in the peptide syntheses are commercially available. 2,6-dimethyl-tyrosine (Dmt) was prepared as described by J. H. Dygos et al. Synthesis, No 8 (August) pp. 741-743 (1992).
All peptides were prepared by solid-phase techniques. The usual polystyrene/-divinylbenzene resin was used for the solid-phase synthesis of peptides with a free C-terminal carboxyl group, whereas peptide amides were synthesized by using the p-methylbenzhydrylamine resin. Boc protection of the amino group was employed in the preparation of all peptides. The syntheses were performed according to protocols that have been extensively used in the inventor's laboratory (P. W. Schiller et al, Biochemisty 16, 1831-1832 (1977)). Couplings were performed in CH 2 Cl 2 , DMF or a mixture thereof, using N,N'-dicyclohexylcarbodiimide/1-hydroxybenzotriazole (DCC/HOBt), N,N'-diisopropylcarbodimide/1-hydroxybenzotriazole, benzotriazolyloxytris-(dimethylamino)phosphonium hexafluorophosphate, or any other suitable coupling agent. Completeness of coupling was carefully examined after each coupling step by means of the ninhydrin color test. The fully assembled peptide chain was cleaved from the resin and completely deprotected by treatment with liquid HF at 0° C. and in the presence of anisole as scavenger (60-90 min).
Crude products obtained from solid-phase peptide synthesis required extensive purification by various chromatographic techniques or by other methods. Following HF cleavage and extraction of the resin, gel filtration on Sephadex (G-15 or G-25) was routinely performed. Various subsequent purification steps included partition chromatography on Sephadex G-25 (using various butanol-acetic acid-pyridine-water two phase systems), ion exchange chromatography (DEAE-Sephadex, SP-Sephadex and CM-cellulose) and reversed-phase chromatography on an octadecasilyl-silica column using linear gradients of methanol in 1% trifluoroacetic acid (low pressure). If necessary, final purification to homogeneity was performed by semi-preparative HPLC. Semi-preparative μ-Bondapak C-18 columns (Waters; 0.7×25 cm), which, depending on the separation problem, permitted purification of 2-20 mg peptide material per run were used. Several highly sensitive and efficient analytical methods were used to demonstrate homogeneity of the prepared peptides and to verify their structures. Thin layer chromatography in at least two different solvent systems was used to establish purity. Furthermore, analytical HPLC in two or three different solvent systems was routinely used in the laboratory as a highly sensitive purity test. Verification of peptide structures was mainly based on amino acid analysis and fast atom bombardment-mass spectrometry (FAB-MS). For amino acid analyses, peptides were hydrolyzed in 6N HCl containing a small amount of phenol for 24 h at 110° C. in deaerated tubes (in some case hydrolyses lasting for 12 and 48 h were also performed to take into account amino acid degradation). Hydrolysates were analyzed on a Beckman Model 121 C amino acid analyzer equipped with a system AA computing integrator. FAB mass spectrometry was used to establish the correct molecular weights of the peptides.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described in more detail by the following examples.
EXAMPLE 1
Preparation of H-Tyr-Tic-Cha-Phe-OH (SEQ ID NO:1)
Boc-Phe-O-resin (1 g, 0.61 mmol Boc-Phe/g resin; Peninsula, Belmont, Calif.) was washed with reagents in the following sequence: CH 2 Cl 2 (3×1 min), 50% (v/v) TFA in CH 2 Cl 2 (30 min), CH 2 Cl 2 (5×1 min), 10% (v/v) DIEA in CH 2 Cl 2 (2×5 min), CH 2 Cl 2 (5×1 min). Boc-Cha-OH (412 mg, 1.52 mmol) was then coupled using HOBt (205 mg, 1.52 mmol) and DCC (313 mg, 1.52 mmol) in CH 2 Cl 2/ DMF (3:1, v/v) for 17 h. The resin was then washed with CH 2 Cl 2 (3×1 min), EtOH (1 min), CH 2 Cl 2 (3×1 min). This sequence of washes and reactions was repeated for the addition of each of the residues with the following modifications.
After coupling of Boc-Tic-OH the resin was washed with CH 2 Cl 2/ DMF (3:1, v/v) (3x) and a recoupling step using the same amounts of Boc-Tic-OH, HOBt and DCC in CH 2 Cl 2/ DMF (3:1, v/v) was performed for another 17 h. The same recoupling step was also carried out to couple Boc-Tyr(Boc)-OH: After final deprotection with 50% (v/v) TFA in CH 2 Cl 2 (30 min), the resin was washed with CH 2 Cl 2 (3×1 min) and EtOH (3×1 min) and was dried in a desiccator. The dry resin was treated with 20 ml of HF plus 1 ml of anisole (per gram of resin) first for 90 min at 0° C. and then for 15 min at room temperature. After evaporation of the HF, the resin was extracted three times with Et 2 O and, subsequently three times with 7% AcOH. The crude peptide was then obtained in solid form through lyophilization of the combined acetic acid extracts.
The peptide was purified by gel filtration on a Sephadex-G-25 column in 0.5 N AcOH followed by reversed-phase chromatography on an octadecasilyl silica column with a linear gradient of 0-80% MeOH in 1% TFA. After solvent evaporation the pure peptide was dissolved in conc. AcOH and was obtained in solid form through lyophilization. Yield: 45 mg FAB--MS:MH + =640
______________________________________TLC (silica) Rf0.75 n-BuOH/AcOH/H.sub.2 O (4/1/5, organic phase) Rf0.70 n-BuOH/Pyridine/AcOH/H.sub.2 O (15/10/3/12)______________________________________
Amino acid analysis: Tyr 0.96, Phe 1.00
EXAMPLE 2
Preparation of H-Tyr-TicΨ CH 2 --NH!Cha-Phe-OH (SEQ ID NO:2)
The synthesis of this peptide was performed as in the case of EXAMPLE 1 using the same resin except that the introduction of a reduced peptide bond between the Tic 2 and Cha residue required a reductive alkylation reaction between Boc-Tic aldehyde and the amino group of the resin-bound H-Cha-Phe dipeptide.
Preparation of N-t-butoxycarbonyl-L-1,2,3,4-tetrahydroisoquinoline-3-aldehyde (Boc-Tic Aldehyde) Via N-t-butoxycarbonyl-L-1,2,3,4-tetrahydroisocluinoline-3-N-methoxy, N-methylamide
BOP (benzotriazol-1-yl-oxytris(dimethylamino)phosphonium hexafluorophosphate) (3.48 g, 10 mmol) was added to a stirred solution of Boc-Tic-OH (2.8 g, 10 mmol) and triethylamine (1.33 ml, 10 mmool) in CH 2 Cl 2 . After five minutes, N-dimethylhydroxylamine hydrochloride (1.2 g, 12 mmol) and triethylamine (1.68 ml, 12 mmol) were added to the solution. The reaction was carried out for 17 h. Subsequently, the reaction mixture was diluted with dichloromethane and washed with 3N HCl, a saturated aqueous solution of NaHCO 3 and a saturated aqueous solution of NaCl. The organic solution was dried over MgSO 4 prior to evaporation of the solvent. The resulting crude product of N-t-butoxycarbonyl-L-1,2,3,4-tetrahydroisequinoline-3-N-methoxy, N-methylamide was purified by chromatography on a silica gel column in EtOAc/hexane(1:2, v/v). Yield: 2.1 g (65%), oil
______________________________________TLC (silica) Rf0.57 EtOAc/hexane (1/1) Rf0.30 EtOAc/hexane (1/2)______________________________________
NMR (CDCl 3 ) δ1.45 (9H,t-butyl), 3.00 (2H,H-4), 3.18 (3H, NCH 3 ), 3.8(3H, OCH 3 ), 4.42-4.90(3H, 2H-1 and 1H-3), 7.17(4H, ar)
To a stirred solution of N-t-butoxycarbonyl-L-1,2,3,4-tetrahydroisoquinoline-3-N-methoxy, N-methylamide (1.2 g, 4 mmol) in 30 ml ether 190 mg (5 mmol) of lithium aluminium hydride were added. The reduction reaction was carried out for 1 h and the reaction mixture was then hydrolyzed with a solution of KHSO 4 (954 mg, 7 mmol) in water (20 ml). Subsequently, the aqueous phase was separated and extracted with three 50 ml portions of ether. The four organic phases were combined, washed with 3 N HCl, a saturated aqueous solution of NaHCO 3 and a saturated aqueous solution of NaCl, and finally dried over MgSO 4 . After solvent evaporation the aldehyde was obtained in pure form as an oil. Yield: 635 mg (60%), oil
______________________________________TLC (silica) Rf0.84 EtOAc/hexane (1/1) Rf0.57 EtOAc/hexane (1/2)______________________________________
NMR(CDCl 3 ) δ1.5 (9H, t-butyl), 3.0-3.27 (2H, H-4), 4.4-4.8 (3H, 1H-3 and 2H-1), 7.0-7.2 (4H, ar), 9,43 (1H, CHO)
Reductive Alkylation Reaction Between Boc-Tic Aldehyde and the H-Cha-Phe-O Resin
The resin was washed with DMF (2×1 min) and then Boc-Tic aldehyde (392 mg, 1.52 mmol) in DMF containing 1% AcOH was added to the resin. Sodium cyanoborohydride (115 mg, 1.83 mmol) was then added portionwise over a period of 40 min and the reaction was allowed to continue for 3h.
After coupling of the N-terminal tyrosine residue and deprotection the peptide was cleaved from the resin, purified and lyophilized as described in EXAMPLE 1. Yield: 285 mg FAB--MS: MH + =627
______________________________________TLC (silica) Rf0.73 n-BuOH/AcOH/H.sub.2 O (4/1/5, organic phase) Rf0.85 n-BuOH/pyridine/AcOH/H.sub.2 O (15/10/3/12)______________________________________
The compounds of Examples 3-14 have been synthesized as described for Example 1 above, and the compound of Example 15 was synthesized as described for Example 2 above.
The compounds in Table 1 according to the invention have been synthesized and tested as δ antagonists.
TABLE 1______________________________________ FAB--MS MH.sup.+ (molecularEx. Compound weight)______________________________________1 H--Tyr--Tic--Cha--Phe--OH (SEQ ID NO:1) 6412 H--Tyr--Ticψ CH.sub.2 --NH!Cha--Phe--OH 627 (SEQ ID NO:2)3 H--Tyr--Tic--Cha--Phe--NH.sub.2 (SEQ ID NO:3) 6404 H--Tyr--Tic--Leu--Phe--OH (SEQ ID NO:4) 6015 H--Tyr--Tic--Val--Phe--OH (SEQ ID NO:5) 5876 H--Tyr--Tic--Nva--Phe--OH (SEQ ID NO:6) 5877 H--Tyr--Tic--Nle--Phe--OH (SEQ ID NO:7) 6018 H--Tyr--Tic--Ile--Phe--OH (SEQ ID NO:8) 6019 H--Tyr--Tic--Thr--Phe--OH (SEQ ID NO:9) 58910 H--Tyr--Tic--Met--Phe--OH (SEQ ID NO:10) 61911 H--Dmt--Tic--Cha--Phe--OH (SEQ ID NO:11) 66912 H--D--Dmt--Tic--Cha--Phe--OH (SEQ ID NO:12) 66913 H--Dmt--Tic--Cha--Phe--NH.sub.2 (SEQ ID NO:13) 66814 H--Tyr(3'-I)--Tic--Cha--Phe--OH (SEQ ID NO:14) 76715 H--Dmt--Ticψ CH.sub.2 --NH!Cha--Phe--OH 655 (SEQ ID NO:15)______________________________________
Pharmacological Testing in Vitro of δ Opioid Antagonists
Biosassys based on inhibition of electrically evoked contractions of the mouse vas deferens (MVD) and of the guinea pig ileum (GPI) were made. In the GPI assay the opioid effect is primarily mediated by μ opioid receptors, whereas in the MVD assay the inhibition of the contractions is mostly due to interaction with δ opioid receptors. Antagonist potencies in these assays are expressed as so-called K e -values (H. W. Kosterlitz & A. J. Watt, Br. J. Pharmacol. 33, 266-276 (1968)). Agonist potencies are expressed as IC 50 values (concentration of the agonist that produces 50% inhibition of the electrically induced contractions).
Bioassays Using Isolated Organ Preparations
The GPI and MVD bioassays were carried out as reported in P. W. Schiller et at., Biochem. Biophys. Res. Commun 85, 1332-1338 (1978) and J. Di Maio et al., J. Med. Chem. 25, 1432-1438 (1982). A log dose-response curve was determined with Leu 5 !enkephalin as standard for each ileum and vas preparation, and IC 50 values of the compounds being tested were normalized according to A. A. Waterfield et al., Eur. J. Pharmacol. 58, 11-18 (1979). K e values for the δ opioid antagonists were determined from the ratio of IC 50 values (DR) obtained in the presence and absence of a fixed antagonist concentration (a) (K e ═a/(DR-1)) H. W. Kosterlitz & A. J. Watt, Br. J. Pharmacol. 33, 266-276 (1968). These determinations were made with the MVD assay, using two different δ-selective agonists DPDPE and D-Ala 2 !deltorphin I.
Conclusion
All compounds show high δ antagonist properties.
Peptides containing a cyclohexylalanine (Cha) residue in the 3-position of the peptide sequence are more potent δ antagonists than corresponding peptides with an aromatic amino acid in position 3.
All compounds showed no μ antagonist activity in the GPI assay at concentrations as high as 10 μM.
In the GPI assay most compounds showed very weak partial μ agonist activity (maximal inhibition of electrically evoked contractions ranging from 20% to 53%)
Opioid Receptor Binding Assays
μ and δ opioid receptor binding constants (K i .sup.μ, K i .sup.δ) of the compounds were determined by displacement of relatively selective μ and δ radioligands from binding sites in rat brain membrane preparations (calculated from the measured IC 50 values on the basis of the equation by Cheng & Prusoff (Y. C. Cheng and W. H. Prusoff (Biochem. Pharmacol. 22, 3099-3102 (1973)).
Opioid Receptor Binding Studies
The μ-, δ- and κ-opioid receptor affinities of all new analogs were determined in binding assays based on displacement of μ-, δ- and κ-selective radioligands from rat brain membrane binding sites in the case of κ-ligands guinea pig brain homogenates were used, since the relative proportion of κ-binding sites is higher in guinea pig brain than in rat brain. The experimental procedure being used in our laboratory represents a modified version of the binding assay described by Pasternak et al. (Mol. Pharmacol. 11, 340-351, (1975)). Male Sprague-Dawley rats (300-350 g) from the Canadian Breeding Laboratories were decapitated and after removal of the cerebellum the brains were homogenized in 30 volumes of ice-cold standard buffer (50 mM Tris-HCl, pH 7.7). After centrifugation at 30,000 x g for 30 min at 4° C. the membranes were reconstituted in the original volume of standard buffer and incubated for 30 min at 37° C. (to realease bound endogenous ligands). Subsequent centrifugation and resuspension of the pellet in the initial volume of fresh standard buffer yielded the final membrane suspension. Aliquots (2 ml) of the membrane preparations were incubated for 1-2 h at 25° C. with 1 ml standard buffer containing the peptide to be tested and one of the following radioligands at the final concentration indicated: 3 H!DAMGO, μ-selective, 0.7 nM; 3 H!DSLET, 3 H!DPDPE, or 3 H!TIPP, δ-selective, 1.0 nM; and 3 H!69,563, κ-selective, 0.5 nM. The incubation was terminated by filtration through Whatman GF/B filters under vacuum at 4° C. Following two washings with 5 ml portions of ice-cold standard buffer the filters were transferred to scintillation vials and treated with 1 ml Protosol (New England Nuclear) for 30 min prior to the addition of 0.5 ml acetic acid and 10 ml Aquasol (New England Nuclear). After shaking for 30 min the vials were counted at an efficiency of 40-45%. All experiments were performed in duplicate and repeated at least three times. Specific binding of each of the three radioligands was defined by performing incubations in the presence of cold DAMGO, DSLET and U69,563, respectively, at a concentration of 1 micromolar. Values of half-maximal inhibition (IC50) of specific binding were obtained graphically from semilogarithmic plots. From the measured IC50-values, binding inhibition constants (K i ) were then calculated based on Cheng and Prusoff's equation (Biochem, Pharmcol. 22, 3099-3102 (1973)). Ratios of the K i -values in the μ-, δ- and κ-representative binding assays are a measure of the receptor selectivety of the compound under investigation (e.g. K i .sup.μ /K i .sup.δ indicates the selectivity for δ-receptors versus μ-receptors). None of the compounds according to the claimed invention had significant affinity for κ-receptors.
Potential Use
The δ antagonists may be used in combination with analgesics of the μ agonist type (e.g. morphine) to prevent the development of tolerance and dependence, as suggested by the results of E. E. Abdelhamid et at., J. Parmacol. Exp. Ther. 258, 299-303 (1991).
The δ antagonists according to the invention may also be therapeutically useful as immunosuppressive agents. Immunosuppressive effects of the less δ-selective and less "pure"δ antagonist naltrindole have been described by K. Arakawa et al. Transplantation Proc. 24, 696-697 (1992); Transplantation 53, 951-953 (1992).
Abbreviations
Aib=α-aminoisobutyric acid
Boc=tert-butoxycarbonyl
Cha=cyclohexylalanine
DAMGO=H-Tyr-D-Ala-Gly-Phe(N.sup.α Me)-Gly-ol
DCC=dicyclohexylcarbodiimide
DIEA=diisopropylethylamine
Dmt=2',6'-dimethyltyrosine
DPDPE= D-Pen 2 ,D-Pens 5 !enkephalin
DSLET=H-Tyr-D-Ser-Gly-Phe-Leu-Thr-OH
FAB-MS=fast atom bombardment mass spectrometry
GPI=guinea pig ileum
HOBt=1-hydroxybenzotriazole
MVD=mouse vas deferens
Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylic acid
TIPP=H-Tyr-Tic-Phe-Phe-OH
U69,593=(5α, 7α, 8β)-(-)-N-methyl- 7-(1-pyrrolidinyl)-1-oxaspiro 4,5!dec-8-yl!benzeneacetamide
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 15(2) INFORMATION FOR SEQ ID NO: 1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=Cha=cyclohexylalanine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 1:TyrXaaXaaPhe(2) INFORMATION FOR SEQ ID NO: 2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note= "X=Tic(psi) CH2-NH!;Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=Cha=cyclohexylalanine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 2:TyrXaaXaaPhe1(2) INFORMATION FOR SEQ ID NO: 3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Peptide(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=Cha=cyclohexylalanine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 3:TyrXaaXaaPhe1(2) INFORMATION FOR SEQ ID NO: 4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 4:TyrXaaLeuPhe1(2) INFORMATION FOR SEQ ID NO: 5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 5:TyrXaaValPhe1(2) INFORMATION FOR SEQ ID NO: 6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=x/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=Nva=norvaline"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 6:TyrXaaXaaPhe1(2) INFORMATION FOR SEQ ID NO: 7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=x/note="X=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=norleucine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 7:TyrXaaXaaPhe1(2) INFORMATION FOR SEQ ID NO: 8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 8:TyrXaaIlePhe1(2) INFORMATION FOR SEQ ID NO: 9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 9:TyrXaaThrPhe1(2) INFORMATION FOR SEQ ID NO: 10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 10:TyrXaaMetPhe1(2) INFORMATION FOR SEQ ID NO: 11:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 1(D) OTHER INFORMATION: /label=X/note= "X=Dmt=2',6'-dimethyltyrosine"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquionoline-3-carboxylic acid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=Cha=cyclohexylalanine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 11:XaaXaaXaaPhe1(2) INFORMATION FOR SEQ ID NO: 12:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 1(D) OTHER INFORMATION: /label=X/note= "X=D-Dmt; Dmt=2',6'-dimethyltyrosine"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=Cha=cyclohexylalanine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 12:XaaXaaXaaPhe1(2) INFORMATION FOR SEQ ID NO: 13:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 1(D) OTHER INFORMATION: /label=X/note= "X=Dmt=2',6'-dimethyltyrosine"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=x/note= "X=Cha=cyclohexylalanine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 13:XaaXaaXaaPhe1(2) INFORMATION FOR SEQ ID NO: 14:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 1(D) OTHER INFORMATION: /label=X/note= "X=Tyr(3'-I)"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note="X=Tic=1,2,3,4-tetrahydroisoquinoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=Cha=cyclohexylalanine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 14:XaaXaaXaaPhe1(2) INFORMATION FOR SEQ ID NO: 15:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(v) FRAGMENT TYPE: N-terminal(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 1(D) OTHER INFORMATION: /label=X/note= "X=Dmt=2',6'-dimethyltyrosine"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 2(D) OTHER INFORMATION: /label=X/note= "X=Tic(psi) CH2-NH!;Tic=1,2,3,4-tetrahydroisoqiunoline-3-carboxylicacid"(ix) FEATURE:(A) NAME/KEY: Modified-site(B) LOCATION: 3(D) OTHER INFORMATION: /label=X/note= "X=Cha=cyclohexylalanine"(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 15:XaaXaaXaaPhe1__________________________________________________________________________
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Compounds of the formula I as well as methods for their preparation, their pharmaceutical preparations and their use. ##STR1## The compounds of formula I are useful in therapy, especially as analgesics and as immunosuppresive agents.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a reproducing apparatus for a remote rental system, and more particularly to a reproducing apparatus for enabling a remote rent of video titles, comprising an information-stored medium on which video information such as movies is stored together with a unique ID code; a player for reproducing the data on the information-stored medium; and an external device which communicates with a remote server and processes the data read out from the information-stored medium.
2. Brief Description of the Prior Art
A digital video disc (DVD) is the next generation of compact disc media that is capable of recording a large amount of digital information of about 5 GB on one side of the disc, even if DVD has the same diameter of 12 cm as CD. The DVD's larger capacity is due to the enhancement of aiming and focusing mechanisms and recording density, and so on. Since a 135-minute movie fits on the DVD if it is compressed in MPEG-2 format, the DVD is expected to replace a magnetic video tape and CD.
A general optical disc player converts the compressed video and audio data on the CD or the DVD into high-quality video and CD-quality audio for output to TVs and stereo systems.
FIG. 1 depicts a block diagram of a conventional optical disc player. It comprises an optical disc 1 which contains audio and/or video data; an optical pickup 3 for reading out the audio/video data; a disc controller for controlling the rotation of the disc for accurate the read-out operation; a data buffer 5 for temporarily storing the data read out by the optical pickup 3 ; an audio/video signal processor 9 for converting the data in the data buffer 5 to output video/audio signal to an external display unit 11 such as TV or monitor; and a micro control unit (MCU) 7 for controlling the operations of the audio/video signal processor 9 , the optical pickup 3 , and the data buffer 5 .
The reproduction operation of the optical disc player configured as above is as follows. The data read out from the optical disc 1 by the optical pickup 3 are temporarily stored in the data buffer 5 and are then fed to the digital signal processor 9 . The digital signal processor 9 outputs them after signal processing and decoding. The MCU 7 controls overall processes from the read-out operation by the optical pickup 3 to audio/video signal decoding by the digital signal processor 9 .
Even though the optical disc player has several advantages, its market has not grown rapidly yet. Considering big rental markets of movies, education, and music video titles of magnetic video tape or CD, it is probable that the DVD titles will be distributed for rental as well as for sales. Current video tape rental systems, however, have several inconveniences to both customers and retailers. First, customers have to return the rented video tapes in the rent period regardless of viewing the rented video tapes. And they have to visit the video stores to return the video tape.
Moreover, even if customers desire to keep good video titles, the current video tape rental system does not satisfy the customers' needs completely. On the other hand, retailers and producers have to try to prevent theft of video titles at the rental shop as well as unauthorized copying of the video titles. Moreover, if the unauthorized copying happens, it is impossible to trace which the video tapes are used in the unauthorized copying because the tapes do not have their own ID information.
Especially, because the quality of the DVD titles does not deteriorate even if they are copied too many times, more care must be taken to prevent the unauthorized copying. The retailers have to check the status of the video titles continually.
Video on demand (VOD) system may solve the above mentioned problems, but in the VOD system huge amount of video information must be transmitted over the public phone line, which is still technically challenging.
SUMMARY OF THE INVENTION
It is a primary objective of the present invention to solve the above mentioned problems of the conventional video title rental system and to provide a reproducing apparatus, which is composed of an information-stored medium requiring remote playback permission, a player for the information-stored medium, and a communication device, for enabling a remote rental system, thereby allowing customers to keep the information-stored medium and offering advertisements to customers continuously.
The apparatus according to the present invention comprises an information-stored medium on which data are contained together with an ID code; a player which reproduces the data on the information-stored medium; and an external device which communicates with a remote central server for playback permission and processes the data that are read out from the information-stored medium after playback permission. With the apparatus, customers can purchase the information-stored medium at a low cost, use the medium whenever they want, and never return it.
For the player enabling the remote rental system in accordance with the prevent invention, there is the effect of allowing customers to keep the information-stored medium at a lower cost than purchase general information-stored medium titles, not to visit to the title rental stores to return it after an initial use period is completed, and to use them again whenever they want.
It is possible to reduce the overload of the public communication network because the data related only to playback permission are transmitted over the communication network. Due to the apparatus of the present invention, public and commercial advertisements are provided to customers continually over the communication network. Moreover, the unauthorized copying of the information-stored medium is prevented or reduced by monitoring the unique ID information, thereby protecting the title producer's and retailer's interests.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention, illustrate a preferred embodiment of this invention, and together with the description, serve to explain the principles of the present invention.
In the drawings:
FIG. 1 is a schematic diagram of a conventional optical disc player;
FIG. 2 is a schematic diagram of a reproducing apparatus enabling a remote rental system according to the present invention;
FIG. 3 is a flow chart of receiving and displaying information from a remote server according to the present invention;
FIG. 4 is a schematic diagram showing a communication protocol between a controller and a sub-controller;
FIG. 5 is a schematic diagram showing data paths and the signal I/O of the components on the data paths at the time of reproduction of an information-stored medium;
FIG. 6 is a flow chart of determining whether or not the player enabling remote playback control is equipped with an external device;
FIG. 7 is a flow chart of transmitting the data that are recorded on a prescribed area of an information-stored medium requiring remote playback permission to an attached external device;
FIG. 8 is a flow chart of processing the data that are stored in an internal memory of an external device in an audio/video signal processor; and
FIG. 9 is a flow chart of controlling the read-out of a unique ID information that is recorded on the information-stored medium requiring the remote playback permission.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The reproducing apparatus for a remote rental system according to the present invention will be described in detail referring to the accompanying drawings.
Referring to FIG. 2, there is shown an embodiment of reproducing apparatus according to the present invention, comprising an information-stored medium 21 on which audio and/or video information is recorded; an optical pickup 22 which reads out the data on the information-stored medium 21 ; a servo control unit 23 which controls the rotation of the information-stored medium 21 and the position of the optical pickup 22 ; a data buffer 24 in which the data read out from the information-stored medium 21 by the optical pickup 22 are temporarily stored; an audio/video signal processor 25 which processes and decodes the data that are outputted from the data buffer 24 ; a controller 26 which controls the operations of the servo control unit 23 and the audio/video signal processor 25 ; an external device 27 which communicates with a remote central server for playback permission and processes the data read out from the information-stored medium 21 after the playback permission; and multiplexor (MUX) circuit 28 which routs one of the data from the external device 27 and the data from the data buffer 24 to the audio/video signal processor 25 .
As shown in FIG. 2, an embodiment of the external device 27 comprises a modem 31 for communicating with the remote central server; a memory 32 for temporary storage of the data that are received from the modem 31 ; a BCA processor 33 for processing the unique ID code on the information-stored medium 21 ; a decryption unit 34 for decrypting the audio/video data from the information-stored medium 21 ; a sub-controller 36 for controlling all components of the external device 27 and the overall operation by communication with the controller 26 .
The control method of the reproducing apparatus configured as above is as follows. Once the information-stored medium 21 is loaded in the apparatus, the apparatus determines whether or not the medium is an information-based medium requiring remote playback permission. This is done by checking the existence of a prescribed directory in the root directory on the information-stored medium. Once the type of the information-stored medium is identified based on the determination result, the controller 26 sends information on the medium type to the sub-controller 36 so that the sub-controller 36 determines whether to establish a communication path between the external device and the remote central server.
Even when it is determined that the loaded medium is not the information-stored medium requiring the remote permission, the information about the medium type should be sent to the sub-controller 36 to guarantee that the external device 27 operates independently without waiting the command of the controller 26 . Furthermore, the determination and sending of the information about the medium type are made when the information-stored medium is ejected or when there is no information-stored medium loaded. This is because the type of information-stored medium may be changed and/or the information-stored medium may be ejected when a tray is open. In this way, the external device 27 can maintain the state that is linked to the operation condition of the information-stored medium player.
Basically, the information-stored medium requiring remote playback permission is controlled and reproduced in a general DVD playback environment. Therefore, when a DVD is loaded that is not designed for remote playback permission, the communication path between the controller 26 and the sub-controller 36 is established. In the case that the information-stored medium loaded is neither a DVD nor an information-stored medium for the remote playback permission, the controller 26 sends information on the type of the loaded medium to the sub-controller 36 and cuts off the communication path so that the external device 27 operates independently under control of the sub-controller 36 .
When it is determined that the information-stored medium requiring remote playback permission is loaded, first, the player reads out a unique ID information that is recorded on the information-stored medium. Every information-stored medium requiring remote playback permission has its own unique ID information that is recorded in a particular way so as to allow the remote server to identify each information-stored medium.
To be specific, unlike the data area on DVD information-stored medium in which data are recorded in constant linear velocity (CLV) drive mode, the ID information is recorded in constant angular velocity (CAV) drive mode at an inner area than the innermost track of the data area of the information-stored medium in the form of a bar-code.
Therefore, in order to read out the ID information, the player according to the present invention uses a different read-out mode from the read-out mode for the data area on the DVD information-stored medium. Specifically, the optical pickup 22 is moved inwards more than the innermost track to the area on which the ID information is recorded and, at the same time the information-stored medium is rotated in CAV mode so as to read out the ID information correctly.
In order to prevent general DVD players from reading out the ID information, information on the CAV drive mode is kept in the external device 27 . The rotation of the information-stored medium is servo-controlled based on the CAV information, which is transmitted from the external device 27 .
In short, if it is determined that the information-stored medium inserted is one requiring remote playback permission, the player sends the information on the medium type to the external device 27 . Once receiving the information, the external device 27 sends a signal that requests read-out of the ID information on the information-stored medium to the player, together with information on CAV drive mode. Then, the player reads out the ID information by servo control of the rotation of the information-stored medium on the basis of the CAV drive information.
The ID information is absolutely required to request permission of playback of the information-stored medium. In order to reduce read-error of the ID information, the read-out operation by the optical pickup is repeated in such a way that rotation per minute (RPM) of the information-stored medium is adjusted step-by-step until an RPM difference between the actual rotation of the information-stored medium and the CAV information received from the external device 27 falls into an allowable RPM error range. The RPM of the information-stored medium is servo-controlled in such a way that the required RPM error range depends on information on the total number of previous trials of the ID information read-out.
To be more specific, the ID information is read out from the information-stored medium when the RPM difference between the CAV information transmitted from the external device 27 and the actual RPM falls into the RPM error range, which is determined by information on the number of previous read-out trials including the current trial. Initially, a wide RPM error range is used for rapid read-out of the ID information, but as the read-out operation of the ID information is repeated, the RPM error range gets narrower.
Therefore, besides the request signal for read-out of the ID information and the CAV drive information, the external device 27 transmits information on the trial number of the read-out operation to the player. On receiving them, the player reads out the ID information by servo control of the rotation of the information-stored medium according to the CAV drive information and the iteration number.
After the ID information on the information-stored medium is read out, the BCA processor 33 in the external device 27 extracts an ID number of the information-stored medium through signal processing of the ID information and then requests permission of the playback of the information-stored medium by transmitting the ID number to the remote server through the modem 31 .
The operations of the external device 27 and the player depends on whether or not the request signal for the playback permission is provided by the external device 27 , which will be described in detail.
First, in the case that an acknowledge signal is received from the remote server in response to the request of the playback permission, the controller 26 in the player drives the optical pickup 22 so that the data on a specified area of the information-stored medium are read out.
The data on the information-stored medium requiring the remote playback permission are recorded, encrypted by two encryption schemes. Some data are encrypted with the same encryption scheme as that in a general DVD, and the other by a specific encryption scheme which is developed for this type of information-stored medium. Therefore, before playback of the data read out, some portion of the data, which are encrypted by the specific encryption scheme, are sent to the decryption unit 34 in the external device 27 . The decryption unit 34 decrypts the received data on the basis of decryption information which can be transmitted from the remove server or read out from the information-stored medium.
The decryption unit 34 uses different decryption schemes, depending on the type of the data that are read out from the information-stored medium. For example, in the case of audio/video or sub-picture data, decryption is made, but not in the case of control data such as navigation data for real-time playback control.
The data decrypted by the decryption unit 34 are temporarily stored in the memory 32 and are then transmitted to the audio/video signal processor 25 . Then, they are processed and decoded by the audio/video signal processor 25 and are outputted to the external display unit.
On the other hand, in cases where the external device 27 does not request remote playback permission, the reproducing apparatus according to the present invention can display useful information for users or advertisements of new information-stored medium titles through communication between the remote server and the external device 27 . In the case, the operations of the external device 27 and the player are described below.
When the external device 27 receives a signal indicating the transmission of information from the remote server, the sub-controller 36 in the external device 27 stores the information in the memory 32 temporarily, and then sends the information to the MUX circuit 28 after permission of the controller 26 is made, so that the audio/video signal processor 25 processes the information for output to the display unit.
FIG. 3 shows a flow chart of the operations for receiving and displaying public and commercial advertisements from the remote server in the reproducing apparatus according to the present invention.
Even when main power of the apparatus is off, both the controller 26 of the player and the sub-controller 36 of the external device 27 are maintained in ON state for communicating with the remote server. In other words, some portion of the apparatus such as the modem 31 , the controller 26 , the sub-controller 36 , and the external memory 32 are in the ON state so that the apparatus receives/transmits data from/to the remove server.
When it is necessary for the remote server to send information such as advertisements to users, first, the server sends a signal to the sub-controller 36 through the modem 31 to confirm whether or not the apparatus is in the state in which data communication is possible. If the sub-controller sends an acknowledge signal in response to the request signal, a communication path is established (STEP 301 in FIG. 3 ).
Basically, the establishment of the connection between the external device 27 and the remove server is allowed only when a user does not use the player so as to avoid an overload of the player that may happen when a large amount of data are received at a time otherwise.
Once the communication path is established, the remove server transmits the data to the apparatus over the communication path and then the external device 27 receives them (STEP 303 of FIG. 3 ).
The data which are received through the modem 31 are stored in the memory 32 . The capacity of the memory 32 is large enough to accommodate the amount of the data that are usually transmitted from the remove server. Moreover, the write operation into the memory 32 is controlled such that the data which are received since overflow overwrite the previously stored data (STEP 305 of FIG. 3 ).
When a user turns on the player, the data which have been stored in the memory 32 are displayed in the following way. Once the player turns on, power is supplied to components that are needed to play a information-stored medium by the controller 26 and then a set-up operation for playback starts.
During the time of the set-up operation, the sub-controller 36 checks whether or not the player can display the data in the memory 32 by communication with the controller 26 (STEP 307 and FIG. 3 ).
Specifically, the sub-controller 36 requests the use of the data buffer 24 and the audio/video signal processor 25 under supervision of the controller 26 .
On receiving the request signal from the sub-controller 36 , the controller 26 stops the operation that is running in the audio/video signal processor 25 and clears the data stored in an internal memory (not shown) of the audio/video signal processor 25 so as to avoid decoding conflict due to the remained data. In addition, the controller 26 sends a signal indicating the data transmission from the external device 27 to the audio/video signal processor 25 . When the series of operations is completed and thus the player-comes to be in the state for receiving the data, the controller 26 sends an acknowledge signal to the sub-controller 36 .
After obtaining a permission of the data transmission from the controller 26 , the sub-controller 36 transmits the data in the memory 32 to the player. And then, the data are transmitted to the audio/video signal processor 25 for digital signal processing and decoding and are then outputted to TV or monitor (STEP 309 of FIG. 3 ).
When the controller 26 permits the data transmission from the external device 27 is determined by the controller 26 . For example, The data transmission may be permitted during only the set-up period right after power-on of the player.
In this case, the video data of several frames that are received from the remove server and stored in the memory 32 are displayed during the set-up period, thereby enabling users to view information such as advertisements instead of waiting display of the video data from an information-stored medium in the player.
The transmission of data block of arbitrary size may be permitted in the middle of reproduction of the information-stored medium by a prescribed amount according to a predetermined program.
Furthermore, in the case that a DVD contains several titles, the data transmission may be allowed during each period of time which is required to play the next title. When a user inputs a command for viewing the data received from the remove server, of course, the controller 26 requests the transmission of the data stored in the external device 27 to the sub-controller 36 immediately.
In short, if only the display of the data that are received from the remote server does not interfere with the playback of the information-stored medium in the player, it is possible for the data to be reproduced in the player anytime.
FIG. 4 is a schematic diagram showing a two-wire serial communication link embodying a communication between the controller 26 and the sub-controller 36 , which will be explained in detail in reference to FIG. 2 .
The input port Rx/the output port Tx of the controller 26 are connected to the output port Tx/the input port Rx of the sub-controller 36 , respectively. Therefore, the data from the output port Tx of the controller 26 are inputted to the input port Rx of the sub-controller 36 , and the data from the output port Tx of the sub-controller 36 are inputted to the input port Rx of the controller 26 . The data are transmitted serially by 8-bit or 16-bit unit.
The data communication between the controller 26 and the sub-controller 36 shown in FIG. 4 can be accomplished in parallel mode by connecting data lines between two controller 26 and 36 as much as the bits of single data.
In the configuration shown in FIG. 4, the controller 26 and the sub-controller 36 communicate each other in the following way. Before transmitting the data in the memory 32 to the player, the sub-controller 36 sends a check signal through the output port Tx to the controller 26 to confirm whether the controller 26 can receive the data from the external device 27 . On receiving the check signal through the input port Rx, the controller 26 checks the status of the MUX circuit 28 and the audio/video signal processor 25 , and sends a signal that notifies whether or not the MUX circuit 28 and the audio/video signal processor 25 are available to the sub-controller 36 .
If the sub-controller 36 receives the signal that notifies a permission of the data transmission through the input port Rx, the data stored in the memory are transmitted to the controller 26 by the sub-controller 32 .
FIG. 5 is a schematic diagram showing data path and control signal path of the components at the time of reproduction of the information-stored medium requiring remote playback permission.
As shown in FIG. 5, the data buffer 24 and the external device 27 are connected to the audio/video signal processor 25 by way of the MUX circuit 28 , whose function is to select one of the data from the data buffer 24 and the data from the external device 27 and to output the selected data to the audio/video signal processor 25 .
The MUX circuit 28 comprises a MUX 28 a for transmitting a data transmission request signal from the audio/video signal processor 25 or the external device 27 to the data buffer 25 ; and a MUX 28 b for transmitting one of the data supplied from the external device 27 and the data from the data buffer 25 to the audio/video signal processor 25 .
It is desirable that the multiplexors 28 a and 28 b are implemented by one switching element and thus they operates on the same state. When the MUX 28 a is ON the transmission request signal from the external device 27 is sent to the data buffer 24 , and at that time, because the MUX 28 b is ON as well, the data from the external device 27 are selected and sent to the audio/video signal processor 25 . Conversely, when the MUX 28 a is OFF, the request signal from the audio/video signal processor 25 is directly sent to the data buffer 24 and because the MUX 28 b is OFF as well, the data from the data buffer 24 are sent to the audio/video signal processor 25 .
The operation of the MUX 28 a and MUX 28 b for reproducing the information-stored medium requiring remote playback permission is controlled by the controller 26 . To be specific, the sub-controller 36 of the external device 27 requests for the transmission of the data on the information-stored medium to the controller 26 . On receiving the request signal, the controller 26 sets the MUX 28 a ON to enable the transmission request signal from the external device 27 to be sent to the data buffer 24 , and generates a command signal to request of clearing some data that may remain in the data buffer 27 . The reason of clearing the remained data in the data buffer 27 is to prevent the remained data from being outputted to the audio/video signal processor 25 . The remained data have discontinuity with data read out from the medium, so that the remained data causes malfunction of the audio/video signal processor 25 while decoding the input data streams.
For the same reason, before the data stored in the data buffer 24 are transmitted to the external device 27 over the established communication path, the data that have remained in the memory 32 of the external device 27 are cleared to avoid the conflict in the decoding operation due to the remained data.
FIG. 6 shows a flow chart of a method for determining whether or not the reproducing apparatus according to the present invention is equipped with an external device 27 and the type of the external device, if it is connected. The confirmation of the connection is based on the communication method between the controller 26 and the sub-controller 36 as shown in FIG. 4 .
Once a user powers on the reproducing apparatus, the controller 26 sets the period of time in which the procedure of FIG. 6 is repeated to check whether the apparatus is equipped with the external device 27 (STEP 101 ). The reason why the STEP 101 is needed is due to delayed or no response of the external device 27 that may happen because of incomplete set-up. Instead of timer setting, the number of trial of the procedure can be used.
The controller 26 sends a signal to the sub-controller 36 through the output port Tx to identify which type of external device is connected (STEP 103 ). And then, the controller 26 and the sub-controller 36 send and receive a predefined code each other through their own input/output ports Rx, Tx (STEP 105 ). The controller 26 examines the type of the external device based on the received the code (STEP 107 ). If the code is not sent to the controller 26 , the controller 26 cannot identify the type of the external device. This may be due to no external device or delayed response.
In this case, the controller 26 decreases the timer's value that was set in the STEP 101 by 1 second (STEP 113 ) and then examines whether the remained time is zero or not (STEP 111 ). If it is zero, the controller 26 determines that there is no connected external device (STEP 115 ). When it is determined that there is no external device or the information-stored medium in the player is not information-stored medium requiring remote playback permission, the controller 26 makes the MUX 28 a and the MUX 28 b turn OFF to maintain the data path only from the data buffer 24 .
When the controller 26 receives the predefined code of the external device from the sub-controller 36 , it determines the type of the connected external device based on the received code and uses the code for controlling the operations of data communication with the sub-controller 36 and signal processing of the data reproduced from the information-stored medium (STEP 109 ).
FIG. 7 is a flow chart for transmitting the data that are recorded on a pre-specified area of the information-stored medium requiring the remote playback permission to the external device 27 . In the case where the information-stored medium needs the remote playback permission, the external device 27 requires information needed to process the data that are read out from the information-stored medium 21 . Because the data containing the information are recorded on a prescribed area on the information-stored medium 21 , the sub-controller 26 of the external device 27 sends a signal to the controller 26 to read out the data on the information-stored medium, along with location information on the prescribed area or a predetermined file (STEP 201 ).
Once the controller 26 receives the signal, it controls the optical pickup 22 to move the pre-specified area on the basis of the location information or the file name that the sub-controller sent. The location information on the Prescribed area may be sent to the controller 26 in the form of sector numbers. In the case, the start and end sector numbers are used to locate the prescribed area on the information-stored medium 21 . On the other hand, when the file name is sent to the controller 26 , the controller 26 reads out the file location information from the information-stored medium 21 and then uses the start and end sector numbers of the file to read out the file (STEP 203 ).
The data that are read out by the optical pickup 22 are transmitted to the input port Rx of the sub-controller 36 by way of the data buffer 24 . In order to avoid the unwanted display and/or decoding conflict due to the data that remains in the data buffer 24 , the data in the data buffer 24 are cleared by the controller 26 before the data transmission (STEP 205 ).
The transmission in the STEP 205 is maintained until all of the data on the prescribed area or the file are transmitted to the sub-controller 36 .
FIG. 8 is a flow chart of processing in the audio/video signal processor 25 of the reproduction data, in the MPEG format or in other format which is decodable in this player, that are transmitted from the external device 27 .
First, if the sub-controller 36 sends a signal signifying that the data stored in the memory 32 are transmitted to the player to controller 26 , the controller 26 examines whether or not the MUX circuit 28 and the audio/video signal processor 25 are available.
If it is determined that they are available, the controller 26 makes the MUX circuit 28 turn ON so that the data path from the external device 27 to the player is established (STEP 401 ). In addition, the controller 26 identifies the type of the data to be transmitted through communication with the sub-controller 36 and controls the audio/video signal processor 25 to prepare for processing according to the data type.
Specifically, on receiving the request signal from the sub-controller 36 , the controller 26 stops the operation that runs in the audio/video signal processor 25 and clears the data that may remain in an internal memory (not shown in Figure) of the audio/video signal processor 25 to prevent the decoding conflict due to discontinuity of the unwanted data. Besides, the controller 26 sends a signal indicating the data transmission from the external device 27 to the audio/video signal processor 25 .
Once the set-up of the audio/video signal processor 25 for processing the incoming data is completed, the controller 26 sends an acknowledge signal indicating that the audio/video signal processor 25 is ready to the sub-controller 36 (STEP 403 ).
After the sub-controller 36 receives the acknowledge signal, it outputs the data that are stored in the memory 32 (STEP 405 ). The data are transmitted to the audio/video signal processor 25 through the MUX circuit 28 and are then processed for output to the display unit.
FIG. 9 is a flow chart showing the control method for reading out a unique ID information which is recorded on the information-stored medium requiring the remote playback permission.
In general DVD players, the first operation for the DVD title playback is to read out the content management data after moving the optical pickup 22 to the correspondent area in the DVD's data area. Then, The location information of the video title which a user wants to watch is extracted from the content management data and then the audio/video data are read out based on the location information. Because general DVD titles do not require management for remote rental, the general DVD player does not need to have a mechanism to identify the DVD title.
However, the reproducing apparatus capable of reproducing the information-stored medium that needs the playback permission from the remove server according to the present invention requires a mechanism for identification of the information-stored medium. To accomplish this, the information-stored medium requiring the remote playback permission has its own unique ID information that is recorded on a prescribed area in a predetermined way. For example, the ID information is recorded in an inner area than the lead-in area in CAV drive mode rather than CLV drive mode.
When reproducing information-stored medium requiring remote playback control, first, the ID information is read out by moving the optical pickup 22 to the prescribed area and is then sent to the remote server so as to determine whether the playback of the information-stored medium is permitted or not.
The read-out of the ID information, however, needs a particular servo-control because the ID information is recorded on the information-stored medium by a prescribed way, which will be described below in detail.
If it is determined that the information-stored medium inserted is one requiring remote playback permission, the controller 26 of the player sends the corresponding information to the sub-controller 36 of the external device 27 . Once receiving the information, the sub-controller 36 sends a request signal for read-out of the ID information on the information-stored medium to the controller 26 of the player.
On receiving the request signal, the controller 26 moves inwards the optical pickup 22 to an inner area, which contains the ID information of the disc, beyond the innermost track of the data area (STEP 501 ), and at the same time, rotates the information-stored medium in CAV drive mode to read out the ID information correctly.
In order to prevent general DVD players from reading out the ID information, information on the CAV drive mode is kept in the external device 27 . In the apparatus according to the present invention, the rotation of the information-stored medium is servo-controlled based on the CAV information, which is transmitted from the external device 27 together with the request signal for the read-out of the ID information.
As a result, the player reads out the ID information on the information-stored medium by servo-control on the basis of the CAV drive information.
The ID information is absolutely required to reproduce the information-stored medium. In order to reduce read errors of the ID information that may happen, the read-out operation by the optical pickup 22 is iterated until the difference error between the CAV rotation information and actual rotation becomes zero (STEP 503 ).
In this case, besides the request signal for read-out of the ID information and the CAV drive information, the external device 27 transmits information on the iteration number of the read-out operation to the player. On receiving them, the player reads out the ID information iteratively by servo-controlling the rotation of the information-stored medium according to the CAV drive information and the iteration number.
After the ID information on the information-stored medium is read out, the ID information is processed by the BCA processor 33 of the external device 27 and is then sent to the remote server through the modem 31 (STEP 505 ). Depending on the ID information, the remote server transmits a signal indicating whether or not the playback of the information-stored medium is permitted to the controller 26 by way of the external device 27 .
The foregoing is provided only for the purpose of illustration and explanation of the preferred embodiment of the present invention, so changes, variations and modifications may be made without departing from the spirit and scope of the invention.
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The present invention relates to a reproducing apparatus for a remote rental system, and in particular to a reproducing apparatus and control method for the apparatus by which the playback permission of the video title, advertisements, and charge collection are performed remotely over a public communication network between a remote server and a reproducing apparatus. The remote rental system of the present invention comprises an information-stored medium with a unique ID code, a reproducing apparatus for playing the data on the information-stored medium, and a remote server for controlling the playback of the information-stored medium on the reproducing apparatus over the communication network. The remote rental system enables customers to keep the information-stored medium at a low cost without return, to use the information-stored medium whenever they want, and to receive useful information such as public advertisements that are provided continually over the communication network.
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